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29 HIRA Annexure H

This document provides a hazard identification and risk assessment for dismantling and erecting an ammonia tank. It identifies several potential hazards including physical hazards from handling materials, working at heights, being struck by moving vehicles, and vehicle accidents. Control measures are outlined to mitigate these risks, such as ensuring proper training and use of personal protective equipment. Responsibilities are also defined for managing risks and ensuring safety protocols are followed. The nature of the work could impact surrounding plant operations, so extra care is needed during execution.

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Suraj Singh

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100% found this document useful (2 votes)

340 views155 pages

29 HIRA Annexure H

Uploaded by

Suraj Singh

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 155

ANNEXURE – R

HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187
Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site
Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr.

GENERAL – MECHANICAL
RISK RISK RESPONSIBILI
RATING RATING TY
STEPS/ POTENTIAL CONTROL MEASURES/
WITH WITH
Sr. METHODS SUB HAZARD MITIGATIONS PPEs TO BE G P L

RISK

RISK
EXISTING ADDITIO N
No. (MAIN ACTIVITIES (What can cause (What can be done to prevent it USED N D S
RISK CONTRO L
ACTIVITIES) harm?) from going wrong?) F I T
CONTROL MEASURES
C L K
C L R C L R
• Compliance on PTW
requirements to be ensured.
• Basic PPEs
• Trained and competent person
• Physical hazard (Safety S
to be monitored. P
while handling helmet, =
• Conduct TBT to all craftsmen =
material. Safety S
Mobilization of involved in the work activities. P
• Working at Glass, U
Personnel, • Compliance with GNFC safety E
height. Leather P
requirements to be ensured. R
vehicles, • Struck by gloves, E
• Only competent and licensed F
1 Equipments & moving vehicle. 5 3 15 A drivers to deliver material at
3 1 3 C Safety R S O
Delivery of • Unskilled Labor Shoe) V
site. R
material to job • Unconditioned • Full body I
• Driver to be made aware of M
site. / damaged harness S
requirements and deliver to E
Equipment • Respirator I
designated area only. R
• Vehicle • Dust O
• Ensure all personnel are
accident coverall N
properly trained and competent
with appropriate PPE.
• Ensure the equipment/trailer

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

have updated and valid

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

using and competent for rigging and • Full body

Tower tower crane operation. harness
crane / • Ensure tower crane operator with 100%
Manually having valid license. tie up of
• Tool Box Talks to be conducted lanyard
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 • Basic PPEs
Manual for manual lifting activity. • Fall
shifting of • Personnel • Tool Box Talks to be conducted arrestors
Scaffold injury
5 4 20 A before starting the activity.
3 1 3 C • Full body
S S P
Materials • Deploy the workers according to harness
the weight of the materials. with 100%

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

• Ensure proper access for tie up of

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Provide adequate warning signs

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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properly before going for the with 100%

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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of tools • Full body harness to be used. • Full body

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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roof structure is allowed for trailer driving.

material • Proper equipment should be
used to lift and shift the
material.
• T.P.I certified hydra / crane
should be used to pull the loads.
• All cranes / hydras used in the
lifting / shifting the material
should be fit for the laying
• Hit by objects. activity.
Lifting • Vehicle • Ground conditions should be
work by accident. assessed prior to setting up the
using • Failure of lifting 4 5 20 A crane / hydra for lifting the 3 3 9 B • Basic PPEs S S P
Hydra/Cran tools & Tackle. material.
e toppling • Trip / fall • No tandem lifts should be
hazard carried out and no hydras should
be used to transport the
material.
• No lifting activity should be
carried out if wind speed is more
than 9.8m/min.
• Plates should be unlashed only
after inspection and confirmed
that it will not slip from the
• Fall of plates
during lifting
4 5 20 A trailer. 3 3 9 B • Basic PPEs S S P
• Enough support should be
provided to all Sides of trailers.
• Plate clamps should be used to

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

lift plates.
• One plate should be lifted at a
time.
• No plates should be lifted with
forklifts.
• Plates should not be pushed or
pulled from the trailer.
• Area of lifting radius / material
movement should be barricaded
• Proper lifting tools should be
selected and used.
• Lifting tools should not be
subjected to tensions and should
not be used to pull the loads.
• Damaged lifting tools should not
be used.
• Failure of lifting
tools.
5 4 20 A • All lifting tools should be 3 3 9 B • Basic PPEs S S P
inspected prior to use.
• All lifting tools should be
protected from sharp edges.
• All lifting tools should have TPIs
& should be colour coded
according to the project colour
code.
• No lifting should be carried out
during high wind conditions.
• Hit by object 5 3 15 A • Load should be controlled by
3 3 9 B • Basic PPEs S S P
guide ropes & should not be

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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handled directly.
• Area of plate handling should be
kept barricaded to restrict the
entry of unwanted personnel.
• Proper sign boards should be
displayed.
• No one should be allowed to
work under the suspended load.
• Ensure all personnel have
undergone Site Safety Induction.
• Ensure PTW Issued by the PMC
before starting the work.
• Plate clamps should be used to
lift plates. One plate should lift
at a time. • Hard Hat,
Loading and • No plates should be lifted with • Leather
forklifts. gloves,
Unloading of • Hit to men or
• Ensure trained and competent • Safety
5 steel plates materials 5 5 25 A personnel operating tower crane
3 1 3 C glasses,
S S P
using Hydra/ to lift the Bucket • Safety
Crane • Tool Box Talks to be conducted shoes,
before start of the activity. • Coverall.
• Ensure the LG and machines
have legal documents Like TPI.
• Ensure before starting the work
physical inspection should be
done for the crane and Sand
Bucket using the check list

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• 5.While loading the teeth of the

VR hook should be inserted fully
in the
• Avoid overloading.
• Ensure Center of gravity should
be stable while loading and
unloading.
• Ensure proper supervision until
the task complete.
• 8. Provide proper PPEs for the
work men who work in the
activity.
• Inspected hydra / crane should
be used to pull the loads.
• Ground conditions should be
assessed prior to setting up the
crane / hydra for lifting the • Hard Hat,
• Hit by objects.
material. • Leather
Lifting • Vehicle
• No lifting activity should be gloves,
work by accident.
carried out if wind speed is more • Safety
using • Failure of lifting 5 5 25 A than 9.8m/min.
2 1 2 C glasses,
S S P
Hydra/Cran tools & Tackle.
• Flagman should be assigned to • Safety
e toppling. • Trip / fall
guide the traffic. shoes,
hazard
• Drivers should follow the traffic • Coverall.
rules while driving inside the
project areas.
• No lifting activity should be
carried out during night shift if

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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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.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Signal to the crane operator

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Unsafe loading • Forklifts should never be • Reflective

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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required materials / • Gas cutting set shall be up right • gauntlets,

personnel. position and secured by chain. • face shield
• Gas leaking • Wear protective clothing, • welding
from hoses / gauntlets, face shield and glass/
valves or flash welding glass along with other shield
back arrester 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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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line & vice versa.

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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inspect the machine every day

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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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.
• Crush injuries 5 4 20 A • Proper fencing should be 2 2 4 C S S P
maintained around the machine.
• After rolling, rolled plates should
be stored properly and should
be locked against rolling from
stored place.
• Leather hand gloves should be • Basic PPEs
used to handle plate. (Safety
• Employees should be provided helmet,
with full body protective Safety
• Injuries due to clothing. Glass,
sharp edges
5 4 20 A • Guide lines should be used to
1 3 3 C Leather
S S P
control the load. gloves,
• Area of lifting / shifting should Safety
be barricaded. Shoe)
• Proper coordination between • Full body

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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crew to avoid communication protective

gap. clothing
• Rolling machine should be
placed at proper location.
• Basic PPEs
• No one other than electrician
• Full body
should be allowed to do the
harness
electrical maintenance work for
• Electrocution 5 4 20 A the machine.
1 1 1 C • Respirator S S P
• Dust
• Machine should be inspected on
coverall
daily basis and thoroughly on
periodic basis for identifying any
damages.
• Welding machine should be
placed at proper location.
• Electrical cables of machines
should be protected from the
damages.
• No one other than electrician
Hot work should be allowed to do the
• Basic PPEs
(welding, electrical maintenance work for
8
cutting
• Electrocution 5 5 25 A the machine.
3 3 9 B • Rubber S S P
Gloves
,grinding) • Proper earth should be provided
to the machine.
• Power supply of the machine
should be provided through
proper rated ELCBs or GFCIs.
• Machine should be protected
from rain and other bad weather

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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conditions.
• Machine should be inspected on
daily basis and thoroughly on
periodic basis for identifying any
damages.
• Cables should be protected from
the damages due to its exposure
to sharp edges.
• Cables should be protected from
hot surfaces.
• Plugs of welding machine should
not be inserted / removed from
the sockets while socket is live.
• Naked electrical cable should
not be allowed.
• All combustible material should
be removed from the area.
• Buds of the welding rods should
be collected and disposed at
proper location.
• All electrical connections should
• Fire 5 4 20 A be made with proper plugs, 2 4 8 B • Basic PPEs S S P
sockets, connectors.
• No loose connections are
allowed.
• Cables with damage insulation
should be taken out of use.
• Welder should inspect the

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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cables every day for identifying

damages.
• Electrical supply of welding
machine should be switched off
• Fire extinguishers should be
made available at site and
employees should be trained to
use the same.
• Employees engaged in the hot
works should be provided with
proper PPEs & its use should be
ensured.
• Welding flux should be disposed • Basic PPEs
in proper manner. • Leather
• Burn injuries 5 4 20 A • Welding rod buds should be 3 3 9 B apron S S P
disposed at a designated • Leather
location only. Coveralls
• Welder / employees engaged in
over head hot works should be
provided with leather apron &
leather sleeves.
• Hoses should be laid in proper
manner.
• Damage to gas • Hoses should be protected from • Basic PPEs
cylinder & 5 5 25 A sharp edges. 2 4 8 B • Repertory S S P
hoses • Hoses should be checked for mask
damages on daily basis and if it
is cracked, cut it should be

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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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. • Basic PPEs
• Proper scaffolding platform • Fall
• Fall of person
from height
5 5 25 A should be provided to the 3 3 9 B arrestors S S P
employees working at height. • Full body
• Fall arrestors, full body harness harness
should be provided & its use
should be ensured.
• 100% tie off should be explained
and practiced.
• Scaffolding should be designed
& erected properly; no

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

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 Site Safety Induction.
• Ensure PTW Issued by the PMC
before starting the work.
• Deploy trained worker for to cut
the steels
• Hard Hat,
• Tool Box Talks to be conducted
• Leather
before start of the activity.
Cutting of steel • Crush Injury gloves,
• Ensure the machine is inspected
using bar • Hit the men • Safety
9
cutting due to temper.
5 4 20 A by EHS dept before entering to 3 1 3 C glasses,
S S P
site and color coded.
machine • Safety
• Ensure safety guard provided for
shoes,
the rotating parts of machine.
• Coverall.
• Pedal guard/Hand lever
protection against accidental
activation.
• Ensure cover guard protection
for cutting part of machine.
• Place re bar in position and

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 24 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

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
Roof plate and activity.
• Basic PPEs
compressor • Ground conditions should be
• Fall
• Crane / hydra assessed prior to setting up the
10 ring
toppling
5 5 25 A crane / hydra for lifting the
3 3 9 B arrestors S S P
dismantling & • Full body
material.
erection harness
• No tandem lifts should be
carried out and no hydras should
be used to transport the
material.
• No lifting activity should be
carried out if wind speed is more
than 9.8m/min.
• Fall of person 4 5 20 A • Only trained employees should 3 3 9 B • Basic PPEs S S P

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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from height be engaged in working at height. • Fall

• Employees should be medically arrestors
fit for working at height. • Full body
• Working at Height” permit harness
should be taken prior to starting
the work.
• Proper scaffolding platform
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.
• All the plate shall be properly
• Fall of plates • Basic PPEs
weld to avoided any fall
during lifting, • Fall
• Remove all unwanted materials
demounting & 4 5 20 A from height
2 4 8 B arrestors S S P
after • Full body
• After erection the job engineer
installation harness
shall be check and ensure there
is no any lapse.
• All jacks should be inspected for
• Basic PPEs
Installation of damages before taking it into
• Fall of lifted • Fall
hydraulic jacks use.
11
and lifting of
material due to 5 5 20 A • All hydraulic hoses should be
4 3 12 A arrestors S S P
failure of jacks • Full body
tank laid properly & should be
harness
prevented from damages.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 26 of 66
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• Hydraulic jacks and its

accessories selected should be
more the 1.5 times of the load
which is being lifted.
• Approximately 20 hydraulic jacks
each capacity of 12 ton shall be
use to lift the tank step by step.
• Before start lifting of tank, it
must be ensured that all shell
plates are welded properly and
are safe for lifting.
• Tank shell to be lift Maximum
2.6 meter height
• After reaching the required
height of lifting of each level,
lifted shell should be properly
supported to prevent its fall
from height.
• Jacks should be placed at
appropriate locations of the tank
to avoid fall of shell due to
bending of shell plates.
• Proper coordination should be
maintained between the crew
• Pinch point
engaged in the lifting of shell.
injuries & crush 4 5 20 A • No employees should allow
3 2 6 B • Basic PPEs S S P
injuries
passing under the shell while it is
being lifted.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• All area around the tank should

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 28 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

accessories selected should be

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 29 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

• Spilled oil must be cleaned off

immediately.
• Proper masks should be
provided to crew engaged in the
DP test.
• MSDS of chemicals used in the
DP test should be available and
it should be explained to the
employees engaged in the DP
test.
• Eye protection should be used to
prevent eye injuries.
• Exposure to • Basic PPEs
ND Testing – • Ensure radiography permit is
chemicals • Eye
DP Test, obtained
13
Radiography,
5 5 25 A • Proper communication to be
2 3 6 B protection S S P
• Exposure to the • Proper
Vacuum Test done to all personnel working
radiation Mask
inside
• Barricade and clear off all
personnel in the affected area.
• Ensure the standby man people
at all the entry point to be
effected area.
• Confirm sign board is place at all
entry point.
• Locate the flash light at
prominent place.
• Preferable time for the

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 30 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

radiography is break times and

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Separate PIT room shall be

provided for handling and store
the source.
• Proper lighting arrangements
should be made to work inside
the tank.
• Fall of person • Hoses, cables should be laid
due to bad properly and maintained the
lighting and
5 3 15 A same
2 2 4 C • Basic PPEs S S P
housekeeping • Daily housekeeping should be
practiced at the end of the day.
• Proper working platform if RT
works at height.
• Basic PPEs
• Only trained employees should
• Fall
Nozzle • Fall of person be engaged in working at height.
14
installation from height
5 5 25 A • Employees should be medically
3 2 6 B arrestors S S P
• Full body
fit for working at height.
harness
• Material should not be stacked
on the scaffolding or any other
place at height.
• Basic PPEs
• Platforms should be constructed
• Fall
• Fall of material in such a manner that there
from height
5 4 20 A should not be any gaps in the
3 3 9 B arrestors S S P
• Full body
platform, proper toe guard
harness
should be provided to the
platforms of the scaffolding.
• Structure components should

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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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 taken prior to starting • Basic PPEs
Painting work
the work. • Fall
at tank outer • Fall of person
15
from height
5 5 25 A • FBH shall be provided for height 3 3 9 B arrestors S S P
shell (work at work. • Full body
height) • If ladders are used, it should be harness
secured prior to start working on
it.
• Proper life lines should be
installed and used while working
at height
• Hoses cables should be laid in • Basic PPEs
• Injuries due to proper manner. • Fall
slip, trip & fall 4 5 20 A • Paint box should be removed 2 3 6 B arrestors S S P
from the scaffolding platform on • Full body
daily basis. harness

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Platform should be maintained

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 34 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

uncontrolled and should be prevented from • Full body

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 36 of 66
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• Automatic grit blasting machine

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Paint should be stored away

from the 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
• Environmental considered as hazardous waste,
• Basic PPEs
pollution due it should be disposed at
• Shield for
to paint drums 5 4 20 A designated location. 2 3 6 B blasting
S S P
disposal & • Ensure proper shield for blasting
shed
• grit disposal shed to avoid dust flying to
environment.
• Use calibrated gauge in the
pump. Ensure proper
supervision at all times
• Use calculated value of pump
• Pressurized
pressure in case of bolt
system
Torque tensioning.
17
/tensioning
• Bursting of 4 3 12 A • Release pressure in hose before
2 2 4 C • Basic PPEs S S P
hoses.
disconnection.
• Personal injury
• Barricade area at ground level to
prevent unauthorized entry.
• Tommy bar should be tied with
rope to prevent falling.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 38 of 66
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• 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
• Slip/trip/fall of work.
• Pinch hazards • Inspect to all equipments before
• Over use at site.
Hydro Testing/
General pressurization • Barricade the work area.
pneumatic test S/
18
if required.
requireme • Personnel 4 5 20 A • Display related safety sign / 2 3 6 B • Basic PPEs
P
S P
nts injury due to caution boards.
hose rupture. • Use leather gloves
• Unauthorized • Use calibrated and certified
entry 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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 39 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

such a way that it does not pose

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• The flanges / joints shall be

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 41 of 66
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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
Releasing safely.
of pressure • Workers should maintain a safe
• Slip /trip/ fall
/
hazards
4 5 20 A distance from the vent point 2 2 6 B • Basic PPEs S S P
Dewatering while releasing pressure.
of pipe • 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
• Blast of tank
of the tank.
• Hand injury
• If required, permits should be
Pressure • Failure in
taken before starting the
identifying S/
19 testing & Box
blind(s) may
5 4 20 A pressure test the same should 1 2 2 C • Basic PPEs
P
S P
up be communicated to the other
leads to
contractors working in the
process
vicinity of the tank being
hindrance
pressure tested well in advance.
• All equipments used for

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 42 of 66
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pressure testing should be

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 43 of 66
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HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

• Sudden release be provided to release the

of pressure pressure of tank in case of
emergency.
• Arrangements for safe release of
medium used for testing should
be made & proper barication
with required signs should be
provided to the same.
• Area barricading shall be
ensured .
• Before box up all unwanted
materials shall be removed.
• Before box up, it should be
• Entrapment of ensured that the tank is
person
3 5 15 A completely vacant.
2 4 8 B • Basic PPEs S S P
• Company safety officer shall give
final box up clearance after sign
in procedure.
• Sharp surfaces • Obtain a valid Permit to Work as • Hard hat,
• Possible hydro- well as a Confined Space Permit • safety
carbon vapors Issued at the site glasses,
Confined Space
present. • Ensure PTW is in place and • Dust
Entry for
• Insufficient ensure check for Gases and shall mask,
20 cleaning and
Oxygen Levels.
5 4 20 A ensure that Oxygen 20.8% & LEL
3 2 6 B • coverall,
S S P
repair activities • Insufficient - 0% which need to be • Rubber
(if required) light. monitored continuously. gum
• Slippery • All crew members working in boots,
surfaces. confined space shall be trained • Leather

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 44 of 66
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because of the and competent to work in gloves,

viscous confined space • Safety
material inside • Ensure standby man remains at shoes
• High entrance with constant • Full body
temperatures communication with the crew. harness
inside the • Post signage and barricades with
confined space CONFINED SPACE ENTRY – DO double
NOT ENTER. lanyard
• Erect sufficient lighting. and shock
• Ensure adequate ventilation and absorber
airflow. (when
• Ensure constant air monitoring. working at
• Do gas testing for explosive or heights
flammable atmospheres due to
hidden hydro-carbon vapors.
• Ensure that an ENTRY LOGSHEET
is completed by all ENTRANTS
and controlled by the STANDBY
MAN.
• Constant supervision is vital.
• Hand injuries • Ensure that hand protection and • Basic PPEs
Vacuum out while setting- all other PPE, as required are • Safety
sludge using up and making worn. Goggles,
vacuum truck connections • Ensure all hoses are arranged in • Respirator S/
21
and disposed • Possible
4 2 8 B such a way that it does not pose
2 1 2 C • Dust
S
P
P
designated injuries as any unnecessary tripping coverall,
area. result of hazards. • Leather
tripping over • Qualified Gas Tester gloves,

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
Page 45 of 66
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hoses. • Ensure no one is standing close

• Flammable, to the Equipment man way.
Radioactive • To follow GNFC procedure
and health • Ensure to assess the vacuum
• Failure to truck approach roads & its set
follow up area in coordination with
procedure GNFC 's competent
• Hose failure representative and ensure that,
• Static it is clear from all obstacles
electricity before obtaining PTW
generation may • Depute only qualified and
be a source of trained vacuum truck drivers
ignition and ensure to wear appropriate
• Inhalation of PPE.
Toxic Fumes • Ensure all hoses are inspected,
• Inhalation of tested and certified prior to its
Hazardous use.
Substance • Barricade the area and post “DO
• Possibility of NOT ENTER” sign board.
fire • 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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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depending on the type of

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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platform level of the scaffolding.

• Drowsiness • Ensure use of personal
(feeling sleepy)
4 3 12 A protective equipments-Shoe-
2 1 2 C S S P
Helmet-Gloves.
• Break needs to be taken at
• Fatigue 4 3 12 A regular intervals. 3 1 3 C S S P
• Full or alternative supervision
throughout the work.
• Emergency vehicles with driver
should be there through the
work time.
• Lack of • Effective supervision will be
amenities.
4 3 12 A made by nominating designated 2 1 2 C S S P
decision making person as in
charge for night shift.
• Drinking water, snacks and other
amenities will be available.
• Ensure frequent cleaning of
work station from obstructing, • Safety
unwanted material / objects and helmet,
slippery floor. • Safety
• Possible
• Any spillage should be cleaned Goggles,
slipping and S/
23 Housekeeping
falling of
4 3 12 A up immediately and stored into 2 1 2 C • Respirator S
P
P
approved container. • Dust
personnel
• Make sure that hoses used are coverall,
arrange in such a way that it will • Leather
not pose a tripping hazard gloves,
during the housekeeping job.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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CIVIL WORK
RISK RISK RESPONSIBILI
RATING RATING TY
STEPS/ POTENTIAL CONTROL MEASURES/
WITH WITH
Sr. METHODS SUB HAZARD MITIGATIONS PPEs TO BE G P L

RISK

RISK
EXISTING ADDITIO N
No. (MAIN ACTIVITIES (What can cause (What can be done to prevent it USED N D S
RISK CONTRO L
ACTIVITIES) harm?) from going wrong?) F I T
CONTROL MEASURES
C L K
C L R C L R
• Fall on the
same level due
• Be cautious while walking on
to tripping • Safety
uneven ground surface.
because of helmet,
Layout of • Wear safety shoes for
uneven ground. • Safety
protection.
pilling area • Dust entering Goggles,
• Removal of thorny plants, debris
1 and line eyes and nose 5 4 20 A and other material if any before
3 1 3 C • Respirator S S P
marking with due to loose • Dust
marking.
chalk powder soil & gusty coverall,
• Plan marking when the wind is
winds • gloves,
low and wear safety glasses and
• Skin irritation
dust mask
and trip
hazards.
Loading & • Inadvertent • Check the stack condition for • Safety
unloading of movement / any disturbance that may cause helmet,
2 materials from roll of materials 4 4 16 A movement. 2 1 2 C • Safety S S P
truck for pilling from the stack • Do not step over the load that Goggles,
work while loading / may cause imbalance; instead • Respirator

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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unloading use tailor made platforms, • Dust

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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ground, if any. • Dust

coverall,
• gloves,

• Ensure SWL, Lifting radius etc. of

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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assembly • May hit the for signaling. Goggles,

of second , persons • Provide licensed operator. • Dust
third , involved. • Area shall be barricaded. coverall,
fourth and • Fall of persons • Double lanyard Full body • gloves,
fifth stage might result harness with shock absorber • Double
of A- during height with fall arrester, where lanyard
Frame works. necessary, shall be used while Full body
• 3. Hit may work at height. harness
result due to • Tag Line shall be used to control with shock
breaking of movement of lifted loads. absorber
wire ropes / • Ensure TPI for all lifting tools and with fall
slings. tackles including Rig assembly. arrester
Area • Valid permit should be obtained
clearance on daily basis, which can provide
• Basic PPEs
and information about the existence
• Safety
identificati of underground utilities, if any.
• Damage to Goggles,
on of • If required, cable detectors
underground • Respirator
4 Driving of piles buried 4 5 20 A would be used to detect 2 2 4 C • Dust
S S P
cables, utilities underground cables.
coverall,
utilities • A signal man shall be assigned to
and • Leather
monitor the excavation.
chemicals gloves,
• TBT shall be conducted on daily
etc. basis.
Placement
• Hand injury • Basic PPEs
of piling • All workers should use hand
might happen. • coverall,
shoe on
• Pile shoe could
4 3 12 A gloves/ safety shoes. 2 2 4 C • Leather
S S P
the pile • 2.TBT shall be held with crew
slip and fall. gloves,
location

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Basic PPEs
• Reverse horn of miller shall be in
• Safety
working condition
Placing the • Collision with Goggles,
• Signal man shall be provided
5 concrete mixer piling rig 4 3 12 A • Ensure area is clear from
2 2 4 C • Dust S S P
near to the rig • Hit to person coverall,
obstacles for movements.
• Leather
• Provide valid licensed driver
gloves,
Vertical, Lateral
and Pull out • Basic PPEs
test • Keep clear access and hand • Safety
Shifting of • Struck by rebar, Goggles,
gloves shall be in use.
6 rebar, farm and slip, trip, fall to 4 4 16 B 2 2 4 C • Dust S S P
• Provide steps for excavation or
same level coverall,
scaffolding provide ladder for assess.
materials for • Leather
pile head gloves,
preparation
• Load or hydra • Load shall be lifted as per the
may collapse load chart
Lifting, shifting • Basic PPEs
due to • Licensed and experienced
and Placing of • Safety
overloading operator shall be allowed to
Goggles,
load (concrete • Load collapsed operate the hydra
• Respirator
7 block and due to failure 5 5 25 A • Proper training shall be provided 3 3 9 B • Dust
S S P
beams) with of lifting tools to the hydra operator and
coverall,
the help of • Load or hydra helper
• Leather
hydra may be • Certified and inspected lifting
gloves,
collapsed due tools shall be allowed to lift the
to uneven floor load Ground area shall be

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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surface Strike properly leveled.

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Ensure the machine is inspected

by EHS dept before entering to
site and color coded.
• 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
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.
• Ensure all personnel have • Basic PPEs
undergone Site Safety Induction. • Safety
Bending of • Crush Injury • Ensure PTW Issued by the PMC Goggles,
steel using bar • Hit the men before starting the work. • Respirator
9 due to temper. 5 4 20 A 3 1 3 C S S P
bending • Deploy trained worker for to cut • Dust
machine the steels coverall,
• Tool Box Talks to be conducted • Leather
before start of the activity. gloves,

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Ensure the machine is inspected

by EHS dept before entering to
site and color coded.
• Ensure safety guard provided for
the rotating parts of machine.
• Ensure the second stopper for
protection against struck by
swing arm in case of failure of
first stopper.
• Ensure pinching will happen by
using multiple rods.
• While operating the machine
stand front to the machine to
hold the rod to avoid hit.
• Ensure emergency switch is in
working condition.
• Provide proper PPEs for the
work men who work in the
activity.
• Adequate supervision until the
task completed.
• Ensure all personnel have • Basic PPEs
undergone Site Safety Induction. • Safety
Binding of
• Ensure PTW Issued by the PMC Goggles,
steels using • Pinching hazard
binding
4 4 16 A before starting the work. 3 1 3 C • Respirator S S P
• Deploy trained worker for to cut • Dust
wire
the steels coverall,
• Tool Box Talks to be conducted • Leather

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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before start of the activity. gloves,

• Use proper gloves to avoid
pinching of wires.
• Ensure workers are free from
heat stress.
• Adequate supervision until the
task completed.
• Ensure all personnel have
undergone Site Safety Induction.
• Ensure PTW Issued by the PMC
before starting the work. • Basic PPEs
• Deploy trained worker for to cut • Safety
Shifting Of • Fall of the steels Goggles,
fixed rods materials on • Tool Box Talks to be conducted • Respirator
to working men/hit the 4 4 16 A before start of the activity.
3 1 3 C • Dust
S S P
area men
• Ensure access free from coverall,
manually
obstruction. • Leather
• Ensure no unwanted men gloves,
movement in the shifting area.
• Ensure proper positioning of
fixed rods
• Ensure Competent Person Must • Basic PPEs
work with electrical machine • Safety
Like motors Goggles,
Electrical • Electrocution
10
Operation
5 4 20 A • Ensure cables free from 3 2 6 B • Respirator S S P
damaged. • Dust
• Ensure Safety devices Like coverall,
ELCB/RCCB Connected with the • Leather /

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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circuit. rubber
• Ensure isolation of power source gloves,
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 working area should be
barricaded.
• Ensure LOTO is following while
electrical maintenance.
• Ensure Proper PPEs provided for
the Electrical Technician and
operator
• Ensure adequate supervision
until the task complete.
• Ensure trained workmen • Basic PPEs
working in height. • Safety
• Ensure workmen undergone Goggles,
• Fall of with height work training. • Respirator
Reinforcement materials and • Ensure Scaffold is inspected • Dust
11.
Work
5 5 25 A daily before starting the work.
3 1 3 C coverall,
S S P
men
• Ensure proper working platform • Leather
provided for the workmen. gloves,
• Ensure all tools and tackles Tied • Safety
with rope avoid falling. harness

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Ensure Reinforced materials

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Collapse of • Ensure cables free from damage • Respirator

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Ensure Edge protection/proper

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Proper PPE’s like gumboot and Goggles,

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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• Stacking of LPG shall be placed

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

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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and electric fires with water. gloves

• Use sand bucket/CO2/DCO/sand • FRC
or earth. Cloths
• Ensure proper PPEs to work • Basic PPEs
(helmet, shoes, goggles, leather • Safety
• Bitumen liquid hand gloves, protective cloth Goggles,
may chance to etc.) • Respirator
Applying fall hand/feet • Activity shall be always carried • Face
17 bitumen to /lower body 5 5 25 A out by trained and experienced
3 3 9 B shield
S S P
surface. part. person. • Leather
• Burn injury. • Working under supervision. gloves
• Awareness/ training program to • Protective
be conducted. cloth
• Work area shall be barricaded to
• Men/ material restrict entry. • Basic PPEs
may fall down
• Openings shall be covered if • Safety
through cut out Goggles,
work is preceded in the higher
Restriction of opening.
elevation. • Respirator
unauthorized • Slip, trip & fall
• Access shall be kept clean. • Face
18
entry near • Physical injury 5 5 25 A • No loose materials shall be
4 3 12 B shield
S S P
• Person may get stacked near the edge of the • Leather
work area.
injure. openings. gloves
• May prove • When people are working close • Protective
fatal. to the cut out openings wearing cloth
of full body harness.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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RISK MATRIX
Rating 5 = Almost certain 5 10 15 20 25
Rating 4 = Very likely 4 8 12 16 20
C = CONSEQUENCES

Rating 3 = Possible 3 6 9 12 15
Rating 2 = Unlikely 2 4 6 8 10
Rating 1 = Very unlikely 1 2 3 4 5

* Rating 1 = Negligible Rating 2 = Slight Rating 3 = Moderate Rating 4 = High Rating 5 = Very High
First aid injury or Minor injury or '3 day' injury or Major injury or Fatality, disabling
illness illness illness illness injury, etc.
L = LIKELIHOOD / SEVERITY

Risk Risk Level Action

May be acceptable but review task to see if risk can be reduced
A = 1 to 5 Low Risk
further.
Task should only be undertaken with appropriate management
B = 6 to 10 Medium Risk
authorization after consultation with specialist personnel.
Task must not proceed. It should be redefined or further control
C = 12 to 25 High Risk
measure put in place to reduce risk.

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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Prepared By: SAFETY ENGINEER/PDIL

Checked By: RCM/PM/PDIL

Approved By: GNFC

Other

NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work.
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ON SITE EMERGENCY PLAN

INTRODUCTION
Emergency planning is an integral part of the overall loss control programme and is
essential for our organization. The same is important for effective management of an
accident to minimize the losses to the people and property, both in and around the
facility. The important aspect in emergency management is to prevent by technical
and organizational measures, the unintentional escape of hazardous materials out of
the facility and minimize accidents and losses. Emergency planning demonstrates
the organizational commitment to the safety of employees and increases our
organization’s safety awareness.

An emergency in the factory has potential to cause serious injuries or loss of live or
extensive damage to the property and / or environment and serious disruption both
inside and / or outside the works. In such cases sometimes outside agencies are
required to call for help in handling the situation. The causative factors like plant /
equipment failure, human error, earthquake, sabotage etc. will normally manifest in
various forms viz. Fire, Explosion, Toxic and Structure collapse etc.

In spite of best design and layout of plant, safe operating procedures and various
preventive measures the possibility of a disaster cannot be totally ruled out. During
this event timely and organized action must be taken to control the situation and to
minimize the damage or loss to the factory, human beings and environment hence,
the need of a proper “On–Site Emergency Plan (EPRP)”. Such plan gives the
guidelines for employees, contractors, transporters and Visitors etc. The EPRP not
only defines the responsibilities but also inform about prompt rescue / evacuation
/co-ordination operations and some more.

WHY INTRODUCTION OF EMERGENCY PLANNING IS REQUIRED?

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

OBJECTIVE
The main objective of On-site emergency management plan (On-SEMP) is in
emergency management planning is to ensure that everyone knows:

• What are the hazards and risk in the plant

• What and how to do in the event of an emergency; and
• Preparations for potential and unexpected incidents at the workplace.

The types of emergencies to plan for include fire, explosion, toxic releases, injuries
and rescues in the hazardous events. Plan improves local, district, state and national
capacity to respond to disasters and public health emergencies, scaling up the
actions with vulnerable communities in health promotion, disease prevention and
disaster risk reduction.

As per our Indian regulations we have regulatory provisions that On-site Emergency
Management Plan (On-SEMP) will be prepared by industrial units and Off-site
Emergency Management Plan (Off SEMP) by District Collector.

An occupier will prepare and keep an up-to date on-site emergency plan containing
details of Manufacture, Storage and Import of Hazardous Chemicals (MS&IHC)
Rules 1989 and detailing how major accidents will be dealt with on the site on which
the industrial activity is carried on and that plan will include the name of the person
who is responsible for safety on the site and the names of those who are authorized
to take action in accordance with the plan in case of an emergency. The occupier
will ensure that the emergency plan prepared takes into account any modification
made in the industrial activity and that every person on the site who is affected by
the plan is informed of its relevant provisions.

The occupier will prepare the emergency plan required –

• In the case of a new industrial activity, before that activity is commenced;
• (In the case of an existing industrial activity within 90 days of commencing
into operation of these rules.
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On-site emergency can be due to the following causes

Man-made Cause Natural Cause Extraneous

Riots / Civil
Fire Flood
disorder
Explosion/ Leakage Earthquake Terrorisms
Failure of critical control system Cyclone Sabotage
Outbreak of
Design deficiency Bomb Threat
Disease
War/Hit by
Unsafe Acts Extensive Rains
missiles
In-adequate maintenance Tsunami Abduction
Food poisoning / Water
Poisoning

WHAT IS EMERGENCY?

An emergency is a situation, which may lead to or cause a large-scale damage or

destruction to life or property or environment within or outside the factory.
Sometimes emergency results into uncontrollable situations which leads towards the
disaster. Such an unexpected severe situation may be too great for the normal
workforce in the area within the plant. In any industry emergency can arise at any
moment and this depends on the type of Structure, Raw Materials, Machines / Plant,
Nearby Industries etc.

A major emergency can be defined as an accident/ incident that have potential to

cause serious injuries or loss of life. It may cause extensive damage of property,
serious disruption both in production and working of factory and may adversely
affect the environment. The following factors may cause major emergency.

(i) Plant failure.

(ii) Human error.
(iii) Vehicle crash.
(iv) Sabotage.
(v) Earthquake.
(vi) Natural Calamities.

ON-SITE EMERGENCY: If an accident/ incident takes place in a factory, its effects

is confined to the factory premises, involving only the persons working in the factory
and the property inside the factory it is called as On-site Emergency.

OFF-SITE EMERGENCY: If the accident is such that it affects inside the factory are
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uncontrollable and it may spread outside the factory premises, it is called as Off-site
Emergency.

NATURE OF EMERGENCY

The emergency has been identified and can be specified in one or more of the
followings with source and effect:

Sr.
Emergency Source Effect
No
Small fires complete
Electrical Panels, equipment loss,
Flammable oil storage tanks, complete Area burn
1 Fire / Explosion
Compressors, coolants, out, Air pollution, Soil
paints, etc. pollution, Dangers to
Human beings.
Spillage of
Fire, Burns, Soil
flammable / Hydraulic oil, Furnace Oil,
2 pollution,
Hazardous Oils & Coolant etc.
Injury by slippage
coolant etc
Electrical panels, Power
Distribution Board, DG Set, Burns, suffocation,
Overhead Crane, Voltage Death. Toxic chemical
3 Electric Shock
stabilizer, Electric ingestion into blood
Transformer & Machine stream
Operated by electricity, etc.
Fall from height & Falling
Accidents – Factory
4 of Heavy Materials, Dies, Fracture
(Major)
Bins or other Heavy object.
Accident due to
Death or Injury to
5 Accidents-Transport transportation of man &
Body
material
Personal
6 Toilets, offices, Basement Suffocation
confinement
Natural calamities
Structural collapse,
7 such as storm, Nature
Death
earthquakes, etc.
Office building, & Any Wall Serious injury, Major
8 Structure collapse
or part Of Factory building. Fracture, Death
Riots, Arson, Serious injury, major
9 Anti Social elements.
Sabotaging Fracture, Death.
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10 Toxic gas leakage Fire Hazard, Suffocation Serious injury, Death

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

EMERGENCY ACTION PLAN:

The Action Plan should consist
Designated Emergency Control Centre/Room.
Key Personnel.

EMERGENCY CONTROL CENTRE:

This is the main center from where the operations to handle the emergency are
directed and co-ordinate.

Maximum facilities to be made available in the emergency control are –

i. Internal and external communication.

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

KEY ELEMENTS OF THE ON-SEMP

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

a) Classification and identifying potentially hazardous situations;

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

a) Information on the preliminary hazard analysis:

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

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

THE KEY PERSONNEL & THEIR ROLE FOR ONSITE EMERGENCY

1. Works main site controller.

2. Works incident controller.
a. Communication Officer.
b. Security and Fire Officer.
c. Telephone Operators.
d. Medical Officer.
e. Personnel/Administrative Officer.
f. Essential work team leaders.

SITE CONTROLLER is the person who assumes absolute control of the Factory
and determines the action necessary to control the Emergency. He / She will wear
a Red & White Helmet to confirm his identity. The General Manager will be the
site controller. Site controller will ensure that all members of his/her team have
been informed to collect at Emergency Control centre. He / She will then
proceed to Emergency Control Centre to take charge.

After firsthand assessment of situation he/she will give necessary instructions to

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

• Meet media/ other people coming at site from outside.
• Arrange for Medical Aid

INCIDENT CONTROLLER is the person who goes to the scene of emergency

and supervises the actions taken at the incident to overcome the Emergency.
Shift Manager will act as Incident Controller. His responsibilities will be
• Direct all efforts to contain and control the incident.
• Keep non-essential persons away from the site.
• Guide outside emergency services at the site.
• Arrange to remove any casualties at the site.
• Keep in touch with Emergency Controller.

SECURITY IN-CHARGE WILL

• Actuate the Emergency Siren, if not done already.
• Send one guard to start the fire pump.
• Attend to incoming telephone.
• Await instructions from the Emergency Controller

COMMUNICATION OFFICER
Public Relations Officer will act as Communication Officer. On hearing alarm He
will proceed to Emergency Control Centre.
• Maintains communication with Incident Controller and Deputy Incident
Controller
• Recruits suitable staff to act as messengers if telephone and other
communications fail
• Organizes all requirement of Emergency Control Centre
• Arranges Food, Transport, Nursing Home etc

PERSONNEL MANAGER
• He/she will work as Liaison officer. He should be positioned in the office
near gate.
• Will deal with police, media and outside enquiries in consultation with Site
Controller.
• Will keep in touch with Union
• Will arrange for refreshments if required
• Will control traffic movement inside the factory and arrange for alternative
transport if required
• Will keep a record of attendance of workers, staff, contractor’s personnel,
and visitors at the Gate which will act as Assembly Point.

SAFETY OFFICER
• Will assist the Incident Controller with his special knowledge on the safety
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aspects in the factory. He will help to identify the hazardous chemicals,

hazard zones and zone of probable impact in different accident scenarios
• Will select people with special training in safety matters to assist in the
control activities

FIRE & SECURITY OFFICER

• His/her main task is fire fighting and control
• Announce through PAS about the incident zone and any other immediate
information needed for the people nearby
• Maintains liaison with the Fire Brigade team from outside

MEDICAL OFFICER
• Will immediately open a First Aid Centre at Control Centre or at Assembly
Point
• Will take up the full responsibility of providing medical assistance during
emergency
• Will arrange for outside medical help if required.

TELEPHONE OPERATOR
• On hearing the emergency alarm, he/she will immediately contact Site
Controller
• On the advice of Site controller/Incident Controller/Security Officer will ring
Fire brigade, Police etc
• Keep telephone board free for urgent communications.

GENERAL EMPLOYEES
Who have not been specified a duty in case of emergency should proceed
to/contact the Emergency Assembly Point in their area. Designated persons will
carry out the actions detailed in the Individual Plant Emergency Procedure. The
Roll Call leader will hold a Roll call. Personnel not at their normal work place
must go to the emergency assembly point. Personnel will remain at these points
and await instructions from the Site Controller.

Essential Works and Team Leaders: During emergency the plants immediately
affected or likely to be affected, as determined by the Works Main Controller, need to
be shut down for safety. In the area immediately affected, it may be possible to
isolate equipment from which flammable or toxic material is leaking. This work must
be immediately carried out by plant supervisors and essential operators.
Workers/ staffs need to be nominated to carry out the following essential works at
the time of emergency-
• Extra first aid personnel to deal with casualties.
• Emergency engineering works, provision of extra or replacement of light,
isolation of equipment, temporary by pass electrical lines etc.
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• Moving tankers or other vehicles from area of risk.

• To carry out tests on ambient air quality.
• To act as runner in case of communication system fails.
• The Works Main Controller will require a task force of suitable trained people
for the following works-
i. Manning of assembly points to record the arrival of evacuated people.
ii. Assistance of casualty arrival areas to record details of casualties.
iii. Manning the factory entrance in liaison with security to direct
emergency vehicle containing the gate e.g. ambulance, fire tenders
etc.

For these essential jobs designated teams should be made available. The
responsibilities of the team and the leader should be given. The essential work
teams are-
1. Task Force and repair team.
2. Fire fighting team.
3. Communication team.
4. Security Team.
5. Transport Team.
6. First aid and medical team.
7. Safety team.

CONTRACTOR’S EMPLOYEES
Contractor's employees will be instructed in the Emergency Procedures before
commencing work on this site. They will report to the emergency assembly point
on this site. Personnel Manager will guide them in case a major decision like
evacuation from the factory is taken.

VISITORS
Infrequent visitors are registered on each visit. They will be given a Visitors pass
which includes an emergency action statement. The responsibility for visitors in
emergency situation rests with the person being visited.

RESPONSIBILITIES OUTSIDE GENERAL SHIFT HOURS SHIFT

SUPERVISOR
He/she will act as Site controller for the time being. As soon as becomes aware
of the emergency and its location, he will proceed to the scene. He will assess
the scale of the incident and direct operations within the affected areas.

He/she will contact and inform the Site Controller and Incident Controller
immediately. Till their arrival he will continue to perform their duties.

He/she will contact the departmental head to act as incident controller and guide
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Safety Officer and Security Officers for containing the damage.

He/she will call the Medical Officer to the plant if necessary. Other staff with
designated responsibilities will act as instructed.

INFRASTRUCTURE:
FIRE FIGHTING FACILITIES:
The plant will have adequate fire fighting aids including fire hydrants close to the
required locations. There will be Portable Fire Extinguishers of different types
and sizes are installed in specific places.
The factory siren will be used for raising the alarm and also for ALL CLEAR
signal.

FIRST AID BOXES are provided in specific locations including at the Assembly
point for administering preliminary treatment. A number of employees are trained
for first aid use.
EMERGENCY CONTROL CENTRE is the point from which the Site Controller
directs the movements of Personnel and Equipment during an Emergency.

Contents of Emergency Control Centre:

• External telephone line and a list of relevant telephone numbers. Below
Table 1 provides a list of relevant telephone numbers
• Internal telephone and telephone list of Emergency Assembly Points.
• List of Emergency Control Team, who must be called showing addresses
and telephone numbers.
• Emergency Controller's Red & White Helmet.
• A list of all persons (by title) responsible for groups of employees.
• Logs and Emergency Controller's checklist.
• Emergency lighting.
• Copy of the emergency plan.
• List of persons trained in First Aid & Fire Fighting.
• List of safety cabinets and their contents & locations.
• Battery operated torches.
• Detailed site plan.
• First aid equipment including stretchers (in surgery).
ASSEMBLY POINT is a place containing an internal telephone and paging
system, where people can wait in a group during emergency to receive
instructions from the Emergency Controller.
A safe place far away from the plant should be pre determined as assembly point
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where in case of emergency personnel evacuated from the affected areas are to be
assembled. The plant workers, contract workers and visitors should assemble in
assembly point in case of emergency and the time office clerk should take their
attendance so as to assess the missing person during emergency.

ALARM SYSTEM: Alarm system varies and will depend on the size of the works
area. Simple fire bell, hand operated siren – break open type, fire alarm etc.
Automatic alarm may be needed for highly hazardous nature of plant.

COMMUNICATION SYSTEM: Communication is a key component to control an

emergency.

The following communication system may be provided in the plant-

• Walky Talky.
• Telephone (internal & external).
• Cell phone.
• Intercom/paging.
• Runners (verbal or written messages).

SIREN FOR EMERGENCY: Siren for emergency should be different from the normal
siren. The emergency siren should be audible to a distance of 5 KM radius. The
emergency siren should be used only in case of emergency.

ESCAPE ROUTE: The escape route from each and every plant should be clearly
marked. The escape route is the shortest route to reach out of the plant area to open
area, which leads to assembly point. This route should be indicated on the layout
plan attached to the On-site Emergency Plan.

EVACUATION: All non-essential staff should be evacuated from the emergency site.
As soon as the emergency siren rings the workers have to shut down the plant and
move to the assembly point. The plant shut down procedure in case of emergency
should be prepared and kept ready and responsible person should be nominated for
the purpose.

PERSONNEL COUNTING: All personnel working in the plant should be counted.

Time office person should collect the details of personnel arriving at the assembly
point. These should be checked with the attendances of regular workers, contract
workers present in the site on the day of emergency. The accident control should be
informed and arrangement should be made for searching missing person in the
emergency affected area. The employees’ address, contact number of next to kin
should be maintained in the time office so that during emergency relatives of those
affected due to emergency may be informed accordingly.
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Information in respect of emergency should be given to the media and other agency.

ALL CLEAR SIGNAL: After control of emergency the Work Incident Controller will
communicate to the works main controller about the cessation of emergency. The
main controller can declare all clear by instructing the time office to sound “All Clear
Sirens”.

MUTUAL AID SYSTEM: Mutual aid scheme should be introduced among industries
so that in case of emergency necessary help from mutual aid partner may be
extended.
Essential elements of this scheme are –
• Mutual aid must be a written document signed by the Chief Executive of the
industries concerned.
• Specify key personnel who are authorized to give requisition of materials from
other industries.
• Specify the available quantity of material/equipment that can be spared.
• Mode of requisition during emergency.
• Mode of payment/ replacement of material given during an emergency.
• May be updated from time to time based on experience gained.
MOCK DRILLS on emergency planning should be conducted once in 6 months and
sequence of events should be recorded for improvement of the exercise. Exercises
on On-site Emergency Planning should be monitored by Factory Inspectorate and
the high officials of the organization and the plan is reviewed every year.

EMERGENCY FACILITIES: The following facilities should be provided in any factory

to tackle any emergency at any time.

The onsite emergency plan so prepared shall be documented in a printed form in

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

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

NAME DESIGNATION CONTACT NO EXT.NO (INT)
Security Officer
Fire Officer
Safety Officer
Plant Manager
Operation Manager
ERT Manager
Police Officer
Medical Officer

OFF-SITE EMERGENCY PLAN

Type of emergency facilities/ actions required from outside bodies:
• Fire fighting facilities required: Factory will have its own fire fighting facilities
but during emergency, fire brigade may be called.
• Police help required during emergency for evacuation of the people, traffic
control security arrangements etc. will be available.
• Medical help required: seriously injured personnel may be referred to the local
Hospital / Nursing Home / ESI Hospital depending upon the gravity and type
of injuries.

CONCLUSION:
To carry out mock exercises and rehearsal of the off site plan to ensure its efficiency,
test and response, interaction and co-ordination of operators various service
organizations evaluate the effectiveness and adequacy of the equipments and to
gain experience and confidence to implement the plan. The finalized disaster plan
shall be given to all concerned for implementation and rehearsal for preparedness.
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EMERGENCY RESPONSE DIAGRAM

Message to Proceeds to the Emergency

Emergency
Site Controller Control Centre and takes

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

Personnel Communication Safety Security
to the incident site and takes Officer Officer
Manager Officer
all site related

Works as Organizes all Guides with Fire

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

PHYSICAL & CHEMICAL PROPERTIES / DEFINITION OF CHEMICAL

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

POTENTIAL HAZARDS / TOXICITY

Potential Health Effects
Target Organs: Lungs, Central nervous system, Liver, Kidney
May be harmful if inhaled. Material is extremely destructive to
Inhalation:
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 cartridges.
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Respirators should be used only under any of the following circumstances:

• As a last line of defense (i.e., after engineering and administrative
controls have been exhausted).
• When Permissible Exposure Limit (PEL) has exceeded or when there
is a possibility that PEL will be exceeded.
• Regulations require the use of a respirator.
• An employer requires the use of a respirator.
• There is potential for harmful exposure due to an atmospheric
contaminant (in the absence of PEL)
• As PPE in the event of a chemical spill clean-up process

HAND PROTECTION: Gloves must be worn. Use proper glove removal technique to
avoid any skin contact. Nitride or Neoprene gloves are recommended.
• NOTE: Consult with your preferred glove manufacturer to ensure that
the gloves you plan on using are compatible with Ammonia.

EYE PROTECTION: Wear chemical splash goggles or a face shield to protect from
splash hazards and chemical vapors.

SKIN & BODY PROTECTION:

• Flame resistant lab coat
• Full-length pants
• Closed-toe rubber or leather shoes

HYGIENE MEASURES: Avoid contact with skin, eyes, and clothing. Wash hands
before breaks and immediately after handling the product.

ENGINEERING CONTROLS: Handle using a chemical fume hood with good

ventilation and electrically grounded lines and equipment.

FIRST AID PROCEDURES

If inhaled…Move to fresh air and give oxygen. If the person is not breathing,
give artificial respiration. Avoid mouth to mouth contact.

In case of skin contact…Remove all contaminated clothing. Immediately

(within seconds) flush affected area for FIFTEEN (15) minutes.

In case of eye contact…Remove any contact lenses. Use nearest emergency

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

an unconscious person.

SPECIAL STORAGE & HANDLING REQUIREMENTS

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

SPILL AND ACCIDENT PROCEDURE

PERSONAL PRECAUTIONS: Avoid breathing vapors, mist or gas. Ensure
adequate ventilation. Evacuate personnel to safe areas. Do not attempt clean-up
without minimum PPE. Beware of vapors accumulating to form explosive
concentrations. Vapors can accumulate in low areas.
ENVIRONMENTAL PRECAUTIONS: Prevent further leakage or spillage – if safe to
do so. Do not allow product to enter drains. Discharge into environment must be
avoided.
METHODS AND MATERIALS FOR CONTAINMENT AND CLEAN-UP: Consider
material compatibility prior to clean-up. Verify spill kit is available. Contain spillage
and the collect with an electrically protected vacuum cleaner or by wet-brushing and
place in container for disposal according to regulations.
• Immediately assess amount spilled, follow posted Emergency
Response Guide procedures for hazardous materials incidents.
• If a chemical exposure has occurred, a fellow worker shall call
Emergency number and EH&S department.
ANNEXURE – R
HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

• Don compatible gloves and other protective PPE if not already being
worn.
• Secure / restrict access to the area of the spill to prevent spread of the
chemical.
• Use the available spill kit to stop and contain the spill. Bag the
collected material.
• Label and tag as hazardous waste and submit a pick-up request to
EH&S using EHS Assistant.

DECONTAMINATION / WASTE DISPOSAL PROCEDURE

LABEL WASTE: Attach a completed Hazardous Waste tag to all waste containers
as soon as the first drop of waste is added to the container.

STORE WASTE
• Store hazardous waste in closed containers, in secondary containment
and in a designated storage location.
• Double-bag dry waste using sealable transparent bags.
• Waste must be under the control of the person generating and
disposing of it.
DISPOSE OF WASTE
• Dispose of regularly generated chemical waste within 90 days.
• Use EHS Assistant online hazardous waste pick-up request system.
• Contact EH&S Department with questions.

DOCUMENTATION OF TRAINING
• Prior to conducting any work with this material, Principal Investigator or
designee must provide to his/her laboratory personnel specific to the
hazards involved in working with this substance, work area decontamination,
and emergency procedures.
• The Principal Investigator must provide his/her laboratory personnel with a
copy of SOP and a copy of the MSDS provided by the manufacturer.

EDUCATION OF PUBLIC / WORKER

People working within the influence zone will be educated on the emergency in a
suitable manner. This can be achieved only through the Local and District
Authorities. However, necessary information can be extended to the Authority.

*******
ANNEXURE – R
HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

STANDARD OPERATING PROCEDURE (EHS)

PROJECT

PROJECT MANAGEMENT CONSULTANCY SERVICES

FOR
REPLACEMENT OF SINGLE WALL AMMONIA
STORAGE TANK BY DOUBLE WALL STORAGE TANK
AT
GNFC AMMONIA PLANT, BHARUCH

OWNER

GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS

BHARUCH - GUJARAT, INDIA

ENGINEERING CONSULTANT

PROJECTS & DEVELOPMENT INDIA LIMITED

(A Govt. of India Undertaking)
SAMTA, SUBHANPURA, VADODARA

0 17.12.2020 17.12.2020 FOR IMPLEMENTATION TAV KMS SNY

REV REV DATE EFF.DATE PURPOSE PREPD REVWD APPD
All rights reserved
ANNEXURE – R
HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

CONTENT
PAGE
CLAUSE TITLE
NO.
1 .0 Scope 6
2 .0 References 6
Requirement of Health, Safety and Environment (HSE)
3 .0 7
Management System to be complied by Bidders
3.1 Management Responsibility 7
3.1 .1 HSE Policy & Objective 7
3.1 .2 Management System 7
3.1 .3 Indemnification 7
3.1 .4 Deployment & Qualification of Safety Personnel 7
3.1 .5 Implementation, Inspection & Monitoring 10
3.1 .6 Behavior Based Safety 12
3.1 .7 Awareness & Motivation 14
3.1 .8 Fire prevention & First-Aid 14
3.1 .9 Documentation 15
3.1 .10 Audit 15
3.1 .11 Meetings 16
3.1 .12 Intoxicating drinks & drugs and smoking 17
3.1 .13 Penalty 18
3.1 .14 Accident/Incident investigation 21
3.2 House Keeping 22
3.3 HSE Measures 23
3 .3 .1 Construction Hazards 23
3 .3 .2 Accessibility 25
3 .3 .3 Personal Protective Equipments (PPEs) 26
3 .3 .4 Working at height 27
3 .3 .5 Scaffoldings & Barricading 29
3 .3 .6 Electrical installations 30
3 .3 .7 Welding/Gas cutting 34
3. 3 .8 Ergonomics and tools & tackles 35
3.3 .9 Occupational Health 36
3.3.10 Hazardous substances 37
3.3.11 Slips, trips & falls 38
3.3.12 Radiation exposure 38
3.3.13 Explosives/Blasting operations 39
3.3.14 Demolition/Dismantling 39
3.3.15 Road Safety 40
3.3.16 Welfare measures 41
3.3.17 Environment Protection 42
3.3.18 Rules & Regulations 42
3.3.19 Weather Protection 43
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DOCUMENT NAME: ENVIRONMENT HEALTH &
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3.3.20 Communication 43
3.3.21 Confined Space Entry 44
3.3.22 Heavy Lifts 44
3.3.23 Key performance indicators 45
3.3.24 Unsuitable Land Conditions 46
3.3.25 Under Water Inspection 47
3.3.26 Excavation 47
3 .4 Tool Box talks 48
3 .5 Training & Induction Program 49
Additional safety requirements for working Inside a running
3 .6 51
plant.
3 .7 Self Assessment and Enhancement 53
3 .8 HSE Promotion 53
3 .9 LOTO for isolation of energy source 53
4 .0 Details of HSE Management System by Contractor 54
4 .1 On Award of Contract 54
4 .2 During Job Execution 55
4 .3 During short listing of the sub-contractors 57

APPENDICES

1. Standards/Codes on HSE Appendix-A

2. Details of First AID Box Appendix-B

3. Types of Fire Extinguishers & their Appln. Appendix-C

4. Indicative List of statutory Acts & Rules Appendix-D

5. Training subjects / topics Appendix-E

6. List of HSE procedures Appendix-F

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ABREVATIONS
AERB : Atomic Energy Regulatory Board
ANSI : American National Standards Institute
BARC : Bhabha Atomic Research Centre
BS : British Standard
PDIL : Projects & development India Limited
ELCB : Earth Leakage Circuit Breaker
EPC : Engineering, Procurement and Construction
EPCC : Engineering, Procurement, Construction and Commissioning
ESI : Employee State Insurance
GCC : General Conditions of Contract
GM : General Manager
GTAW : Gas Tungsten Arc Welding
HOD : Head of Department
HSE : Health, Safety & Environment
HV : High Voltage
IS : Indian Standard
IE : Indian Electricity
JSA : Job Safety Analysis
LOTO : Lock Out & Tag Out
LPG : Liquefied Petroleum Gas
LSTK : Lump Sum Turn Key
MV : Medium Voltage
PPE : Personal Protective Equipment
RCM : Resident Construction Manager or Site-in-Charge, as applicable
ROW : Right of Way
SCC : Special Conditions of Contract
SLI : Safe Load Indicator
TBM : Tool Box Talks/Meeting
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1.0 SCOPE

This specification establishes the Health, Safety and Environment (HSE)

management requirement to be complied by Contractors/Vendors including their
sub-contractors/sub vendors during work.
This specification is not intended to replace the necessary professional judgment
needed to design & implement an effective HSE system for construction activities
and the contractor is expected to fulfill HSE requirements in this specification as
a minimum. It is expected that contractor shall implement best HSE practices
beyond whatever are mentioned in this specification.
Requirements stipulated in this specification shall supplement the requirements
of HSE Management given in relevant Act(s)/legislations, General Conditions of
Contract (GCC), Special Conditions of Contract (SCC) and Job (Technical)
Specifications. Where different documents stipulate different requirements, the
most stringent shall apply.

REFERENCES

The document should be read in conjunction with following:

- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers Act,
- Indian Factories Act
- Job (Technical) specifications
- Relevant International / National Codes
- Relevant State & National Statutory requirements.
- Operating Manuals Recommendation of Manufacturer of various
construction Machineries
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3.0 Requirements of HSE Management system to be complied by Bidders

3. 1 Management Responsibility

3 .1.1 HSE Policy & Objectives

The Contractor should have a documented HSE policy duly & objectives to
demonstrate commitment of their organization to ensure health, safety and
environment aspects in their line of operations. HSE Policy of the contractor shall
be made available to Owner / PDIL at the place of execution of specific contract
works, as a valid document.

3 .1.2 Management System

The HSE management system of the Contractor shall cover the HSE
requirements and commitments to fulfill them, including but not limited to what
are specified under clause 1.0 and 2.0 above. The Contractor shall obtain the
approval of its site specific HSE Plan from PDIL /Owner prior to commencement
of any site works. Corporate as well as Site management of the Contractor shall
ensure compliance of their HSE Plan at work sites in its entirety & in true spirit.

3 .1.3 Indemnification

Contractor shall indemnify & hold harmless, Owner /PDIL & their representatives,
free from any and all liabilities arising out of non-fulfillment of HSE requirements
or its consequences.

3 .1.4 Deployment & qualifications of Safety personnel

The Contractor shall designate/deploy various categories of HSE personnel at

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

Engineer what is indicated in relevant statute of BOCW Act i.e. deployment of
safety officer /Safety Engineer is compulsory at project site. The Safety
supervisors, Safety stewards etc. would facilitate the HSE tasks at grass root
level for construction sites and shall assist Safety Officer / Engineers.

A) Safety Steward

For every 250 workmen, one safety steward shall be deployed. As a minimum,
he shall preferably possess School leaving Certificate (of Class XII with Physics
& Chemistry etc.) and trained in fire-fighting as well as in safety/occupational
health related subjects, with minimum two year of practical experience in
construction work environment and preferably have adequate knowledge of the
language spoken by majority of the workers at the construction site.

B) Safety Supervisor

For every 500 workmen, one safety Supervisor shall be deployed. As a minimum,
he shall possess a recognized Degree in Science (with Physics & Chemistry) or
a diploma in Engineering or Technology with minimum Two years of practical
experience in construction work environment and should possess requisite skills
to deal with construction safety & fire related day-to-day issues.

C) Safety Officer / Safety Engineer

One for every 1000 workers or part thereof shall be deployed. Safety officer/
Engineer Should Possess following Qualification & Experience:

• Recognized degree in any branch of Engineering or Technology or

Architecture with practical experience of working in a building or other
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construction work in supervisory capacity for a period of not less than two
years, or possessing recognized diploma in any branch of Engineering or
Technology with practical experience of building or other construction work in
supervisory capacity for a period of not less than five years.
• Recognized degree or diploma in Industrial safety with one paper in
Construction Safety.
• Preferably have adequate knowledge of the language spoken by majority of
the workers at the construction site.
• Person possessing Graduation Degree in Science with Physics & Chemistry
and degree or diploma in Industrial Safety (from any Indian institutes
recognized by AICTE or State Council of Tech. Education of any Indian State)
with practical experience of working in a building, plant or other construction
works (as Safety Officer, in line with Indian Factories Act, 1958) for a period
of not less than five years, may be considered as Safety Officer, in case
Owner/Client of the project agrees for /approves the same.

D) HSE In-Charge

In case there is more than one Safety Officer at any project construction site, one
of them, who is senior most by experience (in HSE discipline), may be
designated as HSE In-Charge. Duties & responsibilities of such person shall be
commensurate with that of relevant statute and primarily to coordinate with top
management of Client and contractors. In case the statutory requirements i.e.
State or Central Acts and / or Rules as applicable like the Building and Other
Construction Workers’ Regulation of Employment and Conditions of Service-
Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules
(wherever notified), etc. are more stringent than above clarifications, the same
shall be followed.
Contractors shall ensure physical availability of safety personnel at the place of
specific work location, where Hot Work Permit is required / granted. No work
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shall be started at any of the project sites until above safety personnel &
concerned Site Engineer of Contractor are physically deployed at site. The
Contractor shall submit a HSE organogram clearly indicating the lines of
responsibility and reporting system and elaborate the responsibilities of safety
personnel in their HSE Plan.
The Contractor shall verify & authenticate credentials of such safety personnel
and furnish Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as
above for PDIL/Owner’s approval, at least 1 month before the mobilization. The
Contractor, whenever required, shall arrange submission of original
testimonials/certificates of their Safety personnel, to PDIL /Owner (for verification
/scrutiny, etc.) Imposition / Realization of penalty shall not absolve the Contractor
from his/her responsibility of deploying competent safety officer at site. Adequate
planning and deployment of safety personnel shall be ensured by the Contractor
so that field activities do not get affected because of non-deployment of
competent & qualified safety people in appropriate numbers.

3 .1.5 Implementation, Inspection / Monitoring

• The Contractor shall be fully responsible for planning, reporting, implementing

and monitoring all HSE requirements and compliance of all laws & statutory
requirements. The Contractor shall also ensure that the HSE requirements
are clearly understood & implemented conscientiously by their site personnel
at all levels at site.
• The Contractor shall ensure physical presence of their field
engineers/supervisors, during the continuation of their contract works /site
activities including all material transportation activities. Physical absence of
experienced field engineers / supervisors of Contractor at critical work spot
during the course of work may invite severe penalization as per the discretion
of EIC, including halting / stoppage of work.
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• Contractor shall furnish their annual Inspection Plan, with regard to project
issues /subjects, frequency and performers to PDIL /Owner.
• The Contractor shall regularly review inspection report internally and
implement all practical steps / actions for improving the status continuously.
• The Contractor shall ensure important safety checks right from beginning of
works at every work site locations and to this effect “Daily Safety Check List”
shall be prepared by field engineer & duly checked by safety personnel for
conformance.
• The Contractor shall carry out inspection to identify various unsafe conditions
of work sites/machinery/equipments as well as unsafe acts on the part of
workmen/supervisor /engineer while carrying out different project related
works.
• Adequate records for all inspections shall be maintained by the Contractor
and the same shall be furnished to PDIL /Owner, whenever sought.
• The Contractor shall not carry-out work by engaging single worker anywhere
without any supervisor anytime during day or night.
• To demonstrate involvement/commitment of site management of Contractor,
at least one Safety Walk through in a month shall be carried out by
Contractor’s head of site (along with his area manager/field engineers) and a
report shall be furnished to PDIL/Owner “Safety walk through report” followed
by compliance for unsatisfactory remarks.
• As a general practice lifting tools/tackles, machinery, accessories etc. shall be
inspected, tested and examined by competent people (approved by
concerned State authorities) before being used at site and also at periodical
interval (e.g. during replacement, extension, modification, elongation /
reduction of machine / parts, etc.) as per relevant statutes. Hydra, cranes,
lifting machinery, mobile equipments / machinery / vehicles, etc. shall be
inspected regularly by only competent / experienced personnel at site and
requisite records for such inspections shall be maintained by every contractor.
Contractor shall also maintain records of maintenance of all other site
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machinery (e.g. generators, rectifiers, compressors, cutters, etc.) & portable

tools /equipments being used at project related works (e.g. drills, abrasive
wheels, punches, chisels, spanners, etc.). The Contractor shall not make use
of arbitrarily fabricated ‘derricks’ at project site for lifting / lowering of
construction materials.
• Site facilities /temporary installations, e.g. batching plant, cement go down,
DG-room, temporary electrical panels/distribution boards, shot-blasting booth,
fabrication yards, etc. and site welfare facilities, like labour colonies,
canteen/pantry, rest-shelters, motorcycle/bicycle-shed, site washing facilities,
First-aid centers, urinals/toilets, etc. should be periodically inspected by
Contractor (preferably utilizing HR /Admin personnel to inspect site welfare
facilities) and records to be maintained.

3 .1.6 Behavior Based Safety

• The contractor shall develop a system to implement Behavior-Based Safety

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

consequences as appropriate.
• Communicate any changes to workforce.

• Contractor through its own HSE committee shall implement the above
process.

The necessary procedures and reporting formats shall be developed by the

contractor for approval by PDIL /Owner.
• The HSE committee of contractor shall observe individual’s behavior for safe
practices adapted for utilization /execution of work for following as a
minimum:-
- PPE
- Tools & equipment
- Hazard Identification & control
- House keeping
- Confined space entry
- Hot works
- Excavation
- Loading & unloading
- Work at height
- Stacking & storage
- Ergonomics
- Procedures

3 .1.7 Awareness and Motivation

• The Contractor shall promote and develop awareness on Health, Safety and
Environment protection among all personnel working for the Contractor.
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• Regular awareness programs and fabrication shop / work site meetings at

least on monthly basis shall be arranged on HSE activities to cover
hazards/risks involved in various operations during construction.
• Contractor to motivate & encourage the workmen & supervisory staff by
issuing / awarding them with tokens/ gifts/ mementos/ monetary incentives /
certificates, etc.
• Contractor shall assess & recognize the behavioral change of its site
engineers / supervisors periodically and constantly motivate / encourage them
to implement HSE practices at project works.

3 .1.8 Fire prevention & First-Aid

• The Contractor shall arrange suitable First-aid measures such as First Aid
Box (Refer Appendix-B for details), trained personnel/nurse (male) to
administer First Aid, stand-by Ambulance vehicle.
• The Contractor shall arrange installation of fire protection measures such as
adequate number of steel buckets with sand & water and adequate number of
appropriate portable fire extinguishers (Refer Appendix-C for details) to the
satisfaction of PDIL /Owner.
• The Contractor shall deploy trained supervisory personnel / field engineers to
cater to any emergency situation.
• In case the number of workers exceeds 500, the Contractor shall position an
Ambulance / vehicle and nurse on round the clock basis very close to the
worksite.
• The Contractor shall arrange FIRE DRILL at each site at least once in three
months, involving site workmen and site supervisory personnel & engineers.
The Contractor shall maintain adequate record of such fire drills at project
site.

3 .1.9 Documentation
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The Contractor shall evolve a comprehensive, planned and documented system

covering the following as a minimum for implementation and monitoring of the
HSE requirements and the same shall be submitted for approval by Owner/PDIL.

- HSE Organogram
- Site specific HSE Plan
- Safety Procedures, forms and Checklist.
- Inspections and Test Plan
- Risk Assessment & Job Safety Analysis for critical works.

The monitoring for implementation shall be done by regular inspections and

compliance of the observations thereof. The Contractor shall get similar HSE
requirements implemented at his sub-contractors work site /office. However,
compliance of HSE requirements shall be the responsibility of the Contractor.
Any review/approval by PDIL /Owner shall not absolve contractor of his
responsibility /liability in relation to fulfilling all HSE requirements.

3 .1.10 Audit

The Contractor shall submit an Audit Plan to PDIL/Owner indicating the type of
audits and covering following as minimum:
• Internal HSE audits regularly at least on quarterly basis by engaging internal
qualified auditors (viz safety officers /Construction personnel having 5 years
experience in construction safety and Lead Auditor Course :OSHA 18001
certification).
• External HSE audits regularly at least on every six months by engaging
qualified external auditors (viz safety officers/Construction personnel having
10 years experience in construction safety and Lead Auditor Course :OSHA
18001 certification). All HSE shortfalls/non-conformances on HSE matters
brought out during review /audit shall be resolved forthwith (generally within a
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week) by Contractor & compliance report shall be submitted to PDIL /Owner.

In addition to above audits by contractor, the contractor’s work shall be
subjected to HSE audit by PDIL /Owner at any point of time during the
pendency of contract. The Contractor shall take all actions required to comply
with the findings of the Audit Report and issue regular Compliance Reports
for the same to Owner /PDIL till all the findings of the Audit Report are fully
complied. Failure to carry-out HSE Audits & its compliance (internal &
external) by Contractor, shall invite penalization.

3 .1.11 Meetings

• The Contractor shall ensure participation of his top most executive at site (viz.
Resident Construction Manager / Resident Engineer / Project Manager / Site-
in-Charge) in Safety Committee/ HSE Committee meetings arranged by
PDIL/Owner usually on monthly basis or as and when called for. In case
Contractor’s top most executive at site is not in a position to attend such
meeting, he shall inform PDIL/Owner in writing before the commencement of
such meeting indicating reasons of his absence and nominate his
representative – failure to do so may invite very stringent penalization against
the specific Contractor, as deemed fit in Contract. The obligation of
compliance of any observations during the meeting shall be always time
bound. The Contractor shall always assist PDIL/Owner to achieve the targets
set by them on HSE management during the project implementation.
• In addition, the Contractor shall also arrange internal HSE meetings chaired
by his top most executive at site on weekly basis and maintain records. Such
internal HSE meetings shall essentially be attended by field engineers /
supervisors (& not by safety personnel only) of the Contractor and its
associates. Records of such internal HSE meetings shall be maintained by
the Contractor for review by PDIL/Owner or for any HSE Audits.
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• Agenda of internal HSE meeting should broadly cover: -

a. Confirmation of record notes / minutes of previous meeting
b. Discussion on outstanding subjects of previous points / subjects, if any
c. Incidents / Accidents (of all types) at project site, if any
d. Current topics related to site activities / subjects of discussion
e. House keeping
f. Behavioral Safety
g. Information / views / deliberations of members / site sub Contractors
h. Report from Owner / Client
i. Status of Safety awareness, Induction programs & Training programs
j. The time frame for such HSE meeting shall be religiously maintained by
one and all.

3 .1.12 Intoxicating drinks & drugs and Smoking

• The Contractor shall ensure that his staff members & workers (permanent as
well casual) shall not be in a state of intoxication during working hours and
shall abide by any law relating to consumption & possession of intoxicating
drinks or drugs in force.
• The Contractor shall not allow any workman to commence any work at any
locations of project activity who is/are influenced / effected with the intake of
alcohol, drugs or any other intoxicating items being consumed prior to start of
work or working day.
• Awareness about local laws on this issue shall form part of the Induction
Training and compulsory work-site discipline.
• The Contractor shall ensure that all personnel working for him comply with
“No-Smoking” requirements of the Owner as notified from time to time.
Cigarettes, lighters, auto ignition tools or appliances as well as intoxicating
drugs, dry tobacco powder, etc. shall not be allowed inside the project / plant
complex.
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• Smoking shall be permitted only inside smoking booths exclusively

designated & authorized by the Owner /PDIL.

3 .1.13 Penalty

The Contractor shall adhere consistently to all provisions of HSE requirements.

In case of non compliances and also for repeated failure in implementation of any
of the HSE provisions, PDIL /Owner may impose stoppage of work without any
cost & time implication to the Owner and/or impose a suitable penalty.
The amount of penalty to be levied against defaulted Contractor shall be up to a
cumulative limit of 2 .0 % (Two percent) of the contract value for Item Rate,
0 .5 % (Zero decimal five percent) of the contract value for LSTK, EPC, EPCC
This penalty shall be in addition to all other penalties specified elsewhere in the
contract. The decision of imposing stop-work-instruction and imposition of
penalty shall rest with PDIL /Owner. The same shall be binding on the
Contractor. Imposition of penalty does not make the Contractor eligible to
continue the work in unsafe manner.

The amount of penalty applicable for the Contractor on different types of HSE
violations is specified below:
Sr.
Violation of HSE norms Penalty Amount
No.
For not using personal protective equipment
Rs 500/- per day/ Item /
1 (Helmet, Shoes, Goggles, Gloves, Full body
Person.
harness, Face shield, Boiler suit, etc.)
2 Working without Work Permit / Clearance Rs 20,000/- per occasion.
Execution of work without deployment of requisite Rs. 5,000/- per violation per
3
field engineer / supervisor at work spot. day
Unsafe electrical practices (not installing ELCB,
using poor joints of cables, using naked wire without
4 Rs 5,000/- per item per day.
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 Rs. 5,000/- per case per day.
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non-standard/ rejected scaffolding and not

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

timeframe.
Degradation of environment (not confining toxic
18 Rs10,000/- per occasion
spills, spilling oil /lubricants onto ground)
Not medically examining the workers before
allowing them to work at height / to work in
confined space / to work in shot-blasting / to work
for painting / to work in bitumen or asphalt works, Rs 5,000/- per occasion per
19
not providing ear muffs while allowing them to work worker
in noise polluted 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
20 Rs. 5,000/- per occasion
extinguisher ready at hot work site, unsafe rigging
practices, non-availability of First-Aid box at site, not
using hood with respiratory devices by blaster for
shot//grit blasting, etc.)
Failure to carry-out Safety audit in time (internal &
21 external), close-out of identified shortfalls of Rs. 20,000/- per occasion
Observations of Safety Aspects(OSA),etc
Carrying out sand blasting instead of grit / shot
22 Rs. 50,000/- per day
blasting
Failure to deploy adequately qualified and Rs. 10,000/- per day per
23
competent Safety Officer Officer
Utilization of hydra/ back-hoe loader for material
24 shifting or any other unauthorized /unsafe lifting Rs 25,000/- per occasion
works
Rs 10,00,000/- per occasion
Any incident / accident at project site has been
(1st Instant)
caused because of willful negligence or gross
Rs 15,00,000/- per occasion
25 violation of safety measures / provisions on the part
(2nd Instant)
of the Contractor or any of its sub-agencies (Fatal
Termination of present
,Major Accidents)
Contract (3rd instant)
Rs. 5,000/- per occasion per
26 Poor Housekeeping
day
To be decided by
27 Any violation not covered above
PDIL/Owner.

The Contractor shall make his field engineers/supervisors fully aware of the fact
that they keep track with the site workmen for their behavior and compliance of
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various HSE requirements. Safety lapses /defects of project construction site

shall be attributable to the concerned job supervisor /engineer of the Contractor,
(who remains directly responsible for safely executing field works). For repeated
HSE violations, concerned job supervisor /engineer shall be reprimanded or
appropriate action, as deemed fit, shall be initiated (with information to PDIL &
Owner) by the concerned Contractor.
Contractor shall initiate levy of mentioned cash fine and verbal warning shall be
given to the worker/employee during his first HSE violation. A written warning
shall be issued on second violation & Fine will be double and specific training
shall be arranged / provided by the Contractor to enhance HSE awareness/skill
including feedback on the mistakes/ flaws. Any further violation of HSE
stipulations by the erring individuals shall call for his forthright debar from the
specific construction site and fine will be 10 times higher. A record of warnings
for each worker / employee shall be maintained by the Contractor, like by
punching their cards / Gate passes or by displaying their names at the Project
entry gate. Warnings, penalizations, appreciations etc. shall be discussed in HSE
Committee meetings by site Head of the Contractor.

3 .1.14 Accident / Incident investigation

All accidents / incidents shall be informed to PDIL / Owner at least telephonically

by Contractor immediately and in writing within 24 hours as applicable, by
Contractor. Thereafter, a Supplementary Accident / Incident investigation Report
shall be submitted to PDIL / Owner within 72 hours. Near Miss incidents,
Dangerous accidents / incident shall also be reported within 24 hours. The
accident/ incident shall be investigated by a team of Contractor’s senior Site
personnel (involving Site-in- Charge or at least by his deputy) for establishing
root-cause and recommending corrective & preventive actions. Findings shall be
documented and suitable actions taken to avoid recurrences shall be
communicated to PDIL / Owner. Owner/ PDIL shall have the liberty to
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independently investigate such occurrences and the Contractor shall extend all
necessary help and cooperation in this regard. PDIL/Owner shall have the right
to share the content of this report with the outside world.

3. 2 House Keeping

The Contractor shall ensure that a high degree of housekeeping is maintained

and shall ensure the followings:
• All surplus earth and debris are removed /disposed off from the working areas
to designated locations.
• Unused /surplus cables, steel items and steel scrap lying scattered at
different places within the working areas are removed to identify locations.
• All wooden scrap, empty wooden cable drums and other combustible packing
materials, shall be removed from work place to identified locations.
• Roads shall be kept clear and materials like pipes, steel, sand, boulders,
concrete, chips and bricks etc shall not be allowed on the roads to obstruct
free movement of men & machineries.
• Fabricated steel structural, pipes & piping materials shall be stacked properly
for erection.
• Water logging on roads shall not be allowed.
• No parking of trucks /trolleys, cranes and trailers etc shall be allowed on
roads, which may obstruct the traffic movement.
• Utmost care shall be taken to ensure over all cleanliness and proper upkeep
of the working areas.
• Trucks carrying sand, earth and pulverized materials etc. shall be covered
while moving within the plant area /these materials shall be transported with
top surface wet.
• The contractor shall ensure that the atmosphere in plant area and on roads is
free from particulate matter like dust, sand, etc. by keeping the top surface
wet for ease in breathing.
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• At least two exits for any unit area shall be assured at all times – same
arrangement is preferable for digging pits /trench excavation /elevated work
platforms /confined spaces etc.
• Welding cables and the power cable must be segregated and properly stored
and used .The same shall be laid away from the area of movement and shall
be free from obstruction.
• Schedule for upkeep /cleaning of site to be firmed up and implemented on
regular basis for maintaining high standard of housekeeping and maintain
records for the same.

3. 3 HSE Measures

3 .3.1 Construction Hazards

The Contractor shall ensure identification of all Occupational Health, Safety &
Environmental hazards in the type of work he is going to undertake and enlist
mitigation measures. Contractor shall carry out Job Safety Analysis (JSA) /Risk
Analysis specifically for high risk jobs /critical jobs like.

• Working at height (+2.0 Mts height) for cold (incl. colour washing, painting,
insulation etc.) & hot works.
• Work in confined space,
• Deep excavations & trench cutting (depth > 2.0 mts.)
• Operation & Maintenance of Batching Plant.
• Shuttering / concreting (in single or multiple pour) for columns, parapets &
roofs.
• Erection & maintenance of Tower Crane.
• Erection of structural steel members /roof-trusses /pipes at height more
than 2.0 Mts. with or without crane.
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• Erection of pipes (full length or fabricated) at height more than 2.0 Mts.
height with Crane of 100T capacity.
• All lifts using 100T Crane plus mechanical pulling.
• All lifts using two cranes in unison (Tandem Lifting).
• Any lift exceeding 80% capacity of the lifting equipments (hydra, crane
etc.).
• Lying of pipes (isolated or fabricated) in deep narrow trenches– manually
or mechanically.
• Maintenance of crane /extension or reduction of crane-boom on roads or
in yards.
• Erection of any item at >2.0 Mts. height using 100T crane or of higher
capacity
• Hydrostatic test of pipes, vessels & columns and water-flushing.
• Radiography jobs (in-plant & open field)
• Work in Live Electrical installations / circuits
• Handling of explosives & Blasting operations
• Demolishing / dismantling activities
• Welding / gas cutting jobs at height (+2.0 Mts.)
• Lifting / placing roof-girders at height (+2.0 Mts.)
• Lifting & laying of metallic / non-metallic sheet over roof /structures.
• Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with &
without using cranes.
• Calibration of equipment, instruments and functional tests at yards / work-
sites.
• Operability test of Pump, Motors (after coupling) & Compressors.
• Cold or Hot works inside Confined Space.
• Transportation & shifting of ODC consignments into project areas.
• Working in “charged /live” elect. Panels
• Stress Relieving works (Electrically or by Gas-burners).
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• Pneumatic Tests
• Card board blasting
• Chemical cleaning and take feedback from PDIL /Owner. The necessary
HSE measures devised shall be put in to place, prior to start of an activity
& also shall be maintained during the course of works, by the Contractor.
Copies of such JSAs shall be kept available at work sites by the
Contractor to enable all concerned carrying out checks /verification.

Accessibility

• The Contractor shall provide safe means of access(in sufficient numbers) &
efficient exit to any working place including provisions of suitable and
sufficient scaffolding at various stages during all operations of the work for the
safety of his workmen and PDIL /Owner.
• The Contractor shall implement use of all measures including use of “life line”,
“fall arresters”, “retractable fall arresters” , “safety nets” etc. during the course
of using all safe accesses & exits, so that in no case any individual remains at
risk of slip & fall during their travel.
• The access to operating plant /project complex shall be strictly regulated. Any
person or vehicle entering such complex shall undergo identification check,
as per the procedures in force /requirement of PDIL /Owner.

Accessibility to ‘confined space’ shall be governed by specific system /regulation,

as established at project site.

Personal Protective Equipments (PPEs)

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

e. Fall arresters
f. Portable ladders (varying lengths)
g. Life-lines (steel wire-rope, dia not less than 8.0 mm)
h. Full body harness (double lanyard)
i. Lanyard
j. Karabiner
k. Retractable fall arresters (various lengths)
l. Portable fire extinguishers (DCP type) – 6 kg capacity
m. Portable Multi Gas detector
n. Sound level meter
o. Digital Lux meter
p. Fire hoses & flow nozzles
q. Fire blankets / Fire retardant cloth (with eyelets)

Working at height

• The Contractor shall issue permit for working (PFW) at height after verifying
and certifying the checkpoints. He shall also undertake to ensure compliance
to the conditions of the permit during the currency of the permit including
adherence of personal protective equipments. Contractor’s Safety Officer
shall verify compliance status of the items of permit document after
implementation of action is completed by Contractor’s execution / field
engineers at work site. Job Safety Analysis (JSA) for specific works at height
duly commented by PDIL /Owner, shall be kept attached with particular
Permit for Work (PFW) at site for ready reference & follow-up. Such PFW
shall be initially issued for one single shift or expected duration of normal
work and extended further for balance duration, if required. PDIL /Owner can
devise block-permit system at any specific area, in consultation with project
specific HSE Committee to specify the time-period of validity of such PFW or
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its renewal. This permit shall be applicable in areas where specific clearance
from Owner’s operation Dept. / Safety Dept. is not required. PDIL /Owner’s
field Engineers /Safety Officers / Area Coordinators may verify and counter
sign this permit (as an evidence of verification) during the execution of the
job.
• All personnel shall be medically examined & certified by registered doctor,
confirming their ‘medical fitness for working at height. The fitness examination
shall be done once in six months.
• In case work is undertaken without taking sufficient precautions as given in
the permit, PDIL /Owner Engineers may exercise their authority to cancel
such permit and stop the work till satisfactory compliance /rectification is
arranged made. Contractors are expected to maintain a register for issuance
of permit and extensions thereof including preserving the used permits for
verification during audits etc.
• The Contractor shall arrange (at his cost) and ensure use of Fall Arrester
Systems by his workers. Fall arresters are to be used while climbing
/descending tall structures or vessels /columns etc. These arresters should
lock automatically against the anchorage line, restricting free fall of the user.
The device is to be provided with a double security opening system to ensure
safe attachment or release of the user at any point of rope. In order to avoid
shock, the system should be capable of keeping the person in vertical
position in case of a fall.
• The Contractor shall ensure that Full body harnesses conforming EN361 and
having authorized CE marking is used by all personnel while working at
height. The lanyards and life lines should have enough tensile strength to
take the load of the worker in case of a fall. One end of the lanyard shall be
firmly tied with the harnesses and the other end with life line. The harness
should be capable of keeping the workman vertical in case of a fall, enabling
him to rescue himself.
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• The Contractor shall provide Roof Top Walk Ladders for carrying out activities
on sloping roofs in order to reduce the chances of slippages and falls.
• The Contractor shall ensure that a proper Safety Net System is used
wherever the hazard of fall from height is present. The safety net, preferably a
knotted one with mesh ropes conforming to IS 5175 /ISO 1140 shall have a
border rope & tie cord of minimum 12mm dia. The Safety Net shall be located
not more than 6.0 meters below the working surface extending on either side
up to sufficient margin to arrest fall of persons working at different heights.
• In case of accidental fall of person on such Safety Net, the bottom most
portion of Safety Net should not touch any structure, object or ground.
• The Contractor shall ensure positive isolation while working at different levels
like in the pipe rack areas. The working platforms with toe boards & hand rails
shall be sufficiently strong & shall have sufficient space to hold the workmen
and tools & tackles including the equipments required for executing the job.
Such working platforms shall have mid-rails and top-rails, to enable people
work safely in sitting posture.

Scaffoldings & Barricading

• Suitable scaffoldings shall be provided to workmen for all works that cannot
be safely done from the ground or from solid construction except such short
period work that can be safely done using ladders or certified (by 3rd party
competent person) man-basket. When a ladder is used, an extra workman
shall always be engaged for holding the ladder.
• The Contractor shall ensure that the scaffolds used during construction
activities shall be strong enough to take the designed load. Main Contractor
shall always furnish duly approved construction-design details of scaffold &
SWL (from competent designers) free of charge, before they are being
installed /constructed at site. Owner /PDIL reserves the right to ask the
Contractor to submit certification and or design calculations from his Head
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office /Design /Engineering expert regarding load carrying capacity of the

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

3 .3.6 Electrical installations

• All electrical installations/connections shall be carried out as per the

provisions of latest revision of following codes/standards, in addition to the
requirements of Statutory Authorities and IE/applicable international rules &
regulations:

- OISD STD 173: Fire prevention & protection system for electrical
installations
- SP 30 (BIS) : National Electric Code
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• All electrical installations shall be approved by the concerned statutory

authorities.
• All temporary electrical installations/facilities shall be regularly checked by the
licensed/competent electricians of the Contractor and appropriate records
shall be maintained. Inspection of temporary electrical booth/installation at
project construction site”. Such inspection records are to be made available to
PDIL /Owner, whenever asked for.

3 .3 .6 .1 The Contractor shall meet the following requirements:

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

provided around the equipment. Fire extinguishers and insulating mats shall
be provided in all power distribution centers.
• Temporary electrical equipment shall not be employed in hazardous area
without obtaining safety permit.
• Proper housekeeping shall be done around the electrical installations.
• All temporary installations shall be tested before energizing, to ensure proper
earthing, bonding, suitability of protection system, adequacy of feeders
/cables etc.

3.3.6.2 The following features shall also be ensured for all electrical
installations during construction phase by the contractor:

• Each installation shall have a main switch with a protective device, installed in
an enclosure adjacent to the metering point. The operating height of the main
switch shall not exceed 1.5 M. The main switch shall be connected to the
point of supply by means of armored cable.
• The outgoing feeders shall be double or triple pole switches with fuses/
MCBs. Loads in a three phase circuit shall be balanced as far as possible and
load on neutral should not exceed 20% of load in the phase.
• The installation shall be adequately protected against overload, short circuit
and earth leakage by the use of suitable protective devices. Fuses wherever
used shall be HRC type. Use of re-wired fuses shall be strictly prohibited. The
earth leakage device shall have an operating current not exceeding 30 mA.
• All connections to the hand tools / welding receptacles shall be taken through
proper switches, sockets and plugs.
• All single phase sockets shall be minimum 3 pin type only. All unused sockets
shall be provided with socket caps.
• Only 3 core (P+N+E) overall sheathed flexible cables with minimum
conductor size of 1.5 mm copper shall be used for all single phase hand tools.
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• Only metallic distribution boxes with double earthing shall be used at site. No
wooden boxes shall be used.
• All power cables shall be terminated with compression type cable glands.
Tinned copper lugs shall be used for multi-strand wires / cables.
• Cables shall be free from any insulation damage.
• Minimum depth of cable trench shall be 750 mm for MV & control cables and
900 mm for HV cables. These cables shall be laid over a sand layer and
covered with sand, brick & soil for ensuring mechanical protection. Cables
shall not be laid in waterlogged area as far as practicable. Cable route
markers shall be provided at every 25 M of buried trench route. When laid
above ground, cables shall be properly cleared or supported on rigid poles of
at least 2.1 M high. Minimum head clearance of 6 meters shall be provided at
road crossings. Underground road crossings for cables shall be avoided to
the extent feasible. In any case no underground power cable shall be allowed
to cross the roads without pipe sleeve.
• An independent earthing facility should preferably be established within the
temporary installation premises. All appliances and equipment shall be
adequately earthed. In case of armored cables, the armor shall be bonded to
the earthing system.
• All cable joints shall be done with proper jointing kit. No taped /temporary
joints shall be used.
• All cables and wire rope used for earth connections shall be terminated
through tinned copper lugs.
• In case of local earthing, earth electrodes shall be buried near the supply
point and earth continuity wire shall be connected to local earth plate for
further distribution to various appliances. All insulated wires for earth
connection shall have insulation of green colour.
• Separate core shall be provided for neutral. Earth /Structures shall not be
used as a neutral in any case.
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• ON / OFF position of all switches shall be clearly designated /painted for easy
isolation in emergency.

3 .3.7 Welding / Gas cutting

• Contractor shall ensure that flash back arrestors conforming to BS: 6158 or
equivalent are installed on all gas cylinders as well as at the torch end of the
gas hose, while in use. All cylinders shall be mounted on trolleys and
provided with a closing key. Empty & filled-up gas cylinders shall be stored
separately with TAG, protecting them from direct sun or rain. Minimum 2 nos.
of Portable DCP type fire extinguishers (10 kg) shall be maintained at the gas
cylinder stores. Stacking & storing of compressed gas cylinders shall be
arranged away from DG set, hot works, Elect. Panels /Elec. boards, etc
• The burner and the hose placed downstream of pressure reducer shall be
equipped with Flash Back Arrester /Non Return Valve device.
• The hoses for acetylene and oxygen cylinders must be of different colours.
Their connections to cylinders and burners shall be made with a safety collar.
• At end of work, the cylinders in use shall be closed and hoses depressurized.
• Cutting of metals using gases, other than oxygen & acetylene, shall require
written concurrence from Owner.
• All welding machines shall have effective earthing at least at distinctly isolated
two points. In order to help maintain good housekeeping, and to reduce fire
hazard, live electrode bits shall be contained safely and shall not be thrown
directly on the ground.
• The hoses of Acetylene and Oxygen shall be kept free from entanglement &
away from common pathways /walkways and preferably be hanged overhead
in such a manner which can avoid contact with cranes, hydra or other mobile
construction machinery.
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• Hot spatters shall be contained /restricted appropriately (by making use of

effective fire retardant cloth/fabric) and their flying-off as well as chance of
contact with near-by flammable materials shall be stopped.
• The Contractor shall arrange adequate systems & practices for accumulation
/collection of metal & other scraps and remnant electrodes and their safe
disposal at regular interval so as to maintain the fabrication and other areas
satisfactorily clean & tidy.
• All gas cylinders must have a cylinder cap on at all times when not in use.

3 .3.8 Ergonomics and tools & tackles

• The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health.
• All lifting tools, tackles, equipment, accessories including cranes shall be
tested periodically by statutory /competent authority for their condition and
load carrying capacity. Valid test & fitness certificates from the applicable
authority shall be submitted to Owner /PDIL for their review /acceptance
before the lifting tools, tackles, equipment, accessories and cranes are used.
• The contractor shall not be allowed to use defective equipment or tools not
adhering to safety norms.
• Contractor shall arrange non-sparking tools for project construction works in
operating plant areas /hydrocarbon prone areas.
• Wherever required the Contractor shall make use of Elevated Work Platforms
(EWP) or Aerial Work Platforms (mobile or stationary) to avoid ergonomically
risks and workmen shall be debarred to board such elevated platform during
the course of their shifting /transportation.
• Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes
(while in use) to minimize overloading risk. SLI shall have capability to
continuously monitor and display the load on the hook, and automatically
compare it with the rated crane capacity at the operating condition of the
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crane. The system shall also provide visual and audible warnings at set
capacity levels to alert the operator in case of violations.
• The contractor shall be responsible for safe operations of different
equipments mobilized and used by him at the workplace like transport
vehicles, engines, cranes, mobile ladders, scaffoldings, work tools, etc.
• The Contractor shall arrange periodical training for the operators of hydra,
crane, excavator, mobile machinery, etc. at site by utilizing services from
renowned manufacturers.

3 .3.9 Occupational Health

• The contractor shall identify all operations that can adversely affect the health
of its workers and issue & implement mitigation measures.
• For surface cleaning operations, sand blasting shall not be permitted even if
not explicitly stated elsewhere in the contract.
• To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten
Arc Welding shall not contain Thorium.
• Appropriate respiratory protective devices (hood with respiratory devices)
shall be used to protect workmen from inhalation of air borne contaminants
like silica, asbestos, gases, fumes, etc.
• Workmen shall be made aware of correct methods for lifting, carrying,
pushing & pulling of heavy loads. Wherever possible, manual handling shall
be replaced by mechanical lifting equipments.
• For jobs like drilling /demolishing /dismantling where noise pollution exceeds
the specified limit of 85 decibels, ear muffs shall be provided to the workers.
• To avoid work related upper limb disorders (WRULD) and backaches, Display
Screen Equipments' workplace stations shall be carefully designed & used
with proper sitting postures. Power driven hand-held tools shall be maintained
in good working condition to minimize their vibrating effects and personnel
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using these tools shall be taught how to operate them safely & how to
maintain good blood circulation in hands.
• The Contractor shall arrange health check up (by registered medical
practitioner) for all the workers at the time of induction. Health check may
have to be repeated if the nature of duty assigned to him is changed
necessitating health check or doubt arises about his wellness. PDIL/Owner
reserves the right to ask the contractor to submit medical test reports. Regular
health check-ups are mandatory for the workers assigned with Welding,
Radiography, Blasting, Painting, Heavy Lift and Height (>2m) jobs. All the
health check-ups shall be conducted by registered Medical practitioner and
records are to be maintained by the Contractor.
• The Contractor shall ensure vaccination of all the workers including their
families, during the course of entire project span.
• Regular distribution of standard quality soap / sanitizer to all employees of the
company for Hygienic up keeping.
• Provided Medical facilities to employees & their dependent family members
including Hospitalization at companies authorized reputed hospitals. An in-
house dispensary facility is available with part time doctor and trained staff to
take care of emergency services of employee’s health.

3 .3.10 Hazardous substances

• Hazardous, inflammable and/or toxic materials such as solvent coating,

thinners, anti termite solutions, water proofing materials shall be stored in
appropriate containers preferably with lids having spillage catchment trays
and shall be stored in a good ventilated area. These containers shall be
labeled with the name of the materials highlighting the hazards associated
with its use and necessary precautions to be taken. Respective MSDS
(Material Safety Data Sheet) shall be made available at site & may be
referred whenever problem arises.
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• Where contact or exposure of hazardous materials are likely to exceed the

specified limit or otherwise have harmful effects, appropriate personal
protective equipments such as gloves, goggles / face-shields, aprons,
chemical resistant clothing, respirator, etc. shall be used.
• The work place shall be checked prior to start of activities to identify the
location, type and condition of any asbestos materials which could be
disturbed during the work. In case asbestos material is detected, usage of
appropriate PPEs by all personnel shall be ensured and the matter shall be
reported immediately to PDIL /Owner.

3 .3.11 Slips, trips & falls

The contractor shall establish a regular cleaning and basic housekeeping

program that covers all aspects of the workplace to help minimize the risk of
slips, trips & falls. The contractor shall take positive measures like keeping the
work area tidy, storing waste in suitable containers & harmful items separately,
keeping passages, stairways, entrances & exits especially emergency ones
clear, cleaning up spillages immediately and replacing damaged carpet / floor
tiles, mats & rugs at once to avoid slips, trips & falls.

3 .3.12 Radiation exposure

• All personnel exposed to physical agents such as ionizing & non-ionizing

radiation, including ultraviolet rays or similar other physical agents shall be
provided with adequate shielding or protection commensurate with the type of
exposure involved.
• For Open Field Radiography works, requirements of Bhabha Atomic
Research Centre (BARC) /Atomic Energy Regulatory Board (AERB) shall be
followed.
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• The Contractor shall implement an effective system of control (as described in

the AERB regulations) at site for handling radiography-sources & for avoiding
its misuse & theft.
• The contractor shall generate the “Permit for radiation work” before start of
work.
• In case the radiography work has to be carried out at day time, suitable
methodology to be used so that other works, people are not affected.

3 .3.13 Explosives / blasting operations

• Blasting operations shall be carried out as per latest Explosive Rules (Indian /
International) with prior permission. The Contractor shall obtain license from
Chief Controller of Explosives (CCOE) for collection, transportation, storage
of explosives as well as for carrying out blasting operations.
• The Contractor shall prepare exclusive method statement (in cognizance with
statutory requirements) for diffusing unfired explosives, if any, at project site
before carrying out actual task. Nowhere blasting shall be carried out by the
Contractor or its agency without the involvement of competent supervisor and
licensed blaster / shot blaster.

3 .3.14 Demolition /Dismantling

• The contractor shall adhere to safe demolishing/ dismantling practices at all

stages of work to guard against unsafe working practices.
• The contractor shall disconnect service lines (power, gas supply, water, etc.)/
make alternate arrangements prior to start of work and restore them, if
required as directed by PDIL /Owner at no extra cost.
• Before carrying out any demolition/ dismantling work, the contractor shall take
prior approval of PDIL /Owner. For revamp jobs in operating plants where
location of underground utilities is not known with certainty, the contractor
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shall depute an experienced engineer for supervision and shall make

adequate arrangements for Firefighting & First-Aid during the execution of
these activities.
• The Contractor shall arrange approved Job Safety Analysis (JSA) /Method
Statement for the specific demolition /dismantling task and corresponding
action plan commensurate with hazards /risks associated therein. In no case
any activity related to demolition /dismantling shall be carried out by the
Contractor without engaging own supervision /field engineer.

3 .3.15 Road Safety

• The Contractor shall ensure adequately planned road transport safety

management system.
• The Contractor shall also ensure a separate pedestrian route for safety of the
workers and comply with all traffic rules & regulations, including maintaining
speed limit of 20 kmph or indicated by owner for all types of vehicles /mobile
machinery. The maximum allowable speed shall be adhered to.
• The vehicles shall be fitted with reverse warning alarms & flashing lights /fog-
lights and usage of seat belts shall be ensured.
• In case of an alert or emergency, the Contractor must arrange clearance of all
the routes, roads, access. The Contractor shall deploy sufficient number of
traffic controllers at project site routes /roads /accesses, to alert reversing
movement of vehicles & machinery as well as pedestrians.
• Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant
area and also to & from the labour colony to & from project sites.
• Hydras shall only be allowed for handling the materials at fabrication /storage
yards and in no case shall be allowed to transport the materials over project /
plant roads.
• The Contractor shall not deploy any such mobile machinery / equipments,
which do not have competent operator and/or experienced banks-man /
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Signalman. Such machinery /equipments shall have effective limit-switches,

reverse-alarm, and front & rear-end lights etc. and shall be maintained in
good working order.
• The Contractor shall not carry-out maintenance of vehicles /mobile machinery
occupying space on project /plant roads and shall always arrange close
supervision for such works.
• For pipeline jobs, the contractor shall submit a comprehensive plan covering
transportation, loading /unloading of pipes, movement of side booms,
movement of vehicles on the ROW, etc.
• Contractor’s shall arrange /install visible road signs, diversion boards, caution
boards, etc on project roads for safe movement of men and machinery.

3 .3.16 Welfare measures

Contractor shall, at the minimum, ensure the following facilities at work sites:
• A crèche at site where 10 or more female workers are having children below
the age of 6 years.
• Adequately ventilated /illuminated rooms at labour camps & its hygienic up-
keeping. Reasonable canteen facilities at site and in labour camps at
appropriate location depending upon site conditions. Contractor shall make
use of “industrial” variety of LPG cylinder & satisfactory illumination at the
canteens. Necessary arrangement for efficient disposal of wastes from
canteens & urinals /toilets shall also be made and regular review shall be
made to maintain the ambience satisfactorily hygienic & shall also comply
with all applicable statutory requirements. Adequately lighted & ventilated
Rest rooms at site (separate for male workers and female workers). Urinals,
Toilets, washing facilities, adequate lighting at site and labour camps,
commensurate with applicable Laws /Legislation.
• Providing water, milk, Lemon water, glucose etc. to employees working at
heat treatment & Dusty areas.
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• Provided purified drinking water to all employees of company.

• Providing of Personal Protective equipment as per requirement of employees
according to their respective working areas.
• Companies Transportation has been provided to all employees for safe
transportation of employees from their residence to workplace & back.

3 .3.17 Environment Protection

Contractor shall ensure proper storage and utilization methodology of materials

that are detrimental to the environment. Where required, Contractor shall ensure
that only the environment friendly materials are selected and emphasize on
recycling of waste materials, such as metals, plastics, glass, paper, oil &
solvents. The waste that cannot be minimized, reused or recovered shall be
stored and disposed of safely. In no way, toxic spills shall be allowed to percolate
into the ground. The contractor shall not use the empty areas for dumping the
wastes. The contractor shall strive to conserve energy and water wherever
feasible.
The contractor shall ensure dust free environment at workplace by sprinkling
water on the ground at frequent intervals. The air quality parameters for dust,
poisonous gases, toxic releases, harmful radiations, etc. shall be checked by the
contractor on daily basis and whenever need arises.
The contractor shall not be allowed to discharge chemicals, oil, silt, sewage,
sullage and other waste materials directly into the controlled waters like surface
drains, streams, rivers, ponds. A discharge plan suggesting the methods of
treating the waste before discharging shall be submitted to PDIL /Owner for
approval.
For pipeline jobs, top soil shall be stacked separately while making ROW through
fields. This fertile soil shall be placed back on top after backfilling. For offshore
construction barges, arrangements shall be made for safe disposal of human,
food & other wastes and applicable laws in this regard shall be followed.
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3 .3.18 Rules & Regulations

All persons deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulations relating to the hazardous materials,
substances and wastes. Contractor shall not dump, release or otherwise
discharge or disposes off any such materials without the express authorization of
PDIL/Owner. An indicative list of Statutory Acts & Rules relating to HSE is given
under Appendix-D.

3 .3.1 9 Weather Protection

Contractor shall take appropriate measures to protect workers from severe

storms, rain, solar radiations, poisonous gases, dust, etc. by ensuring proper
usage of PPEs like Sun glasses, Sun screen lotions, respirators, dust masks, etc.
and rearranging /planning the construction activities to suit the weather
conditions. Effective arrangement (without creating inconvenience to project
facilities & permanent installations) for protecting workmen from hailstorm, drizzle
in the form of temporary shelter shall be made at site.

3 .3.20 Communication

All persons deployed at the work site shall have access to effective means of
communication so that any untoward incident can be reported immediately and
assistance sought by them. All health & safety information shall be
communicated in a simple & clear language easily understood by the local
workforce. For information to all, typical subjects that should be communicated
are: -

Inside the company (Top to down)

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

Inside the Company (Bottom to up)

a. Complaints
b. Compliances on safety defects / shortfalls
c. Suggestions
d. Proposals for changes & improvements
e. HSE Reports (including near-miss reports)

3 .3.21 Confined Space Entry

The contractor shall generate a work permit before entering a confined space.
People, who are permitted to enter into confined space, must be medically
examined & certified by registered doctor, confirming their ‘medical fitness for
working in confined space’. All necessary precautions mentioned therein shall be
adhered to. An attendant shall be positioned outside a confined space for
extending help during an emergency. All appropriate PPEs and air quality
parameters shall be checked before entering a confined space. It shall be
ensured that the piping of the equipment which has to be opened is pressure-
free by checking that blinds are in place, vents are open and volume is drained.
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Inside confined space works, only electrical facilities /installations of 24V shall be
permitted. Contactor shall ensure usage of safe & suitable arrangement of
oxygen supply for individual workmen (during the course of work in confined
space), if oxygen concentration is found to be less than 19.5% (v/v) there.

3.3.22 Heavy Lifts

• The contractor shall submit detailed rigging studies plan for PDIL/ Owner
approval prior to lifting equipment which cannot be erected with a crane of
approx. 100 Ton capacities due to constraints of its dimensions, location of
foundation height, approach & weight. Contractor shall generate the format
for “Permit for heavy lift /critical erection” Prior to actual lifting activities;
contractor shall check the validity of the crane inspection certificate issued by
statutory / competent authority. This requirement shall also apply to all rigging
equipments utilized for the job.
• The contractor shall, at all times, be responsible for all rigging activities.
• The Contractor shall ensure medical fitness of all workmen who are engaged
/involved in erection of equipments, vessels etc. and such fitness checks shall
be carried-out every six months interval with the help of a registered medical
practitioner & record shall be maintained Adequate safety measures such as
positive barricading, usage of appropriate PPEs, permit to work, etc. shall be
taken during all heavy or critical lifts.
• For lifting any material (irrespective of shape, size or volume), at any height, it
is always advisable to prepare a Plan of Erection (POE) taking into
consideration hazards & risks associated therein – this can enable people to
put their own experiences of various natures & side-by-side establish a
practical method for risk-free erection /lifts. The contractor shall prepare POE
& shall document the same, when risks are identified as “medium” or “high”
and the same shall be approved by its competent /qualified engineer.
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3 .3.23 Key Performance Indicators

The contractor shall measure an activity in both leading & trailing indicators for
statistical and performance measurement. The activities pertaining to key
performance indicators are covered in Monthly HSE Report. The contractor shall
try to achieve a statistically fair record and strive for its continual improvement.
Leading Indicators viz:-

- Number of Safety Inductions carried-out at site (for workmen & staff

members)
- Number of HSE inspections carried out.
- Number of “Safety Walk Through” carried-out by site-head.
- Number of HSE shortfalls / lapses identified per contractor & closed-out
in time.
- Number of Safety Meetings conducted (in-house / with contractors)
- Number of HSE Audits made (internal & external) vis-à-vis non
conformances raised
- Number of HSE Trainings conducted at site for supervisors & workmen
- Number of HSE Awareness / Motivational program conducted by
contractors
- Study of Near miss case reported
- Encouragements /Awards /Recognitions to workmen, job supervisors &
field engineers.
- Suggestions for improvement

Trailing Indicators viz:-

- Calculation of HSE statistics viz frequency rate, severity rate, LTA free
man-hours, etc
- Analysis of incidents / accidents (nature, severity, types etc.)
- Study of Incident / Accident with respect to :-
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- Variety
- Period of the year / project span
- Timings of the incident / accident
- Age profile of victims
- Body parts involved
- Penalty levied for causing incident / accident
3 .3.24 Unsuitable Land Conditions

Contractor shall take appropriate measures and necessary work permits

/clearances if work is to be done in or around marshy areas, river crossings,
mountains, monuments, etc. The Contractor shall make right assessment and
take all necessary action for developing work areas to make them safe & suitable
for crane operations or other vehicular movement before carrying out any project
related activity /operation. Contractor shall take all necessary actions to make the
surroundings of its site establishments (site office, stores, lay-down area etc.)
work-worthy safe and secure.

3 .3.25 Under Water Inspection

Contractor shall ensure that boats and other means used for transportation,
surveying & investigation works shall be certified seaworthy by a recognized
classification society. It shall be equipped with all life saving devices like life
jackets, adequate fire protection arrangements and shall posses’ communication
facilities like cellular phones, wireless, walkie-talkie. All divers used for seabed
surveys, underwater inspections shall have required authorized license, suitable
life saving kit. Number of hours of work by divers shall be limited as per
regulations. PDIL /Owner shall have the right to inspect the boat and scrutinize
documents in this regard.

3 .3.26 Excavation
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The Contractor shall obtain permission from competent authorities prior to

excavation wherever required. The Contractor shall locate the position of buried
utilities (water line, cable route, etc.) by referring to project /plant drawing / in
consultation with PDIL /Owner. The Contractor shall start digging manually to
locate the exact position of buried utilities & thereafter use mechanical means.
The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance
equal to depth of pit (whichever is more).
The Contractor shall maintain sufficient “angle of repose” during excavation –
shall also provide slope or suitable bench as decided by PDIL /Owner.
The Contractor shall arrange “battering” or “benching” wherever required for
preventing collapse of edge of excavations.
The Contractor shall identify & arrange de-watering pump or well-point system to
prevent earth collapse due to heavy rain /influx of underground water.
The Contractor shall arrange protective fencing / barricading with warning signal
around excavated pits, trenches, etc. along with minimum 2 (two) entries, exits /
escape ladders.
The Contractor must avoid “underpinning” /under-cutting to prevent collapse of
chunk of earth during excavation
The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the
edge of excavated pits /trenches.
The Contractor shall arrange strengthening of “shoring” & “strutting” proactively
to avoid collapse of earth /edges due to vehicular movement in close proximity of
excavated areas /pits /trenches, etc.

3. 4 Tool Box Talks (TBT)

Contractor shall conduct daily TBT with workers prior to start of work and shall
maintain proper record of the meeting. A suggested format is given below. The
TBT is to be conducted by the immediate supervisor of the workers The
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Contractor shall conduct TBT before start of every morning or evening shift or
night shift activities, for alerting the workers on specific hazards and their
appropriate dos & don’ts. The Contractor shall provide sufficient rests to the site
workmen and their foremen to avert fatigue & thereby endangering their lives
during the course of site works.

The topics during TBT shall include.

- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards /events /instruction /orders, etc.
The above record can be kept in local language, which workers can read. These
records shall be made available to PDIL /Owner whenever demanded.
TOOL BOX TALK RECORD
Date & Time
Work Location
Subject (Nature of work)
Presenter
Hazards involved
Precautions to be taken
Worker's Name Signature Section

Remarks, in any

3. 5 Training & Induction Program

• Initial induction of workers into Construction oriented activities and appraising

them about the methodology of works and how to carry-out safely and the
same should not be inter mixed with Tool Box Talks or HSE Training. In this
regard careful action should be made & maintained for imparting HSE
induction to every individual, irrespective of his task /designation /level of
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employment, whereas, HSE Training should be imparted to specific person /

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

The topics during training shall cover, at the minimum: -

- Why safety should be considered during work - explanation

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

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

ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A

RUNNING PLANT

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

requirements while working in or in the close vicinity of an operating plant:

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

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

of valve will not be considered sufficient for isolation.
• Welding spatters shall be contained properly and in no case shall be allowed
to fall on the ground containing oil. Similar care shall be taken during cutting
operations.
• The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the
exhaust pipe and got it approved from Safety Department of the Owner.
• Plant air should not be used to clean any part of the body or clothing or use to
blow off dirt on the floor.
• Gas detectors should be installed in gas leakage prone areas as per
requirement of Owner's plant operation personnel.
• Experienced full time safety personnel shall be exclusively deployed to
monitor safety aspects in running plants.

Self Assessment and Enhancement

The contractor shall develop a method of check & balance through self
assessment & enhancement techniques and shall explore the opportunities for
continual improvement in the HSE systems.

3. 8 HSE Promotions

The contractor shall encourage his workforce to promote HSE efforts at

workplace by way of organizing workshops /seminars /training programs,
celebrating HSE awareness weeks & National Safety Day, conducting quizzes &
essay competitions, distributing pamphlets, posters & material on HSE, providing
incentives for maintaining good HSE practices and granting incentives /bonus for
completing the job without any lost time accident.

3. 9 Lock Out and Tag out (LOTO) for isolation of energy source
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• Contractor shall follow the LOTO /Isolation procedure of owner for all energy
source isolations and installed/under purview by /of owner i.e. “Brown field”
For the other entire energy source (not under purview of client/owner) i.e.
“Green field” Contractor shall develop a system to ensure the isolation of
equipments, pipelines, Vessel, electrical panels from the energy source
covering following as minimum:-
- Identification of all energy source viz electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, gravitational, radiation and other forms of
stored or kinetic energy.
- Establishing the energy isolation devices viz: manually operated electrical
circuit breakers, disconnection switches, blind flanges, etc
- Lock Out and Tag out log book
- Installation of Lock Out devices for preventing the inadvertent release of
stored energy and Tag Out devices (“Danger”, “Do Not operate” or Do not
Remove” tags) to indicate that testing, maintenance or servicing is
underway and the device cannot be operated until the tag out device is
removed.
- Permit for isolation and de-isolation of energy source.
- Availability of competent persons like experienced operators at
substations, pump house, units, etc, supervisors, etc.
Contractor shall ensure that all the sources are locked out and tagged
properly before giving clearance to start the job.
After the completion of job, contractor shall ensure all tools and tackles are
removed and nobody is present in the working area and signing on LOTO log
book.
Only on confirmation of above the contractor will remove their lock and tag
from the isolation points and give instructions for energizing the same. Only
the person carrying out the task shall himself carry the key for the lock in
/Lock out.
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4. 0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

On Award of Contract

The Contractor shall submit a comprehensive Health, Safety and

Environment Plan or program for approval by PDIL /Owner prior to start of
work. The Contractor shall participate in the pre-start meeting with PDIL
/Owner to finalize HSE Plans which shall including the following:
- HSE policy & Objectives
- Job procedure to be followed by the Contractor for construction activities
including handling of equipments, scaffolding, electric installations, etc.
describing the risks involved, actions to be taken and methodology for
monitoring each activity.
- PDIL /Owner review/audit requirement.
- Organization structure along with responsibility and authority, on HSE
activities.
- Administrative & disciplinary steps involving implementation of HSE
requirements.
- Emergency evacuation plan / procedures for site and labour camps
- Job Safety Analysis for high risk jobs.
- Procedures for reporting & investigation of accidents and near misses.
- HSE Inspection.
- HSE Training programs at project site.
- HSE Awareness programs, at project site.
- Reference to Rules, Regulations and statutory requirements.
- HSE documentation viz reporting, analysis & record keeping.

During Job Execution

Contractor shall implement approved HSE management program including but
not limited to as brought out under para 3.0. Contractor shall also ensure:
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• To arrange workmen compensation insurance, registration under ESI Act,

third party liability insurance, registration under BOCW Act, etc, as applicable.
• To arrange all HSE permits before start of activities (as applicable), like
permits for hot work, working at height, confined space, Radiation Work
Permit, Demolishing / Dismantling Work Permit, Permit for
erection/modification & dismantling of scaffolding, Permit for heavy lift/critical
erection, Permit for energy Isolation & De-isolation”, storage of chemical /
explosive materials & its use and implement all precautions mentioned
therein. In this regard, requirements of Oil industry Safety Directorate
Standard No.:- 105 "Work Permit Systems” shall be complied with while
working in existing Oil, Gas or Chemical processing plants. List of the persons
involved shall be maintained as annexure to the work permit issued for a
particular activity.
• To submit, timely, the completed checklist on HSE activities, Monthly HSE
report (use of web based package (www.pdil.co.in/conthse) is compulsory
wherever the facility is available else a hard copy is to be submitted),
accident/ incident reports, investigation reports etc. as per PDIL/Owner
requirements. Compliance of instructions on HSE shall be done by contractor
and informed urgently to PDIL /Owner.
• Provide posters, banners for safe working to promote safety consciousness.
• That his top most executive at site attends all the Safety Committee /HSE
meetings arranged by PDIL /Owner and carries out safety walk through
regularly. Only in case of his absence from site that a second senior most
person shall be nominated by him, in advance, and communicated to
PDIL/Owner for performing the tasks.
• Appraise PDIL /Owner on HSE activities at site regularly.
• Display at site office and at prominent locations HSE Policy, caution boards,
list of hospitals, emergency services available, safety signs like Men at work,
Speed Limits, Hazardous Area, various do’s & don’ts, etc.
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• Identify access, analyze & mitigate the construction hazards & incorporate
relevant control measures before actually executing site works. (HIRAC =
Hazard Identification, Risk Analysis and Control).
• Arrange testing, examination, inspection of own as well as borrowed
construction equipments / machinery (stationary & mobile) before being used
at site and also at periodical interval, through own resources and also by 3 rd
party competent agencies (as deemed fit in statutes). Records of such test,
examination etc. shall be maintained & shall be submitted to PDIL /Owner as
& when asked for.
• Carryout audits /inspection (internal & external) at his works as well as sub
contractor works as per approved HSE plan /procedure /program & submit
the compliance reports of identified shortfalls for PDIL /Owner review.
• Arranging HSE training for site workmen (of his own & sub contractors)
through internal or external faculty at periodical intervals.
• Assistance & cooperate during HSE audits by PDIL /Owner or any other 3 rd
party and submit compliance report. Generate & submit of HSE records
/report as per this specification.
• Carry-out all dismantling activities safely, with prior approval of PDIL/Owner
representative.
• The Contractor shall ensure that “Hot works” and painting works do not
continue at the same place /location at project site for which chance or
probability of “fire” incident exists.

During Short Listing of the Sub-Contractors

The contractor shall review the HSE management system of the sub-contractors
in line with the requirements given in this specification. The contractor shall be
held responsible for the shortcomings observed in the HSE management system
of the sub-contractor(s) during execution of the job.
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APPENDIX-A

A. IS CODES ON HSE

- SP: 53 Safety code for the use, Care and protection of hand operated
tools.
- IS: 838 Code of practice for safety & health requirements in electric and
gas welding and cutting operations
- IS: 1179 Eye & Face precautions during welding, equipment etc.
- IS: 1860 Safety requirements for use, care and protection of abrasive
grinding wheels.
- IS: 1989 (Pt -II)Leather safety boots and shoes
- IS: 2925 Industrial Safety Helmets
- IS: 3016 Code of practice for fire safety precautions in welding & cutting
operation.
- IS: 3043 Code of practice for earthing
- IS: 3764 Code of safety for excavation work
- IS: 3786 Methods for computation of frequency and severity rates for
industrial injuries and classification of industrial accidents
- IS: 3696 Safety Code of scaffolds and ladders
- IS: 4083 Recommendations on stacking and storage of construction
materials and components at site
- IS: 4770 Rubber gloves for electrical purposes
- IS: 5121 Safety code for piling and other deep foundations
- IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in
electrical works
- IS: 5557 Industrial and Safety rubber lined boots
- IS: 5983 Eye protectors
- IS: 6519 Selection, care and repair of Safety footwear
- IS: 6994 (Pt-I) Industrial Safety Gloves (Leather & Cotton Gloves)
- IS: 7293 Safety Code for working with construction Machinery
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- IS: 8519 Guide for selection of industrial safety equipment for body
protection
- IS: 9167 Ear protectors
- IS: 11006 Flash back arrestor (Flame arrestor)
- IS: 11016 General and safety requirements for machine tools and their
operation
- IS: 11057 Specification for Industrial safety nets
- IS: 11226 Leather safety footwear having direct molded rubber sole
- IS: 11972 Code of practice for safety precaution to be taken when
entering a sewerage system
- IS: 13367 Code of practice-safe use of cranes
- IS: 13416 Recommendations for preventive measures against hazards
at working place

B. INTERNATIONAL STANDARDS ON HSE

- Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092, BS

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

DETAILS OF FIRST AID BOX

Sr. No. DESCRIPTION QUANTITY
1 Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs.
2 Medium size Roller Bandages, 2 Inches Wide (Hand & Foot Dressing) 6 Pcs.
3 Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs.
4 Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5 Cotton Wool (20 gms packing) 4 Pkts.
6 Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7 Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8 Ammonia Solution (20 ml.) 1 Bottle
9 Pair of Scissors 1 Piece
10 Adhesive Plaster (1.25 cm X 5 m) 1 Spool
11 Eye pads in Separate Sealed Pkt. 4 pcs.
12 Tourniquet 1 No.
13 Safety Pins 1 Dozen
14 Tinc. Iodine/ Betadin (100 ml.) 1 Bottle
15 Polythene Wash cup for washing eyes 1 No.
16 Potassium Permanganate (20 gms.) 1 Pkt.
17 Tinc. Benzoine (100 ml.) 1 Bottle
18 Triangular Bandages 2 Nos.
19 Band Aid Dressing 5 Pcs.
20 Iodex/Moov (25 gms.) 1 Bottle
21 Tongue Depressor 1 No.
22 Boric Acid Powder (20 gms.) 2 Pkt.
23 Sodium Bicarbonate (20 gms.) 1 Pkt.
24 Dressing Powder (Nebasulf) (10 gms.) 1 Bottle
25 Medicinal Glass 1 No.
26 Duster 1 No.
27 Booklet (English & Local Language) 1 No. each
28 Soap 1 No.
29 Toothache Solution 1 No.
30 Vicks (22 gms.) 1 Bottle
31 Forceps 1 No.
32 Note Book 1 No.
33 Splints 4 Nos.
34 Life Saving/Emergency/Over-the counter Drugs As decided at site

Note: The medicines prescribed above are only indicative. Equivalent medicines can
also be used. A prescription, in this regard, shall be required from a qualified Physician.
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APPENDIX-C

TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS

Fire Multi
Extinguisher Water Foam CO2 Dry Powder purpose
(ABC)

Fire

Originated from D D Can control Can control D

paper, clothes, wood minor surface minor surface
fires fires

Inflammable liquids like

alcohol, diesel, petrol, edible X D D D D
oils, bitumen

Originated from gases like

LPG,CNG, H2 X X D D D

Electrical fires X X D D D

LEGEND:
D: CAN BE USED
X: NOT TO BE USED

Note: Fire extinguishing equipment must be checked at least once a year and after
every use by an authorized person. The equipment must have an inspection
label on which the next inspection date is given. Type of extinguisher shall clearly
be marked on it.
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APPENDIX-D
LIST OF STATUTORY ACTS & RULES RELATING TO HSE

- The Indian Explosives Act and Rules

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

1. The Law & Safety – Statutory Requirement / Applicable statutes / Duties of

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

LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:-

A. HSE Management Procedures:

• HSE Risk Management (including JSA/HIRA)

• HSE Legal Compliance and Other Requirements
• HSE Objectives & Performance
• HSE Training and Competence (including Induction)
• HSE Motivation & Award Scheme
• HSE Audits
• HSE Meetings
• HSE Sub Contractor Management
• HSE Emergency Management
• HSE Incidents Reporting and Management
• HSE Reports
• HSE Management System Review
• HSE Change Management
• HSE procedure for Behavior based Safety
• First Aid & Management
• Roles, Responsibility, accountabilities and Authorities

B. Job procedures /Safe Operating procedures

********
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 1 OF 20

SAFETY TALK TOPICS

SR. NO. SAFETY TALK TOPICS SR. NO. SAFETY TALK TOPICS

1 Accident/Incident Prevention 21 Importance of Checklist

2 Ammonia (NH3) Safety 22 Incident reporting

3 Are we Safe or just Lucky? 23 Industrial Radiography Safety

4 Attitude and Behavior 24 Job Safety Analysis (JSA)

5 Back Safety 25 Knowledge of LSC rules

6 Barricade and Signage 26 Ladder Safety

7 Blinding Safety 27 Look out for Your Co-Workers

8 Breathing Apparatus 28 Machine guarding safety

9 Carbon Monoxide Poisoning 29 Manual Material Handling

10 Chemical / Toxic Handling 30 Material Safety Data Sheet - MSDS

11 Chain and Sling Safety Tips 31 Modification of Tools or Equipments

Near Misses are Lucky Escapes -
12 Chemical Safety 32
Report them
13 Compressed Gas Cylinders 33 Over Confidence can kill you

14 Confined Space Entry 34 Personal behavior

15 Crane Operation 35 Personal Hygiene

16 De-blinding Safety 36 Personal Protective Equipment (PPE)

Donning and doffing of safety
17 37 Pinch Points
harnesses
18 Dust mask & Cartridge filter mask 38 Preventing Strains and Sprains

19 Electrical Safety 39 Eye and Face Protection

20 Emergency Response & Evacuation 40 Fall Protection & Prevention

41 Falling Objects 66 Prohibited Items Inside Plant

Page 1 of 2
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 2 OF 20

42 Fatigue 67 Respiratory Protection

44 Fire Prevention and Extinguishing 68 Responsibilities of Fire Watch

45 Fire Safety 69 Responsibilities of Permit Receiver

45 Foot and Leg Protection 70 Responsibilities of Standby Man

46 Forklift Safety 71 Risk Assessment

47 General Safety 72 Safe Handling of Flammable Liquids

48 Grounding of Equipments 73 Safe Storage of Flammable Liquids

49 Hand and Finger Protection 74 Safety is everyone's responsibility

50 Hand tools & Power Tools 75 Scaffold Safety

51 Hazard Recognition 76 Short cuts

52 Hearing Safety 77 Site Safety Rules & Regulation

53 Heat Stress 78 Sleeping at site

54 High Pressure Water Jetting 79 Slip, trip and fall hazards

55 Home Made Tools 80 Smoking safety

56 Horseplay 81 Static Electricity

57 Hot Bolting Safety 82 Take safety ownership of your job

58 Hot work safety 83 The Cost of the Accident

59 Housekeeping is safe keeping 84 Traffic Safety

60 Hurry Up can Hurt!!!! 85 Unsafe acts & conditions

61 Hydro test Safety 86 Vacuum Truck Safety

62 If you are not sure! ASK! 87 What you do not know, can hurt you!

63 Responsibilities of Rigger 88 Why safety audit

64 Excavation Safety 89 Work Permit System

65 Construction site survey for visitors 90 Working at Height

Page 2 of 2
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 1 OF 20

CLASSIFICATION OF LIFTING APPLIANCES

LIFTING APPLIANCES

Lifting tools Lifting tackles

cranes D-shackles
Hoists Wire ropes
Chain pulley blocks Chains
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
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 2 OF 20

INSPECTION OF LIFTING TOOLS & TACKLES

TPI – Third party Inspection

• Third Party Inspection of any product is the Inspection & Testing carried out by Any
Person or Agency who is not Manufacturer or User of that particular product or service.
• Third Agency is always technically strong enough and competent to execute the
checking and testing of all Technical Aspects of the equipment or service.
• In case of Lifting Equipment & Lifting Tools & Tackles, Govt. Approved / Authorized
Competent Person carry out Inspection and testing of the products and certify to use
them.
• State wise competent persons are authorized by State Govt. to carry out Inspection &
testing of various products.

Why TPI? –

• Carrying out TPI of Lifting Equipment and Lifting Tools & Tackles is Statutory Norm /
Requirement as prescribed in Factories Act.
• Safety Level of the Equipment is enhanced, as competent person shall note down the
loop holes during the inspection & testing and recommend or suggest corrective
measures.
• Equipment Manufacturer shall issue Mfr. Test Certificate by Self Attested way and
define products’ attributes.
• However, as per the Law: Obtain ‘Form-10’ (In Gujarat it is ‘Form-10’) Certificate issued
by TPI (Competent Person) from the date of installation or from the date when product
is First Taken for Use.

Procedure:
Procedure of Inspection & Testing is carried out strictly as per checklist developed individually.
Competent Persons also offer their service as per the scope of work:

1). Thorough Inspection & Testing:

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

2). Load Testing:

Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 3 OF 20

• First all operating parameters are checked and then, Load Testing at Proof Load and
Over-Load is carried out.

‘Form-10’ Certificate as per govt. Format is issued on successful Inspection & Testing of the
products.

Note: Form-10 Certificate is issued by Competent Person as per State Govt. Format in Gujarat
State. However, state wise this Form No. is different.

Interval for Inspection & testing:

As directed in the Section-29 of Factories Act, these Tests are carried out annually and Register
should be maintained for every product to keep record regarding Health of the Products.

SECTION – 29 OF FACTORIES ACT - LIFTING TOOLS AND TACKLES

1. In any factory the following provisions shall be complied with in respect of every lifting
machine (other than a hoist and lift) and every chain, rope and lifting tackle for the purpose
of raising or lowering persons, goods or materials :-

• All parts, including the working gear, whether fixed or movable, of every lifting
machine and every chain, rope or lifting tackle shall be –
• Of good construction, sound material and adequate strength and free from
defects;
• Properly maintained; and
• Thoroughly examined by a competent person at least once in every period of
twelve months, or at such intervals as the Chief Inspector may specify in
writing, and a register shall be kept containing the prescribed particulars of
every such examination;

• No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of
test, be loaded beyond the safe working load which shall be plainly marked thereon
together with an identification mark and duly entered in the prescribed register; and
where this is not practicable, a table showing the safe working loads of every kind
and size of lifting machine or chain, rope or lifting tackle in use shall be displayed in
prominent position on the premises;

• While any person is employed or working on or near the wheel track of a traveling
crane in any place where he would be liable to be struck by the crane, effective
measures shall be taken to ensure that the crane does not approach within 63[six
meters] of that place.
Date:
PROJECTS & DEVELOPMENT Project No.: PC-00187
INDIA LIMITED SHEET 4 OF 20

2. The State Government may make rules in respect of any lifting machine or any chain, rope
or lifting tackle used in factories -

• Prescribing further requirements to be complied with in addition to those set out in

this section;

• Providing for exemption from compliance with all or any of the requirements of this
section, where in its opinion, such compliance is unnecessary or impracticable.

3. For the purposes of this section a lifting machine or a chain, rope or lifting tackle shall be
deemed to have been thoroughly examined if a visual examination supplemented, if
necessary, by other means and by the dismantling of parts of the gear, has been carried out
as carefully as the conditions permit in order to arrive at a reliable conclusion as to the
safety of the parts examined.

Explanation:
In this section, -
• "lifting machine" means a crane, crab, winch, teagle, pulley block, gin wheel,
transporter or runway;

• 64(b) "lifting tackle" means any chain sling, rope sling, hook, shackle, swivel,
coupling, socket, clamp, tray or similar appliance, whether fixed or movable, used in
connection with the raising or lowering of persons, or loads by use of lifting
machines.

********

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29 HIRA Annexure H

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29 HIRA Annexure H

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ANNEXURE – R

HAZARD IDENTIFICATION & RISK ASSESMENT (HIRA)

have updated and valid

using and competent for rigging and • Full body

• Ensure proper access for tie up of

• Provide adequate warning signs

properly before going for the with 100%

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

roof structure is allowed for trailer driving.

9.Provide proper tag line to

• 5.While loading the teeth of the

sufficient illumination is not

• Signal to the crane operator

• Unsafe loading • Forklifts should never be • Reflective

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

line & vice versa.

inspect the machine every day

maintained between hydra/

crew to avoid communication protective

cables every day for identifying

alteration should be done by

cover before activating the foot

from height be engaged in working at height. • Fall

• Hydraulic jacks and its

• All area around the tank should

accessories selected should be

• Spilled oil must be cleaned off

radiography is break times and

• Separate PIT room shall be

not be left suspended with the

• Platform should be maintained

made available at site and

uncontrolled and should be prevented from • Full body

• Automatic grit blasting machine

• Paint should be stored away

• Secure the hoses with whiplash

such a way that it does not pose

• The flanges / joints shall be

during testing period.

pressure testing should be

• Sudden release be provided to release the

because of the and competent to work in gloves,

hoses. • Ensure no one is standing close

depending on the type of

platform level of the scaffolding.

unloading use tailor made platforms, • Dust

ground, if any. • Dust

• Ensure SWL, Lifting radius etc. of

assembly • May hit the for signaling. Goggles,

surface Strike properly leveled.

• Ensure the machine is inspected

• Ensure the machine is inspected

before start of the activity. gloves,

• Ensure Reinforced materials

• Collapse of • Ensure cables free from damage • Respirator

• Ensure Edge protection/proper

• Proper PPE’s like gumboot and Goggles,

• Stacking of LPG shall be placed

and electric fires with water. gloves

Risk Risk Level Action

Prepared By: SAFETY ENGINEER/PDIL

Checked By: RCM/PM/PDIL

Approved By: GNFC

ON SITE EMERGENCY PLAN

WHY INTRODUCTION OF EMERGENCY PLANNING IS REQUIRED?

• What are the hazards and risk in the plant

The occupier will prepare the emergency plan required –

On-site emergency can be due to the following causes

Man-made Cause Natural Cause Extraneous

An emergency is a situation, which may lead to or cause a large-scale damage or

A major emergency can be defined as an accident/ incident that have potential to

(i) Plant failure.

ON-SITE EMERGENCY: If an accident/ incident takes place in a factory, its effects

10 Toxic gas leakage Fire Hazard, Suffocation Serious injury, Death

EMERGENCY ACTION PLAN:

EMERGENCY CONTROL CENTRE: