HEALTH, SAFETY & ENVIRONMENT (HSE) PLAN
Larsen & Toubro Limited ENERGY CENTRE, BARODA
HEALTH, SAFETY & ENVIRONMENT (HSE) PLAN
Job Number : 6556 Project Title : Captive Power Plant (CPP) Location : Naphtha Cracker Project, Panipat Client : Indian Oil Corporation Limited, India
Larsen & Toubro Limited ENERGY CENTRE, BARODA
HEALTH, SAFETY & ENVIRONMENT (HSE) PLAN
Job Number : 6556 Project Title : Captive Power Plant (CPP) Location : Naphtha Cracker Project, Panipat Client : Indian Oil Corporation Limited, India
Table of Contents Sl. No.
Topic
Page No.
1.0
Scope
6
2.0
Project Description & Key Personnel
7
3.0
Client HSE Requirements & Expectations
9
4.0
L&T Corporate Policy, HSE Commitment/ Philosophy
11
5.0
L&T Strategic Targets & Objectives
13
6.0
Site HSE Organization & Responsibilities
15
7.0
Risk Management
21
8.0
HSE Meetings/ Communication
22
9.0
Training, Awareness & Competency Development Program
23
10.0
HSE Promotion, Recognition & Penalty Program
24
11.0 12.0
Audits/ Inspection Inspection/ / Management Management Reviews Reviews
21
Safe Work Practices
26
12.1
Statutory Requirements
26
12.2
Personnel Protective Equipment (PPE)
26
12.3
Signs, Signals and Barricades
28
12.4
Work Permits
28
12.5
Piling Activity
31
12.6
Excavation, Trenching and Shoring
31
12.7
Reinforcement/ Form Work/Shoring & Concreting
32
12.8
Scaffolding and Ladders
32
12.9
Steel Erection
34
12.10
Floor and Wall Openings and Stairways
34
12.11
Entry into Confined Spaces
35
12.12
Electrical Safety
35
12.13
Electric arc Welding and Cutting
36
12.14
Gas Welding and Cutting
37
12.15
Short Blasting & Painting
38
12.16
Hand and Portable Power Tools
39
12.17
Cranes and Lifting Equipment
39
12.18
Hazardous Materials
40
12.19
Radiography
41
12.20
Fire Protection
42
12.21
Housekeeping
42
12.22
Check Points During the Construction of Chimney
43
13.0
Environmental control
44
14.0
Health Monitoring & Control
45
15.0
Accident Reporting and Investigation
46
16.0
Emergency Preparedness
53
17.0
HSE Activity Plan
54
APPENDIX No: 1: HIRA Register
ABBREVIATIONS AERB - Atomic Energy Regulatory Board AGM - Assistant General Manager APT - Accident Prevention Tool BARC - Bhabha Atomic Research Center BIS - Bureau of Indian Standard BOCW - Building and Other Construction Works BUH - Business Unit Head BVQI - Bureau Veritas Quality International CB - Circuit Breaker CG - Center of Gravity CI - Chief Inspector CO - Central Office CO2 - Carbon Dioxide CSCE - Contractor Safety Capability Evaluation DB - Distribution Board dBA - Decibel DG - Director General DGM - Deputy General Manager DI - Dangerous Incident/Occurrence
DNV - Det Norske Veritas DP - Dye Penetration ELCB - Earth Leakage Circuit Breaker FPS - Field Production Superintendent FR - Frequency Rate H2S - Hydrogen Sulphide HSE - Health, Safety and Environment IC - Internal Combustion L&T - Larsen & Toubro Limited LPA - Loss Prevention Association of India LRQA - Lloyd’s Register Quality Assurance LT - Lost Time LTA - Lost Time Accident mA - milli Ampere mR - milli Roentgens MD - Mock Drill MFF - Modular Fabrication Facility MI - Minor Injury MOM - Minutes of Meeting MSC - Management Systems Cell MSDS - Material Safety Data Sheet
NICMAR - National Institute of Construction Management And Research NSC - National Safety Council OEP - Onsite Emergency Plan OHS / OH&S - Occupational Health and Safety
OHSAS - Occupational Health and Safety Assessment Series OHSC - Occupational Health & Safety Cold Work Permit OHSCS - Occupational Health & Safety Confined Space Entry Permit OHSE - Occupational Health & Safety General Electrical Permit OHSH - Occupational Health & Safety Hot Work Permit OHSPM - Occupational Health and Safety Procedure Manual OHSR - Occupational Health & Safety Radiography Permit P&M - Plant & Maintenance PM - Project Manager PMC - Project Management Consultant PPE - Personnel Protective Equipment PVC - Poly Vinyl Chloride RCC - Resident Construction Coordinator RCE - Resident Construction Engineer RCM - Resident Construction Manager RPM - Regional Project Manager SBU - Strategic Business Unit
SD - Safety Department SDB - Sub Distribution Board SM - Site Manager SO/E - Safety Officer / Engineer SR - Severity Rate SSO/E - Site Safety Officer / Engineer T&C - Terms and Conditions TBT - Tool Box Talks UA - Unsafe Act UC - Unsafe Condition
1.0 Scope This HSE Plan shall serve as a guidance document for assisting the Site management to effectively implement the L&T HSE management system, Clients HSE requirements, project specification etc. while respecting the statutory laws and regulation of the state & the country. The HSE plan shall be used in conjunction with L&T OHS Procedure manual, OHSPM/01 dated 10th August 2004. The primary objective of this plan is to prevent any accidents, minimizing risk to personnel & properties, protect the environment and enhance company Reputation while executing the IOCL –Panipat, Captive Power Plant (CPP) project. This Plan is applicable to all L&T and contractor personnel involved in this project. In the event of any conflict with the contents of this HSE Plan the following documents shall take the precedence:
All safety rules and regulations adapted by L&T inline with the compliance requirement by the laws of the country. All the applicable local and national laws, rules and regulations including Factory Acts, IS Standards, OISD Standards etc..
Best safety practices in the construction industries, and
All the rules, regulations and procedures as applicable from IOCL.
2.0 Project Description Customer : Indian Oil Corporation Limited, India Contractor : Larsen & Toubro Limited, India Project : Captive Power Plant, PNCP, IOCL 2.1 Brief Description: The contract covers Design, Engineering, Procurement, Manufacturing, Construction, Fabrication, Installation, Testing, Pre-commissioning and Commissioning. The major activities are as follows:
1. Design & Engineering of the System 2. Civil works for foundation of GTG,STG,HRSG,UTILITY BOILER, Pipe Rack structure and other facilities. 3. Site fabrication and associated activities for Captive Power Plant for naphtha Cracker unit. 4. Fabrication & erection of structural steel, UG & AG piping and other associated mechanical Jobs. 5. Heavy Lift activity for erection of GTG, STG, HRSG & UTILITY BOILER. 6. Installation of Electrical, instrumentation and other Process utilities. 7. Hydro testing, Radiography, tie-in activities etc. 8. Pre commissioning & commissioning activity. 9. Final hand over.
2.2 Key Project Personnel from Client (EIL/IOCL- Panipat) Sl. No.
Name
Designation
Contact No
1.
Mr. S. N. Chaudhary
GM (PJ) IOCL
2.
Mr.S.P.S. Jolly
DGM (PJ) IOCL
3.
Mr. P.Chatterjee
DGM (PJ) IOCL
4.
Mr. R.BISWAS
Chief Project Manager IOCL
5.
Mr. S. k. Kaushik
Sr. Mgr (F&S) IOCL
6.
Mr. A.K.Tandon
RCM- EIL
7.
Mr. Ravindra Kumar
Manager (Civil)
8.
Mr. S.Kataria
Safety Officer (EIL)
9416202681
9416871118
3. Key Project Personnel from L&T Office (Baroda & Powai) Sl No.
Name
Designation
01.
Mr. R.K. Mishra
Project Director
02.
Mr. Sunil Bhat
Project Manager
03.
Mr. P. Bala Subramanian
Engg. Co-ordination
04.
Mr. M.D. Bennur
QHSE DGM
05.
Mr. Menon
Head- Admin
Contact Details
9428173180
2.4 Key L&T Site Management Team Sl No. 01.
Name Mr. K. K. Dutta
Designation Site Project Manager
Contact Details 092152 18545
02.
Mr. K. Sanjeevraman
Project Manager
092152 18502
03.
Mr. Ajay Sali
Safety Engineer
092152 18603
04.
Mr. R. Shaktivinayam
QA & I
092152 18504
Mr. Laxane
092152 18539
05.
Mr. Prashant Singh
Planning
092152 18538
06.
Mr. D. Lal &
Civil
092152 18518
Mr. Anil Midha
092152 18507
07.
Mr. A. P. Chhabra
Structural
092152 18511
08.
Mr. Sanjay Kumar
Mechanical
092152 18544
09.
Mr. Samiganeshan
Piping
092152 18512
10.
Mr. M. Shobhana
Electrical
092152 18546
11.
Mr. M. Shobhana
Instrumentation
092152 18546
12.
Mr. P. Elamurughan
Static/ Rotary Equipment
092152 18540
13.
Mr. H.C. Pandya
Stores
092152 18524
14.
Mr. Prasant Trikolvar
Admin
092152 18503
* Names to be modified /added during project execution.
3.0 CLIENT HSE REQUIREMENTS & EXPECTATIONS This section briefly describes IOCL expectation/ project HSE requirements as a minimum apart contract requirement’s Part – A, Section – A 3.12, HSE Management during Construction. In order to fulfill IOCL target to Achieve Safety by design - Not by Chance, the following minimum HSE requirements of IOCL needs to be implemented: 1. Compliance of requirement of OISD- GDN-192 & OISD-207. 2. Submission of Site Safety Plan with all details as per HSE requirements
in contract & OISD standard. 3. Deployment of Qualified & Experienced Safety Engineer/ Officer at each work site for every 500 workers and part there of. 4. Deployment of Safety Supervisor for every 250 worker and part there
of for each work site. 5. Deployment of Safety Officer for work during Nights. 6. All site supervisor & engineers (including sub-contractor) must be imparted structured training on construction safety before start of the Job & record to be maintained. 7. Availability of Qualified & experienced site engineer at site during all
working hours. 8. Site Safety training to be imparted to all workers (including sub contractors) & plan to be made to cover every worker. 9. Toolbox talk (5-15minutes) by supervisor prior to commencement of any job. 10. All accident/ incidents (near miss) to be reported & investigated (formats & procedures should be finalized). 11. Permits shall be issued for following Jobs.
- Working at Height (above 2 M.) - Confined Space Entry - Radiography - Electrical Installation
12. Daily Safety checking by each site engineer along with Safety
engineer. 13. Formation of Safety Committee & monthly safety meeting by site incharge. 14. Reports: weekly/ monthly/ annual HSE report on prescribed formats. 15. All Safety equipment must be ISI marked & checked by Safety Officer
before use. 16. Tag system for erection & use of scaffolding. 17. Use of Safety nets & fall arrestors for work at height. 18. Bamboo Scaffolding material not allowed 19. LPG cylinders not allowed without permission 20. Storage of gas cylinders (Number & Quantity) should be as per CCE
guideline. 21. Flash back arresters to be used in gas cutting sets. 22. Good housekeeping, separate waste bins to be used for flammable & non flammable material. 23. Safety awareness program for workers by display of boards, posters, competition, talks etc. 24. First aid medical facilities & ambulance at site. 25. Display of list of first aid trained persons at site. 26. Testing certificate for lifting tools & tackles available at site. 27. Safety checking & tag of construction equipment like grinding, welding
machine, gas cutting sets etc. by supervisor use. 28. Provision & maintenance of Fire extinguishers at construction site & material stores. 29. Display of Emergency telephone numbers at various locations. 30. For Confined space entry gas test must be done before & at regular
intervals. 31. ELCB at all temporary electrical connections 32. Safety Audit by external team once in three months.
4.0 L&T CORPORATE POLICY, Commitment / Philosophy
LARSEN & TOUBRO LIMITED Engineering & Construction Division CORPORATE POLICY
1. To Engineer and Execute projects with consistent quality, cost and delivery in line with the requirements of our customers, and to exceed or meet their expectations, whilst enhancing our shareholder value.
2. To set and review quality objectives for Continual Improvement of our products and services, whilst implementing the globally recognized management systems for Quality, Safety, Environment and Information Technology, and integrating these systems with our business partners and customers.
3. To design / operate and maintain safe and e nvironmentally friendly plants which meet all applicable statutory and regulatory requirements.
4. To advance / ensure the use of better and cleaner technology to minimise adverse environmental impacts.
5. To continually reduce the risk of pollution through setting environmental objectives in our design / operation and maintenance processes based on the feedback.
6. To deploy Information Technology for increasing the efficiencies of our business processes, while ensuring its security by protecting information as valuable assets and e nsure availability, integrity and confidentiality of all information.
7. To comply with all applicable occupational Health & Safety legislation and continually improve safe working practices through setting health and safety objectives and ensure good health, safety and security of all our people, our biggest asset.
8. To encourage enthusiasm, innovation and empowerment whilst developing inspiring leaders to make working at L&T a rich experience and create new global benchmarks in w hatever we do.
9. To promote a culture of mutual trust, caring and sharing achievements, with our people, our society, our stakeholders and our customers for the growth and benefit of our Nation.
10. As an undisputed leader in the Indian context, we continue to make things that make India proud, and shall strive to be amongst the globally outstanding companies, which the World is proud of. __________________________ Issue : Jan, 2002 K. VENKATARAMANAN (Member of the Board & President)
4.1 HSE Commitment/ Philosophy: L&T’s Corporate policy expresses the view of the L&T management towards the HSE, which considers the Health, Safety and Environment (HSE) of all personnel as important factor and recognize them as very essential for welfare and morale of personnel as also for contributing to company’s growth. L&T understands that high standards of HSE shall only be achieved by the dedicated and demonstrated efforts of all project personnel from top management down. At L&T planning and accountability for HSE of people precedes all other project objectives. L&T corporate policy recognizes the importance of HSE and assures compliance with Law of country and local laws for creating safe working conditions at Project sites.
L&T is committed to upgrade the skills and abilities through continuous training, education, promotion & motivational Programs.
5.0 L&T HSE Strategic Objectives & Targets 5.1 Strategic HSE Objectives: 1. Conduct all construction activities in a manner to prevent any
accidents, minimizing risk to personnel & property, protect the environment and enhance company reputation. 2. Ensure proper allocation of HSE responsibilities and acceptance of
HSE ownership by all levels of Site personnel including contractors. 3. Procure / maintain / manage appropriate HSE resources at site for
safe execution of the project. 4. Conduct regular orientation / training / meetings/ awareness
program to enhance competency levels of the project personnel and improve HSE implementation at site. 5. Analyze the risk involved in all critical activities, ensure that
required preventive measures are adopted, responsibilities and HSE resource requirements are identified and arranged prior to commencing the activity. 6. Ensure that competent contractors with appropriate HSE track
record are selected for the project, their performance is monitored and appropriate actions are initiated to enhance & maintain their HSE performance. 7. Encourage reporting of the accidents, near-misses, dangerous
occurrences, conduct investigation to identify system failure and act upon them. 8. Provide / maintain proper first aid facility, fire fighting equipment
and ensure preparedness to counter emergency at the construction site. 9. Encourage promotion/ motivation/ recognition of HSE importance
by organizing safety months, safety weeks, competitions, displays, demonstration, personal award programs etc. to enhance HSE awareness and encourage personal involvement. 10. Conduct scheduled inspections & audits, review critical issues
pertaining to occupational Health, Safety and Environment, develop
and implement continual improvement plan to enhance HSE performance of the Project.
5.2 Strategic HSE Targets Strategic HSE Targets Fatalities Day Away From Work Frequency rate (based on 200,000 man hours)
Zero 0.5
Recordable Road Accidents per 1 million kilometer’s driven
Zero
Oil spills greater than 1 barrel
Zero
Unplanned discharges / pollution incidents to air, land or water
Zero
Non-compliance with statutory requirements
Zero
Cases of substance abuse (drugs or alcohol)
Zero
Others required by Contractor
Zero
6.0 SITE HSE ORGANISATION AND RESPONSIBILITIES 6.1 HSE Organization of L&T - E&C Division The SHE organisational structure of L&T’s E&C Division Safety Management’s system and personnel responsible for safety aspects are as follows:
2. SITE HSE ORGANISATION (CPP-EPCC 4, PNCP, IOCL,
Panipat)
Head SCD (Powai) Mr. A K Ahuja Head (QHSE) Power, Baroda
Mr. M D Bennur
PROJECT MANAGER
Mr. K K Dutta
Safety Engineer (Site)
Mr. Prasoon Dwivedi
6.3 DUTIES AND RESPONSIBILITIES: 6.3.1 Corporate Management:
1. Formulates and owns of the HSE System, demonstrate commitment and allocate responsibility for effective HSE management system. 2. Set up standards for Loss control in compliance to applicable laws & regulations. 3. Allocate resources for proactive HSE management.
4. Review and act upon safety performances, set up implement continual improvement plan. 5. Integrate HSE management during project tendering, construction and commissioning activities such that all risks are identified and effectively managed at the planning stage. 6. To develop competency and awareness through effective training, motivation & promotional program. 7. Empower personnel to stop activities/ unsafe conditions with imminent dangers of Accident. 6.3.2 Project Manager / Resident Construction Manager (PM/RCM):
1. Demonstrate commitment and allocate responsibility for effective implementation Company HSE management system at the Project site. 2. Review the Site HSE performances, establish HSE Objectives and implement SMART (specific, measurable, achievable, realistic & target oriented) plans for continual HSE improvement at site. 3. Evaluate risk for all activities & integrate HSE requirements for effectively managing the risk while planning for the activity. 4. Regularly hold meeting with the site engineers/ supervisor to discuss the site HSE issues and chair the site HSE committee meeting once a month. 5. Conduct planned HSE site visits & audits including the evaluation of the contractor HSE performance. 6. Participate in the investigation of high potential incidents/Accidents. 7. Ensure availability of adequate HSE resources (shoes, helmets, Safety belts, fire Extinguishers, First aid boxes etc). 8. Provide & maintain safe working conditions inline with company safety procedures, client’s safety requirements and HSE best practices. 9. Ensure proper training for site personnel, apprise them of the job hazards and required safety precautions before putting them on to the job. 10. Coordinate with clients, contractor(s)/sub agencies and ensure compliance of site HSE requirements. 11. Provide & maintain First Aid facility, Fire fighting facility etc. establish mutual aid agreements and develop emergency preparedness at site. 12. To encourage safety suggestions, promotions and motivational program. 6.3.3 Site Engineers/ Supervisors:
1. Demonstrate commitment and effectively implement the HSE management system requirements at site in line with the allocated responsibility.
2. Evaluate risk for all activities & integrate HSE requirements for effectively managing the risk while planning for the activity. 3. Participate in the site Safety Committees, site safety meeting, site visits, inspections, and audits and ensure all sites HSE issues are addressed at the earliest. 4. Ensure the implementation of the following Safety Procedure as minimum to prevent accidents/minimizing the risk: 1. Risk assessment & prevention. 2. Permit to Work System 3. Use of PPE & Safety Equipment at site 4. Excavation 5. Working at height ( using Ladder, Scaffolds, Safety Nets etc) 6. Use of Electricity 7. Welding and Gas cutting safety 8. Entry into confined space 9. Material Handling (Crane Operation, using Lifting accessories etc) 10. Structural Erections 11. Radiography Safety 12. Shot Blasting & Paintings Safety etc. 5. Report accidents and near misses, conduct investigation and implement recommendations at site. 6. Ensure all company & Contractor personnel working under him are trained on safe working procedures. 7. Conduct Safety Toolbox talks daily in the Morning at site. 8. Use only tested /third party certified lifting equipment, tools and tackles. 9. Maintain good housekeeping in their respective area of control. 10. Seek HSE advises and Coordinate with site Safety Officer in effectively implementing the L&T HSE Management system & Project HSE Plan. 6.3.4 Site Safety Personnel:
1. Develop and assist site management in implementing company HSE Management System and project specific HSE Plan. 2. To act in an advisory capacity for all levels of management at site. 3. Provide assistance in solving HSE related problems and making recommendations for to effectively implement HSE requirements at site.
4. Review the site HSE performances against the set HSE Objectives and SMART plans and advise the RCM / Site Safety committee on the areas of improvement. 5. Assist in investigation of near misses/ accidents, identify root causes and recommend corrective action to the site management. 6. Assist site management in formulating, revising and updating the HSE procedures for critical activities/ high-risk activities. 7. Exercise authority to stop work when need arises. 8. To advice site management on legal requirements affecting Safety and coordinates with local authority, clients and contractors/agencies on issues regarding HSE. 9. Motivate, promote & propagate safety through orientation, training, leaflets, memos, posters, notices, etc. 10. Assist Site Engineers/ supervisors in conducting safety toolbox meetings at site. 11. Advise maintenance of such records as are necessary with regards to accidents, dangerous occurrence and occupational diseases. 12. Advice site Engineers/ supervisors on the HSE areas requiring immediate attention especially for housekeeping. 13. To arrange/ participate in periodic safety inspection/ audits of work areas. 14. Review the records of accidents, analyze trends and advice site management to prevent recurrences. 15. Advice purchasing & Quality of PPE conforming to ISI standard. 16. Identify critical equipment and tools and ensure they have a valid statutory test certificates before usage at site. 17. Advise site management on the requirements of First Aider, First Aid Facility, Fire fighting facility, identify mutual aids and develop emergency preparedness at site. 18. In the event of an emergency, coordinate with client and implement emergency evacuation plan as agreed. All Employees
1. Comply with L&T's safety rules and regulations, work practices and procedures to protect himself and his colleagues from any injury; 2. Report all unsafe acts and conditions to his superior immediately; 3. Report all accident and near misses to his superior immediately; 4. Use the personal protective equipment appropriate to the type of activity. 5. Practice “No Smoking” within the Project site and abide strictly compan y “drug & Alcohol” policy.
6. Ensure good housekeeping in the area of the activity. 7. Abstain from abuse/ misuse/ horseplay at site. 8. Attain orientation training, tool box meeting and respect the safety signs. 6.3.6 Safety Committee Members:
1. Arrange/ participate in periodic safety inspection/ audits of work areas and follow up recommended correction status. 2. Participate in the investigation of high potential accident, identify system failure (root causes of accident) and ensure implementation of the recommended action items. 3. Organizing safety weeks, safety competitions to promote & motivate safety awareness among the site personnel. 4. Review the Site HSE performances, establish HSE Objectives and implement SMART plans for continual HSE improvement at site. 5. Recommend measures for improving welfare amenities in the construction sites and other miscellaneous aspects of safety; 6.3.7 Contractors 6.3.7.1 Contractors’ Site Superintendent and Representative
- Liasing with L& T’s project management personnel to ensure provision of a safe and healthy work environment during the Project. - Overseeing the successful implementation of the Safety, Health and Environment (HSE) Plan during the project execution.
Ensure all site personnel are provided with appropriate Personal Protective equipment (Safety Shoe, Helmet, hand gloves etc.) and it is used by all. (note: penalties are applicable for not using PPE at site) Conduct Safety Tool Box meeting daily for all personnel under his control. - Nominate at least one person dedicated to supervise the HSE activities for his team (Note: above 250 worker one qualified & experienced safety officer is needed ) - Supervising and monitoring all his direct and contract employees to ensure constant compliance with the Safety, Health and Environment Management Plan and other local legislated regulations.
- Any deviation from the Safety, Health and Environment (HSE) Plan shall be corrected immediately and where necessary, affected work shall ceased until the affected work or situation is considered safe. - Authorised to immediately stop any work that is potentially unsafe and jeopardising the life of others. .0 Risk management It is the strategic objective of L&T to manage the risk within ALARP (As l ow as Reasonably Practicable) level. To this effect it is necessary that all associated hazards are identified, analyzed and preventive barriers are implemented to effectively manage the risk. A consolidated Hazard Register is enclosed with this Plan Refer Appendix No : 1, however it is the site management responsibility to identify the risk involved for ea ch activity during the job planning, make arrangement to minimize the risk, communicate with all the personnel involved, record it in the permits and ensure effective implementation during the execution of the job. JSA (Job Safety Assessment) for each activity with high Hazard Potential shall be prepared by site management and forwarded to IOCL/EIL for approval during the construction activities (e.g. Heavy lift activities)
7.1 Definition
Hazard – Source or situation with a potential for harm in terms of human injury or ill health, damage to property, damage to the workplace or environment, or a combination of these. Risk – Combination of the likelihood and consequences of a specified hazardous event occurring.
7.2 List of Project Activities (as minimum) with potential Hazards:
1. Site Preparation & layout and access
2. Pile Rig Positioning, Piling & concreting
3. Excavation & pile demolition
4. Reinforcement works
5. Shuttering & concreting activity
6. Fabrication of steel structure
7. Grit Blasting & painting activity
8. Handling of structure & Erection
9. Scaffolding/ Platforms & ladders
10. Working at height
11. Working in confined space
12. Handling & lifting Operation
13. Laying of UG Pipelines
14. Laying of AG pipelines on the structure
15. Radiography / NDT activity
16. Pressure Testing
17. Assembly & testing of 300 Ton crane at site
18. Heavy lifting activity for Boiler/Turbine
19. Electrical connection – Temporary /Permanent
20. Laying of Roads
21. Vehicle & Equipment Movement
22. Use of gas cylinders
23. Pre commissioning & Commissioning
24. Construction of chimney
8.0 HSE MEETINGS & COMMUNICATION 8.1 SITE HSE COMMITTEE: L&T-PM in consultation with L&T-Safety Officer shall form the site HSE Committee, which shall consist of at-least the following personnel (Name shall be finalised later):
1. 2. 3. 4. 5. 6. 7.
Project Manager - Chairman RCM from L&T – Vice Chairman Safety Officers from L&T – Secretary. Project Co-ordinator- L&T Site engineers (Civil, Mechanical, Electrical, Equipment) Representative from each sub-contractor. Safety personnel from each sub-contractor.
The Safety Committee shall meet once a month and perform the following issues:
1. Conduct a visit to site and identify the unsafe condition and practices and poor housekeeping areas and recommend corrective actions. 2. Review the status of completion for the previous audit/ inspection findings, and issue directive for incorporating the same. 3. Review high potential accident and status of implementation of the recommended action items. 4. Establish Plan for Organizing safety weeks, safety competitions etc.
5. Review the Site HSE performances, implementation status of SMART plans and recommend actions where necessary. 6. Review the welfare amenities in the construction sites and other miscellaneous aspects of safety and recommend improvements. The minutes of the meeting shall be recorded in the prescribed format and maintained at site for system audits compliance. 8.2 SITE Meeting & Reviews Project Manager shall chair personally site safety meeting once a month with the site engineers/ supervisors and contractor representative to evaluate the implementation of HSE at site.
Tool Box Meetings Site Engineers/ supervisors responsible to execute the onsite activity shall conduct tool box meeting everyday (prior to start of activity for 5-15 minutes duration) and record it in the L&T prescribed format. In the event of starting any new activity a pep talk shall be conducted to discuss the Hazard associated with the activity & precautionary measures that needs to be adopted.
9.0 Training Awareness & Competency Development program As a part of continuous HSE awareness & competency development program, L&T site management shall ensure the implementation of the following Training program as a minimum. Sr. No. 1.
Course Title
HSE Orientation
Content
L&T Corporate Policy & Strategic Objectives & targets. IOCL’s requirements & project HSE Plan. Risk Management
Accident Prevention & Control Fire Prevention & Control
PPE for the Job
Safety during Construction Electrical Safety
Safety while Working at Height Safe Excavation Procedure Procedure for evacuation. Evaluation by quiz, questionnaires.
Target Group
All Personnel Joining the Site shall under go orientation training.
Frequency
Once a year
2.
Line Management HSE Training
3.
First Aid Training
4
Training on Permit to work system
5
Working at Height
6
Excavation Safety
Duties & responsibilities of the Management for implementation of HSE requirement at site. Implementation of Site HSE Plan
All site management & Contractor site supervisor.
First aid response, duties, Selected Group responsibilities and certification of the personnel as First Aider
IOCL requirement on the Permit to Work system. Various types & uses of PTW
Site Engineers & supervisor & Contractor site supervisor.
Once a year
Depending on the requirement
Once
Prior to start of Job & Working at height -Safety Site Engineers & requirement Supervisor & Contractor Every six Month site supervisor. Scaffolding & Ladder PPE, Lifelines, Fall arresters, safety nets
Site Engineers & Prior to start of Job & Supervisor & Contractor Every six Month Design of slops, benching site supervisor. Safe Excavation Practices Precautions etc.
7
Confined Space Entry
8
9
Hazardous Chemicals
Basic Fire Fighting
MSDS Safe handling, storage, use of the chemicals
Site Engineers & Once a year Supervisor & Contractor site supervisor.
Fire & its composition Types of Fire Extinguisher & use Basic techniques & Practical drill
Site Engineers & Every six months Supervisor & Contractor site supervisor & selected personnel
Types of Emergency
Emergency preparedness
Site Engineers & Every Six Months Supervisor & Contractor
10 Emergency
Prior to start of Job & Safe working practices in Site Engineers & the confined space Supervisor & Contractor Every six Month site supervisor. Permit requirements Ventilation/ lighting/ PPE/ Rescue arrangements.
Preparedness & Drill
& response Emergency contacts & Drills
site supervisor & selected personnel
10.0 HSE PROMOTION, Reorganization & PENALTIES L&T in order to enhance the HSE standard shall implement various programs for HSE promotion, motivation, recognition & Penalty etc. for individuals & contractors/ Sub contractors. Safety Notices, Posters, slogans, important telephone numbers shall be duly displayed to make everyone aware of the prevailing hazards in the construction area. Several training Program, drills & demonstration as detailed in this plan shall be organized during the construction period to enhance the awareness & motivation level. Safety week shall be organized once in a year (during 1st or 2nd week of March), during which several HSE programs shall be organized including lectures, demonstration, competitions etc. the winners shall be awarded accordingly. Summer Safety Week shall be celebrated to communicate the precautionary measures during summer times, where quiz, slogans, posters competition shall be organized. Every Month one site/ contractor / group shall be selected for awarding a rolling Trophy on “Best House Keeping” shall be awarded. Every Month one person shall be chosen and awarded “Best Safe Employee of the Month”, duly awarded & displayed in the notice Board. Every Million Man-hours work with out LTA by the sub-contractor shall be recognized duly by L&T and the achievement shall be Published as Positive safety achievement and distributed to management. Safety Performance Board shall be displayed at suitable location indicating the site Safety Statistic & achievement. Every effort shall be made by L&T to avoid any Penalty as indicated by IOCL in their Tender Document. L&T shall implement similar Penalty program for their contractor & sub contractors (modalities shall be finalized later).
11.0 INSPECTION AUDIT & REVIEW In order monitor effective implementation of HSE requirements at site the following periodic inspections, audits and review shall be carried out. 11.1 Daily Site Inspection Inspections of site shall be carried out regularly, prior to the commencement of daily activity, while executing a new activity or during any time of the day by the Site Engineers/ supervisors, safety officers and all other site management personnel. The high potential HSE deficiencies shall be recorded and forwarded to the RCM for immediate action.
11.2 Monthly Site Inspection Site Engineers/ Supervisors shall inspect their area on work at least once a month, the copy of the report shall be forwarded to HSE section, any deficiencies and corrective actions shall be completed by the Site engineers.
11.3 Quarterly Site Inspection and Audits Site Safety Committee personnel shall inspect the site once a quarter to identify the HSE deficiencies & level of compliance. All findings shall be recorded and corrective actions plan shall be prepared for implementation.
Once a Quarter the Safety personnel from Powai / Baroda office shall conduct a OHS compliance audit. Copy of the audit report and findings shall be forwarded to RCM for action. 11.4 Review of the Contractors HSE Performances Contractors HSE performance shall be reviewed by the RCM and a selected group every six months or at the completion of the project which ever is less. The outcome of the findings shall be maintained for future evaluation of the contact & selection.
12.0 Safe Work Practices in the Construction Sites This section details the minimum HSE requirements that shall be implemented at the L&T constructions sites by all L&T site personnel and contractor personnel.
12.1 Statutory Requirements The content of section by no means substitutes the requirements as stated in the L&T OHS Manual- OHSPM/01 Rev 02, Dec. 2007. In the event of any conflict or clarification, it is advisable to refer to the following documents and incorporate the best industrial practices:
1. L&T OHS Manual- OHSPM/01 Rev 02, December, 2007 2. CPP Contract requirement, Part –A, section- A-3.12 3. “Safety in Construction” –IOCL issued April 2003. 4. Local & National laws & statutes 5. Factories Act, 1948 6. The Punjab Factory Rules 7. OISD standard 8. IS Standard. 9. Air (Prevention and Control of Pollution) Act, 1981 10. Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 11. Electricity Act, 2003 12. Environment (Protection) Act, 1986 13. Water (Prevention and Control of Pollution) Act, 1974 14. Radiation Protection Rules, 2004 15. Chemical Accidents Rules, 1996 16. Gas Cylinder Rules, 2004 12.2 PPE – Personal Protective Equipment
1. All employees shall be oriented on the PPE requirements appropriate for their Job and its benefits. 2. Nobody is allowed to enter construction site without safety shoe & helmet with chinstrap in place. 3. No climbing / working at height allowed with out proper fall protection arrangement (safety belt/ harness/ lifelines /fall arrester/ safety nets etc) for work over 2 m height.
4. Eye and face protective system must be used for all operations such as Grinding, Welding, Gas Cutting, Grit Blasting, chemical handling etc. where there is potential for eye or face injury from contact, impact or radiation. 5. Suitable and approved hearing protection must be provided and worn by all employees engaged in activities where noise level exceeds 85 dB (A). 6. The kind of gloves used depends primarily upon the material or equipment being handled. 7. Aprons made of leather or other flame resistant shall be used to protect the body from spark and hot slag. 8. Safety Nets: shall be placed to arrest a fall for not more than 9m. The table below is a list of basic personal protective equipment (PPE) that shall be used by all personnel at L&T construction site. Depending on the job classifications, need for additional PPE shall be advised by the Safety officer based on the evaluation of work location, type of job, local hazards, conditions, etc. Cat No.
Typical Job Classifications
Basic Personal Protective Equipment to be Worn (see key below)
1.
Abrasive blast cleaner
1, 5, 8, 9, 10D, 11A, 12/13, 14, 15A
2.
Carpenter
1, 8, 9, 10C, 15A
3.
Electrician
1, 2, 8, 9, 10B, 15A, or B
4.
Iron worker - structural
1, 8, 9, 10D, 12/13 & 14 A/B, 15A
5.
Lineman
1, 8, 9, 10C, 12/13 & 14 A/B, 15A
6.
Mason
1, 8, 9, 10C/A, 15 A
7.
Material control man
1, 8, 9, 10C, 15A
8.
Mechanic/machinist
1, 8, 9, 10C/A, 15A
9.
Painter
1, 6/5, 8, 9, 10B, 12/13, 14, 15A
10.
Pipe fitter
1, 8, 9, 10C/D, 15A, 2 (During work)
11.
Plumber
1, 8, 9, 10C, 15A 2 ( During work)
12.
Rigger
1, 8, 9, 10C, 15A 12/13 (During work)
13.
Roof worker
1, 8, 9, 10C, 12/13 & 14 A/B, 15A
14.
Scaffold erector
1, 8, 9, 10C, 13 & 14 A/B, 15A
15.
Sheet metal worker
1, 8, 9, 10C/D, 15B
16.
Welder
1A & B, 4, 8, 9, 10D/E, 15B
17.
L&T Contractor Personnel (General)
1, 8, 9, 10C, I5A
Legends
1.
Safety glasses with side shields (1A=Clear, 1B=Shaded)
10.
Gloves (10A= Rubber coated, 10B=Rubber molded, 10C = General purpose, 10D=Leather, 10E=Heat resistant)
2.
Face shield
3.
Goggles, safety impact (3A=Clear, 3B=Shaded)
4.
Welding hood and skull guard (Lens shaded to suit work)
11.
Ear protection (11A=Ear plugs, 11B=Ear muffs)
5.
Respirable air fed hood with filter
12.
Standard safety belt
6.
Respirator, chemical cartridge
13.
Full body harness
7.
Respirator dust
14.
Lanyard 1.82 m (6FD). (14A=standard,
8.
Safety helmet
9.
Safety foot wear (9A=shoes, 9B= boots)
14B=Shock Absorbing) 15.
Clothing (15A=normal, 15B= arrangement for Fire protection )
Notes : All personal protective equipment shall meet ISI std. requirements. 12.3 Safety Sign, Signals and Barricades
1. Safety signs, signals, barricades appropriate to the type of hazards, cautions, notices and warning/safe guard barriers shall be provided in the construction area. 2. Danger signs must be used only where an immediate hazard exists. Caution sign must be used only to warn against potential hazards or to caution against unsafe practices. 3. Accident prevention tags are used as a temporary means of warning employees of an existing hazard, such as defective equipment, incomplete scaffolding etc. 4. Assemble Points, Escape routes, Fire Extinguisher points, emergency contact no shall be displayed and located with in the construction area. 5. Warning barricades shall be erected before work begins or as soon as specific hazard is identified (in some situations a rigid guardrail is needed) 6. Warning barricades must be erected and maintained at least two (2) meters from the edge of an excavation or opening. 7. Warning Flashing Lights shall be provided in excavation works, near roads & crossing, dark locations inside & outside operating areas to prevent falling hazard of personnel and equipment. 4. Work Permits L&T E&C and its subcontractor shall obtain a work permit from the EIL/IOCL for specific work as describe in Part-A, Section-A 3.12, HSE Management during Construction. L&T E&C and its subcontractor shall not start any work till work permits are signed and available. All personnel shall be instructed in the basic requirement of the work permit system during the orientation. In general the following work permits are available for incorporating during the construction. A. Working at Height Permit
A working at height work permit is required for any work to be carried out above 2 meter height. B. Confined Space Entry Permit Vessel entry permit is required for entries into any confined space e.g. vessel, tanks, furnaces, pits, sewers, excavations more than 1.2 meter deep etc. The permit is required to protect personnel against hazards of oxygen deficiency, toxic, flammable material and power driven equipment etc. C. Electrical Permit An electrical permit is required for any work on electrical system.
4. Permission to Excavate Within the restricted area excavation authorization is required for all excavations regardless of depth. Other appropriate work permits shall be obtained prior to start of excavation.
4. Radiography Permit A radiography permit is required to carry out any radiography work at site. All radiography work shall be carried out as per BARC (AERB) norms. 12.4.1 General Rules Related to Work Permit
1. The authorized receiver must request a work permit form a certified issuer (operation supervisor) before doing any work in a restricted area. 2. The receiver of the work permit must keep the permit posted at the job location 3. The appropriate permit shall be obtained before any job is started. 4. Work permits are valid for the duration mentioned therein. 5. If work is not started or is stopped due to safety considerations the permit is required to be revalidated by the issuing authority before the work is started or resumed. 6. If work is not completed during the time for which the permit was issued the person responsible for performing the work shall get it revalidated.
7. Superintendent Fire and Safety Div. or any officer from Fire & Safety Div. or any responsible member of the operation Dept. is authorized to suspend a work and withdraw the work permit if Safety Regulations being violated and for any of the work permit conditions are not being abide and/or conditions around work site have change which may lead to an imminently hazardous situation 8. The receiver of a work permit must keep a copy in his possession or within view of the job site for duration of the job, so that it may be presented upon request. 9. When the job is completed or at the end of the shift, each work permit must be closed out by both issuer and receiver.
WORK PERMIT PROCESS FLOW CHART
12.5 Piling Activity
1. The Ground condition and underground services shall be established and suitable permit shall be obtained prior to proceeding with the piling activity. 2. Piling Rig of adequate integrity shall inspect and tested prior to proceeding with the piling activity. 3. Any movement, relocation, modification of the structure shall be assessed & adequately supervised. 4. The wire ropes of sufficient diameter and strength to take the impact load of chisel casing shall be used. 5. Competent person & site in-charge shall regularly inspect the wire ropes, pulley, drum, rig structure etc. of any defects, ensure appropriate action for rectification and record in the registrar for weekly verification. 6. Operator & Piling crew shall use Ear protection while performing the piling activity. 7. While working at height (on rig structure) suitable fall protection arrangements (Safety belt/ harness and fall arrester) shall be placed and used. 8. Pile caps shall be place immediately at the completion of the piling. 12.6 Excavation, trenching & shoring
1. The Ground condition and underground services (Electric supplies, IT line, process/ utility/fuel/ water line/ structure etc.) shall be established and suitable permit shall be obtained prior to proceeding with the Excavation. 2. Where underground services are located, exact location shall determined by hand excavation, services uncovered, proper supports provided and safe arrangements made to protect for the existing installation. 3. Depending on the soil type, characteristic, depth of excavation an excavation plan shall be prepared with proper indication of the protective arrangement like slopping / benching/ shoring etc. 4. Proper access & egress / barrication / caution notices / excavated materials stacking shall be arranged by the site incharge. 5. Excavated area shall be regularly inspected and recorded. 12.6.1 Commonly identified Hazards in During Excavation Activity.
1. Collapse of earthwork due to lack of inadequate benching/ slopping or weak shoring. 2. Persons falling into excavation due to lack of barriers or inadequate fencing.
3. Asphyxiation from exhaust gases that have collected in the bottom of the excavation. 4. Soil from excavations not being thrown clear of the sides that then become overloaded and collapse. 5. Failure to maintain shoring particularly after rains and sand storm. 6. Lack of access/ egress or ladders while personnel are inside the excavated area. 7. Lack of barricade or warning sign or tape around all opening hole. 8. Lack of warning notices & signboard at least 1.5m back from edge of the excavation. 9. Lack of slope or benching for depth/over is 1.5m. 10. Spoil dirt must be piled within 1.5 meter from edge of the excavation. 11. Water seepage 12. Person’s working too close to the machinery in operation. 13. Vehicle or plant equipment too close to the edge causing the edge to collapse. 14. Cold work permits shall be required for all excavation regardless of depth. 15. If toxic gases are suspected to be present in the area of excavation, gas test shall be made prior to work. 16. Barricade and warning tape shall be removed when no longer needed. 17. Safety instruction shall be given to workers excavation method prior to start work. 12.7 Reinforcement, Form work shoring and Concreting
1. Personnel associated with the reinforcement activity (straightening, cutting, bending) shall wear Leather hand gloves and chest guard specially while straightening and bending. 2. Bar binders when tying the reinforcement rods shall work from the proper platform. 3. All protruding ends of the exposed reinforcement bars shall be suitably capped. 4. Form work and shoring shall be designed, erected, supported, braced and maintained so that it will safely support all vertical and lateral loads that may be imposed upon during placement of concrete. 5. All concreting activity shall be adequately planned, proper arrangement shall be installed for personnel, machinery 6. Imposition of any construction loads on the partially completed structure shall not be permitted unless such loading has been considered in the design and approved by the Engineer.
12.8 Scaffolding and Ladders (IS 4014, 1967 / Part I - Scaffolding, Part II – Definitions and Materials) Scaffolds are temporary structure/ work platforms that are constructed to provide support for workmen, plant and materials etc. used in building, construction, maintenance, repair and demolition work etc. Competent Persons shall be responsible (Site engineer/ supervisor identified & nominated by RCM undergoes suitable training & evaluation process by Safety Officer in line with national rules IS NO. 4014 Part I & II for scaffold) to inspect & tag the scaffolding prior to use by site personnel. It shall be inspected periodically (every seven days) and or in the event when the condition / structural modification is carried out. Fall of person from height, fall of material, collapse of scaffold etc. are the common type of incidents that are reported from the construction sites. The following section details the general Safety requirements that shall be implemented at L&T construction sites. 12.8.1 General Safety Requirements
1. Use of Sound scaffold Materials, defective materials shall be tagged & removed from site. 2. All tubes shall be straight, inspected & maintained in a clean condition. 3. Fittings should be regularly examined and moving parts should be regularly lubricated for easy movement. 4. Looking at the face of the board, the end shall not be split up more than 12” with the iron fixed. 5. Looking along the board from one end, it must not be twisted by more than ½” thick. 6. Boards that are split, decayed or warped shall not be used, but the parts affected may be cut off to obtain shorter boards. 7. Boards shall not be painted or treated in any way that may conceal defects 8. Timber boards shall not be used where there are in contact with hot lines or surface, which could cause fire. Metallic board shall be used in this case only metallic boards to be used within their construction area). 9. Board shall be properly laid and lashed at both ends. 10. Scaffolds shall be provided with top rail, mid rail & toe board. 11. Makeshift scaffold, such as boxes, crates, drums and poles are prohibited.
12. Scaffold shall not be used as material hoist tower. 13. Never throw a scaffold material from the top on the ground when scaffolding is being dismantled. 14. The poles/legs or uprights of scaffolds shall be plumb, and securely and rigidly braced to prevent swaying and displacement. 15. Strength of guardrail shall be ensured. 16. Sign Boards such as “ SCAFFOLD CHECKED & READY FOR USE ” (i.e. Green Tag), “DO NOT USE SCAFFOLD” (i.e. Red Tag) shall be displayed on scaffold. 17. Sole Plate: a timber or other members of adequate size and suitable quality used to distribute the load from the base plate over an area of ground. 18. Ascending and descending of scaffolding by bracing prohibited. 19. Proper access is required for reaching the working platform. (ladder angled at 1:4 ratio, 1m above landing platform, properly secured) 20. Site fabricated ladder, ladders with broken or missing rungs, broken or split rails or other defective construction is prohibited and shall be removed from site immediately. 21. One person shall use the ladder at a time. 12.9 Steel Erection
1. In all structural erection process, all employees likely to work at height of more than 1.8 meter & above shall use proper fall protection measures (Safety harness, life line, fall arrester, safety net etc. or combination as appropriate). 2. Structural erection plan (sequence of erection, securing, temporary supports, crane access restriction etc.) shall be prepared and communicated to all personnel responsible for the Job. 3. Cranes & lifting accessories required for the job, are inspected maintained and certificate available from the third party. 4. Site fabricated lifting accessories are not allowed for the job unless certified by the third party. 5. Trained & competent erection personnel shall only be employed for the activity. 6. Rigging, signaling, lifting activity shall be carried out by experienced crew and under proper supervision. 7. For fire protection of other crafts, sign and barricades shall be installed at the area where the erection of steel is in progress.
12.10 Floor and Wall Openings and Stairways
1. All floor, grating or roof openings within a building or other structure during the course of construction, alterations or repairing shall be closed with rigid covers (e.g. planks, concrete, metal etc.), fenced on all sides by a standard railing and toe-board and safety notices placed. 2. If the bottom of the wall opening is less than 10cm above the working surface toe-boards must be installed. 3. Every open-sided floor or platform 1.8 meters or more; above adjacent floor or ground level must be guarded by standard guardrail and toe board. 4. Regardless of height, open-sided floors, walkways, platforms or runways above or adjacent to dangerous equipment must be guarded. 5. Crossing over the open trenches shall be designed & constructed appropriately with proper hand rails & guardrails. 12.11 Entry into Confined Spaces
1. A confined space is defined as an area with oxygen deficient/contaminated atmosphere which may threaten the personnel entering into the area, this may include, open pipeline, sewage tanks, deep excavations, vessel including towers, tanks, drums and etc. 2. No person shall enter any confined spaces before the confined Space entry Permit & associated work permit has been issued and the stated requirements adhered to. 3. Initial gas testing and subsequent gas testing for detecting the presence of flammable/toxic/poisonous/corrosive/fumes/vapor & also for oxygen (min. 19.5% & max. - 23%) to be carried out and recorded. 4. Buddy system with mechanism to restrict access shall be put in place. 5. Attendance in and out of the confined space shall be recorded. 6. Rescue equipment must be available at the scene where work is to be carried out. 7. Work permit shall be displayed at the entrance into a confined space. 12.12 Electrical Safety
1. All electric works shall be performed by qualified and experienced workers. 2. Only Electrical Authorized Person shall be allowed to obtain the permit. 3. Equipment shall be locked or secured to prevent starting by unauthorized person.
4. Warning signs or posters, such as DANGER, NO ENTRY, DON'T TOUCH, etc., shall be posted at dangerous places, such as substations, switch boxes and overhead or underground cable. 5. Electrical parts to be used shall be in good condition, including cords for condition. The extension and outlets to connect tools have to be polarized. 6. Transformer Banks or high voltage equipment shall be barricaded with a fence. The entrance shall be locked. 7. Earth leakage circuit breakers (ELCB) shall be provided & regularly tested for all electrical equipment to prevent worker from being injured by electric shock. 8. Temporary switch boxes shall be installed in the space provided with a waterproof roof and door which can be locked. 9. Switch boxes shall be grounded with vinyl insulated copper wire. 10. Before welding machines are used, insulation shall be tested and certified to be in safe operating conditions. 11. Overload devices shall be provided for all welding machines. 12. All exposed terminals shall be covered safely with insulation tape. 13. To prevent a short circuit or electric discharge, special precautions such as grounding shall be taken for wiring work where metal scaffolds or steel structures are erected. 14. Grounding shall be secured by connecting the wire to earth and buried firmly in the ground.
12.13 Electric Arc Welding and Cutting
1. Hot work permit shall be obtained for all welding and cutting operations. 2. All welding equipment shall be properly maintained and regularly inspected. 3. Only qualified, trained & experienced welder with knowledge and awareness of Welding Hazards & precaution shall do the welding. 4. Electric shock protector shall be equipped to welding machine. 5. Leaving holder attached with rod when not in use is prohibited. 6. All of welding equipment must be properly earthed. 7. Hot tapping and patchwork shall not be done unless approved by Inspection Engineer. 8. Welding cables should not cross traffic lanes or walkway, Suitable protective arrangement shall be made (under-ground trunking/ overhead hanging etc).
9. In confined spaces or any other places, the cable shall be protected to prevent contact with falling sparks and slag. 10. The electrode shall never be changed with bare hand, while wearing wet gloves, or when standing on wet floors or ground floor. 11. If a cable (either work lead or electrode) becomes worn and exposes a bare conductor, the cable must be properly repaired or replaced. 12. Welding cable must be kept dry and free from grease and oil to prevent premature break down of the insulation. 13. Welding cable must be kept away from energized power supply cables or high tension wires & hoses from gas cutting sets. 14. Welding ground cable must be attached directly to the object on which welding is being done. 15. Cable of the welding machine shall be arranged so as not to create a tripping hazard or exposed to damage by passing trucks. 16. For all AC driven DC welding generators, no earth connection shall be applied to either pole of the DC welding output. The machine frame shall be effectively earthed. 17. When welding work is not in progress even for a short period the power source of the welding circuit shall be disconnected. 18. Forced ventilation shall be arranged when welding and cutting work is to be carried out in confined spaces.
Note : For further guideline please refer to Indian Standard IS 816 code of practice for use of metal arc welding.
12.14 Gas Welding and Cutting
1. All cylinders shall be kept vertical position and secured in a cylinder trolley or similar handcart. 2. Flash back arrester must be fitted to both Oxygen & Acetylene cylinder. 3. When work is shut down and hoses disconnected all valves at the gas and oxygen cylinder must be closed. 4. Gas cylinder shall be handled with care, properly supported in an upright position. 5. Acetylene cylinders shall be stored, handled and used in vertical position.
6. Cylinder shall not be roll while shifting from one place to another place. 7. Spark lighters shall be used to light torches. Matches and smoldering rags shall not be used. 8. Cylinders shall not be transported with the regulators and hose attached, except on a purpose made trolley. 9. Cylinders shall not be located in any enclosed space where welding or cutting job is taking place. 10. Oxygen and acetylene cylinder shall be kept at least 15 ft away from blowtorches or any other approved source of ignition. 11. Oxygen and acetylene hoses shall be of different colors otherwise identified and distinguished from each other. 12. Safety band (Jubilee Clip) to hose connection shall be used. 13. A blow-torch and hose, when not in use shall not be left unattended in any enclosed space even for short period, lunch breaks. 14. Closing of cylinder valves shall not be treated as disconnection. 15. A safety cap must be securely screwed on every cylinder when not in use. 16. Oxygen and combustible gases should not be stored together. 17. Oxygen should never be used for the purpose of cleaning fume or other blowing purpose. 18. Cylinders should not be allowed to come into contact with electrical apparatus or live wire. 19. Broken cylinder gauge shall not be used and removed from site. 20. Fire extinguisher shall be provided when welding & cutting job is performed. 21. Specially designed and tested man cage will be used for lifting cylinder. 22. Limited numbers of cylinder as approved by Gas Cylinder rules, 1981, shall only be stored at site under proper storage condition with adequate fire protection. 23. The following table elaborates the maximum numbers of cylinders that can be stored at site with out the license.
Sl No. Name of the Gas to be stored
Maximum no. of filled cylinders /quantity which can be stored without license
1
Liquefied Petroleum Gas (LPG)
100 Kg
2
Any Flammable but non –toxic (methane, propane etc.)
25 Cylinders or 200 kg which ever is less at any one time.
3
Any non-flammable non-toxic gas (e.g. Nitrogen, Carbon dioxide etc.)
4
Any toxic gas (Chlorine, ammonia etc.
5
Acetylene Gas containing in cylinder in dissolve state
200 cylinder
5 cylinder
50 cylinders
12.15 Shot Blasting & Painting Activity
1. No blasting or spray painting activity shall be permitted at site without a valid Work Permits. 2. All blasting pots and air receivers used must be inspected and tested according to the requirements and possess a valid test certificates. 3. All areas of intended for blasting must be adequately and appropriately covered to minimise the emission of the blasting dust. 4. All workers undertaking blasting must be provided with a suitable blasting hood that is capable of providing constant fresh air by means of an airline. 5. The Blasting nozzle shall be fitted with “Dead Man Switch” such that in the event of any emergency the release of switch shall cut off the pressurised air supply. 6. All paint and solvent used in spray painting shall be labelled with warning notices to warn others of the hazards involved and MSDS shall be available. 7. No electrical lighting shall be used in the vicinity of the intended spray painting location. 8. All electrical wires must be removed or isolated from the intended spray painting area. 9. Only the day’s supplied of required paints shall be allowed to be brought on project site. Any excess paints shall be removed. 10. All areas of the intended spray painting works shall be adequately ventilated by means of forced ventilation. 11. All workers undertaking spray painting work in any tank, compartment, confined space or any other area shall use an air-fed respirator or suitable and effective breathing apparatus capable of protecting that person from inhaling any harmful substances and any other suitable personal protective equipment. Note : For further guideline please refer to SMPV (unfired) Rules, 1981. 12.16 Hand & Portable Power Tools
1. Power tools shall not be operated without proper training and instruction. 2. All portable power tools exceeding 220-volt rating shall be properly grounded. 3. Tools shall be used for the purpose for which they are designated.
4. Proper guards or shields must be installed on all power tools. 5. Proper PPE appropriate for the Job shall be used by the Operator. 6. Safety guards shall not be tampered with, and any defects shall be immediately rectified. 7. Compressed air should not be used to clean the working place. 8. Tool must not be modified or the labels and inscriptions defaced or removed. 9. All Tools shall be duly inspected & marked by competent person.
12.17 Cranes & Lifting Equipment **
1. All cranes and lifting equipment shall have valid certification and third party approval. 2. Ensure that personnel do not ride on the equipment, hook or with load. 3. Crane operator shall not leave the machine unattended during lift operation. 4. Do not stand, walk or crawl beneath a elevated load. 5. The hoist rope is vertical to prevent swinging. 6. Do not use twisted or kinking wire rope unless inspected and certified. 7. Never use nuts and bolts to join a broken chain. 8. Never drop any item of lifting gear from a height. 9. All out riggers shall be fully extended during lifting operation. 10. No crane shall be operated without a competent signal man and crane operator. 11. Ensure that overload alarm is fitted to the equipment. 12. Crane operator must check soil condition prior to start lifting operations and proper padding shall be place where necessary. 13. SWL shall be mark on the lifting equipment. 14. Do not travel with load on equipment unless planned and all risk assessed. 15. All the lifting equipment shall be checked once in a month and records maintained. 16. Swing alarm, warning system, light system shall be in operational condition to warn the personnel working nearby. ** List of all Heavy lifting equipment to be attached before starting the construction activities.
12.18 Hazardous Material 12.18.1 Classification Hazardous materials are classified as follows: A. Explosive An explosive is any chemical compound, mixture or device whose primary purpose is to function by explosion with substantial release of heat and gas. A.1 Compressed Gases A compressed gas is any material having an absolute pressure in the container exceeding 40 psi at 70 °F (21.1 °C) or having an absolute pressure exceeding 104 psi at 130°F (54°C). A.2 Flammable and Combustible Liquids Flammable liquid is any liquid with a flash point below 100 °F (37 °C) and having pressure not exceeding 40 psi at 100 °F. A.3 Flammable Solids A flammable solid is any solid material which is liable to cause fire through friction or retained heat from manufacturing or processing or that can be ignited readily and when ignited, bums so vigorously and persistently as to create a serious hazard. B. Poisons Poison A is a gas or liquid of such a nature that a very small amount is dangerous to life. (Example: hydrogen cyanide, phosgene, nitrogen tetroxide.) Poison B is any substance (liquid or solid) known to be so toxic that a severe health hazard exists. (Example: Tetraethyl lead, parathion. Aniline). Irritating materials are liquids or solids which, upon contact with fire or exposure to air, give off dangerous or intensely irritating fumes. C. Radioactive Materials
Material/isotopes that spontaneously emits ionizing radiation (Alpha, Beta, Gama rays etc.) which are very harmful to human body, D. Corrosive Material A corrosive is any liquid, solid or gases that can destroy human skin tissue or any liquid that causes a severe corrosion rate of steel or other materials. 12.18.2 Material Safety Data Sheets (MSDS) The Material Safety data sheet (MSDS) covers the major hazards associated with a single substance or family of substances, discuss methods of controlling or eliminating the hazards, and concisely outline safe and efficient handling and disposing procedures. MSDS must be obtained from the manufactures, and/or suppliers for each hazardous chemical/substance. MSDS must be stored in at least one central location, organized and maintained in such a manner as to facilitate easy return to reference. These sheets should be readily available for supervisor's reference and employee review as requested. A typical "Material Safety Data Sheet" is providing following data/information:
1. Properties
2. Uses
3. Containers
4. Storage
5. Personnel hazards
6. Handling
7. Personnel protective equipment
8. Ventilation
9. Fire and explosion hazards
10. Electrical equipment
11. Symptoms of poisoning
12. First aid
13. Treatment at burns
14. Toxicity
15. Threshold limit values
16. Medical examinations
17. Waste disposal
12.19 Radiography
1. All radiography operations shall be carried out in accordance with the regulations laid down by the AERB, department of atomic energy, government of India under the radiation protection rules, 2004. 2. All radiography equipment shall be adequately shielded. 3. All radioactive sources shall be kept in their respective exposure devices, or sealed in the source changer and stored in a safe storage pit. 4. The radiography supervisor shall inform their radiation licensed officer immediately of the loss or damage of the radioactive source, or the malfunction of equipment, resulting in a leak of contamination to the environment. 5. All personnel involved in the industrial radiography shall be provided with the Thermoluminescent dosimeter (TLD) and a portable radiation monitor (meter) for the measurement of radiation in the affected area. 6. The radiography supervisor shall ensure that all possible safety precautions and measures have been implemented, area of operation has been cordon off and the standard radiation hazard signs are displayed. 7. The radiography supervisor shall ensure that all radioactive waste shall be disposed at an authorized dumping area. Follow the AERB of India Safety Guide :
Industrial Radiography (Code No. AERB/SC/IR-1) Enclosed Radiography Installation (Code No. AERB SG/IN-1) Open Field Industrial Radiography (Code No. AERB SG/IN-2) Handling of Radiation Emergencies in Industrial Radiography (Code No. SG/IN-3) Emergency Response Planning & Preparedness for Transport Accidents Involving Radioactive Material (Code No. SC/TR-3) Radiation Protection Rules, 2004
12.20 Fire Prevention/Protection All following fire protection measures shall be implemented at site:
1. Smoking is prohibited in the construction area except in “designated Place”.
2. Flammables shall be stored in properly labeled containers. 3. Accumulation of trash, oily rags, combustible materials and similar fire hazards of any nature will not be permitted. 4. All Gas cutting set must be equipped with flash back arrester. 5. Limited numbers (in line with Gas cylinder Rules, 1981) of Compressed Gas cylinders shall be stored at site under proper storage and issues control. 6. Refueling equipment with the engine in running condition is prohibited. 7. Know the IOCL fire alarm signal and how to turn on an alarm. 8. Know the location of fire extinguishers, and how to use them. 9. Know where the emergency evacuation assembly point is. 10. Fire fighting equipment to be available at the construction site and office. 11. There must be fire extinguisher, water hose, or other fire control equipment easily accessible for each welding, cutting, grinding or other such operation. 12. All Fire Extinguishers at site shall be inspected once in a three months.
12.21 Housekeeping
1. Work location, equipment and buildings are to be kept clean and orderly at all times. (At least half an hour, daily is advisable). 2. All work areas are to be free of dangerous projections or obstructions, and are to be maintained free of rubbish, oil, grease and water. 3. All toilet facilities, including hand basins must be maintained in a clean and hygienic condition. 4. All scrap and refuse bins must be clearly marked as to the type of the scrap or refuse that must be deposited in them. 5. Scrap and refuse bins must be emptied & cleaned on a daily basis. 6. Flammable waste must be stored in metal containers located at a safe distance from any possible ignition source. 7. Spillages of oil, grease etc. must be cleaned up as soon as is practicable. 8. All stacking of material must be made on ground that is level and all stacks must be neat and stable. 9. All circular objects must be suitably chocked to prevent them from rolling. 10. All empty paint/oil drums, packing material shall not be stored for more than a week at the site. 11. At least one scrap bin/refuse bin shall be provided at the site for every 1200 square feet area.
12. A dump yard shall be identified and marked for temporary disposal of construction wastes in consultation with L&T-RCM and IOCL. 12.22 Check Points During the Construction of Chimney
1. Chimney diameter, wall thickness and verticality shall be checked and recorded at least once in the every 6hrs./0.6 m intervals of shell progress, to ensure quality. 2. There are two sets of spindels fixed in the yoke units. One set of spindles is used for adjusting the wall thickness and another for maintaining the required wall inclination. Wall thickness shall be checked b/w outer and inner main shutters i.e. at yoke positions. 3. One set of spindle is fiexd b/w the stare beam and yokes. These spindles are used for adjustying the chimney shell diameter. Chimney shell diameter shall be checked b/w two opposite and yokes. 4. Plumb plate (Target Plate) shall fixed at chimney center point at bottom and plumb shall be checked by means of central plumb bob. Hanging from the slip form top deck. Slip form system level shall be checked at regular intervals and the level will be adjusted as required. 5. Elevation marking shall be done on the access tower at every 0.5 M interval. Other elevation can be checked with respect to access tower levels. 6. Level controller are fixed on the jack rods and used for uniform lifting of slip form system.
13.0 Environmental Control 13.1 General Requirement
1. The construction subcontractor is responsible for the environmental control specified for the job site including all equipment and machines used. 2. Do not dispose of used oil or liquid waste direct to the ground, pit or storm drain. Dispose of these works only in properly labeled containers. 3. Whenever possible, insulation materials scraps, shaving, etc., should be wetted and put into plastic bag in order to eliminate airborne activity. 4. It is the responsibility of all levels of management to conduct operations in accordance with applicable law and regulation, including those relating to the health or employees, the environment, and the use of toxic or hazardous substances. Therefore, personnel will be required to adhere to and comply with this procedure. 13.2 Implementation
1. The safety department will assist line management in the development of appropriate control procedures for those substances that are known to be hazardous to health or the environment. 2. Specific precautions for the handling, use, storage, transportation and disposal of such substances will be developed and communicated to management and the necessary employees. 3. Safety or other designated staff functions at the corporate, regional, divisional, or project level will directly assist managers in the implementation of procedures. 13.3 Environmental Surveys The safety supervisor is responsible for the determination and execution of environmental surveys. 13.4 Internal Communications Environmental survey reports to keep management advised of significant environmental findings. 14.0 Health Monitoring & Control
As part of L&T’s recruitment policy, all personnel joining the company shall under go pre-employment medical check. L&T expects its contractor & subcontractor to comply with the same and personnel found physically fit shall only be employed for this project. Contractor shall confirm in writing to L&T in this regard. Basic welfare facilities shall be set up at site, site management shall initiate for regular inspection and maintenance of this facility. First Aid boxes shall be placed at conspicuous locations, regularly inspected & the contents shall be replenished, the record of inspection shall be maintained by the authorized first Aider. A first Aid facility shall be set up and manned during the working hours apart from a stand by ambulance for transportation of injured personnel. The precaution against noise, dust, eye protection shall be evaluated & duly complied. The Radiography activities shall be planned and executed so as to minimize the radiation hazards to the site personnel. The hazard of the chemicals to be used during the construction shall be evaluated and personnel likely to be exposed shall be trained on the precautionary measures apart from providing the required PPE. Records of incident, first aid cases and other visits to the clinic shall be maintained and evaluated to identify recurrence problems and corrective measures shall be implemented by the site management. Activities during summer shall be evaluated and as far as possible the personnel shall be made aware of summer precautions and preventive measures.
15.0 ACCIDENT REPORTING AND INVESTIGATION
15.1 Introduction There is a possibility of accident in every sphere of human life, at home, whilst traveling, at play and at work. This is mainly concerned with accidents in industrial occupations. In particular, accidents result from the combined effect of physical circumstances, which can often be recognized and hazards engineered out of the working system, or human factors, which can be influenced by training and supervision. The immediate aim of accident reporting and investigations is to obtain the most accurate and full information about the circumstances and causes of the accidents. The ultimate objectives is
to prevent the re-occurrence of similar accident in the future; to uncover new hazards where such exist and; to provide adequate measure to control them.
15.2 Definition of Accident An accident is an unplanned, unexpected or undesired event, in a sequence of events, caused by unsafe acts and/or conditions, resulting in or having the potential to result in personnel injury and/or property damage. 15.3 Classification of Accidents Accidents can be classified under the following headings;
1. Accident - undesired event giving rise to death, ill health, injury, damage or other loss. (defined as per OHSAS 18001) 2. Incident - event that gave rise to an accident or had the potential to lead to an accident Work Related Incidents Work relationship is presumed for incidents resulting from events or exposures in or related to the work environment.
If an event or exposure in the work environment either caused or contributed to the resulting condition.
A pre-existing condition is considered work related if an event or exposure in the work environment results in injury, illness, property damage or environmental harm and would not have occurred but for an event or exposure related to the work environment.
Cases that occur while the employee / subcontractor employee is traveling are considered work related if the employee / subcontractor employee is engaged in work activities
Fatality: The death of an employee / subcontractor employee engaged in a work-related activity, which results from an event or exposure in the work environment. The individual need not actually die in the work environment. Fatality Rate: The number of Fatalities multiplied by 200,000, divided by the total number of hours worked. (Fatalities) x (200,000 / Hours Worked) Lost Workday Cases (LWC)
A Lost Workday Case is a medical case that involves
Fatalities Recordable Incident Cases due to personal injury Cases where an employee/subcontractor employee is away from work one or more days resulting from a recordable incident and Restricted Work Activity Cases. If an employee is unable to work on a schedule shift because of a work related injury or illness, the case is a Lost Workday Case (LWC). Presence at the site does not constitute work. The shift on which the injury or illness occurred and the shift on which the employee returns to work is not counted in the total days lost. Vacation days, holidays and days of rest that were scheduled before occurrence of the injury are also not counted. Days away from work include only full scheduled workdays. Lost Work-Days (LWD): (LWD): Case where the employee/sub contractor employee is away from work one or more days after the day of work related injury or illness. Count the number of calendar days lost (excluding holidays, vacation and weekends) where work is not performed. The day of incident is not counted as a lost work day. Stop count if employee/subcontractor employee leaves company.(Days after incident until days returned to
work).In case of fatality, count 6000 man days lost for the calculation of Incidence Rate. Incidence Frequency Rate: Rate : In Incidence rate is the number of recordable injuries and illnesses occurring among a given number of full-time workers (usually 100 full-time workers) over a given period of time (usually one year). Incident Rate for lost work days can be calculated as follows: Incident Frequency Rate of LWC = (No. of lost workday cases x 200,000/ Total hrs worked during same period) Recordable Incidents : Work-related incidents causing injury or illness to personnel that leads to medical treatment or lost time, including incidents causing property damage and/or damage to the environment. Total recordable/reportable incidents (TRI) is the sum of all work - related
Fatalities Lost work day cases/ Days away from work cases Restricted work day cases
loss of consciousness, transfer to another job, or medical treatment (other than first f irst aid)
Illness.
Restricted Work Day Cases (RWC) : A Restricted Workday Case (RWC) is any work related injury or illness that prevents the employee from either doing one or more parts of his or her regularly scheduled duties or working a complete shift on any subsequently scheduled shift. If an employee misses part of a subsequently scheduled shift because of hospitalization for treatment or observation, then the injury is an RWC only if the employee is unable to perform all normal job assignments. The shift on which injury occurred is not counted as a restricted workday. In other words, if employees are unable to do the job they were doing when they were injured or made ill, they are restricted until they can return to that job. The restriction refers to limits of activity or time that can be spent doing the job (i.e. the employee can do part of the job all of the day or all of the job part of the day). Following cases are generally considered RWC:
1. Temporary transfer: -
While an injured employee may be assigned work other than his or her normal duties, the temporary duties must be meaningful and preestablished, and the injured employee must be qualified to perform them If the employee is injured while working at a temporary assignment and transferred back to his/ her normal job assignment , which he or she can perform without limitation, then no days of restricted work activity are counted.
2. Precautionary transfer:
While an injured employee is transferred to another job because of suspected Illness, such as dermatitis, the time on other job does not need to the recorded as the days of restricted activity (DRA) while the case in being diagnosed. However, if the diagnosis reveals an illness that required continuation of the transfer, all days should be recorded as DRA. If the transfer is for the purpose of keeping an injury free of contamination, the DRA should be recorded. If the transfer is because the wounds, bandages, etc significantly reduce the ability to work, DRA should also be recorded. The case is considered restricted only if the employee develops an illness associated with exposure and if the employee is transferred to another job or area as a precautionary measure because of exceeding norms resulting from exposures.
Examples include the following: o
o
an employee develops a skin rash and is removed from work area. The rash is subsequently determined to have been caused by food eaten at home. Therefore, the illness is not work-related. on the other hand, if the rash is determined to have been caused by exposure to chemicals in work area, then the days from the transfer to the regular assignment are counted as restricted.
Medical Treatment Only Cases (MTOC) : All Medical Treatment Case (MTC) which neither result in restricted workday nor lost workday are termed as a Medical Treatment Only Cases (MTOC). Such cases will require one or more visits to a medical professional, but will not disable or restrict the employee from carrying out his normal duties. Loss of Consciousness: If an employee loses consciousness as the result of a work-related injury, the case must be recorded no matter what type of treatment was provided. The rationale behind this recording requirement is that loss of consciousness is generally associated with the more serious injuries.
Transfer to another job: Injuries requiring transfer of the employee to another job are also considered serious enough to be recordable, regardless of the type of treatment provided. Transfers are seldom the sole criterion for record ability. This is because injury cases are almost always recordable on other grounds, primarily medical treatment or restriction of work or motion.
First aid injury/ Case: A First Aid Case (FAC) is one-time treatment and subsequent observation of minor cuts, scratches, burns, splinters, and other similar injuries, which do not ordinarily require medical care. A case can be classified as first aid if it is administered by a physician or other registered professional personnel. Administration of a single dose of a prescription medication on a first visit for a minor injury is also considered first aid. Multiple use of non-prescription medication, cold packs, heat treatments, and multiple antiseptic applications does not affect the classification. The following are generally considered first aid treatment:
Using a non-prescription medication at non-prescription strength (for medications available in both prescription and non-prescription form, a recommendation by a physician or other licensed health care professional to use a non-prescription medication at prescription strength is considered medical treatment for recordkeeping purposes); Administering tetanus immunizations (other immunizations, such as Hepatitis B vaccine are considered medical treatment); Cleaning, flushing or soaking wounds on the surface of the skin; Using wound coverings such as bandages, Band-Aids TM, gauze pads, etc.; or using butterfly bandages or Steri-Strips TM (other wound closing devices such as sutures, staples, etc., are considered medical treatment); Using hot or cold therapy; Using any non-rigid means of support, such as elastic bandages, wraps, nonrigid back belts, etc. (devices with rigid stays or other systems designed to immobilize parts of the body are considered medical treatment); Using temporary immobilization devices while transporting an incident victim (e.g. splints, slings, neck collars, back boards, etc.); Drilling of a fingernail, or toenail to relieve pressure, or draining fluid from a blister; Using eye patches; Removing foreign bodies from the eye using only irrigation or a cotton swab; Removing splinters or foreign material from areas other than the eye by irrigation, tweezers, cotton swabs or other simple means; Using finger guards;
Using massages (physical therapy or chiropractic treatment are considered medical treatment for record keeping purposes); or Drinking fluids for relief of heat stress.
Dangerous Occurrences
Collapse or failure of lifting appliances, hoist, conveyors etc. Collapse or subsidence of soil, any wall, floor, gallery etc. Collapse of transmission towers, pipeline, bridges etc. Explosion of receiver, vessel etc. Fire and explosion Spillage or leakage of hazardous substances Collapse, capsizing, toppling or collision of transport equipment Leakage or release of harmful toxic gases at the construction site Failure of lifting appliance, loose gear, hoist or building and other construction work machinery, transport equipment etc.
Illness (Occupational). A physiological harm or loss of capacity produced by systemic infection; continued or repeated stress or strain; exposure to toxins, poisons, fumes, etc.; or other continued and repeated exposures to conditions of the work environment over a period of time. For practical purposes, an occupational illness/disease is any reported condition which does not meet the definition of injury (traumatic). Some conditions may be classified as either an injury or an illness (but not both), depending upon the nature of the event that produced condition. Ex.
I.
II.
Loss of hearing resulting from an explosion (an instantaneous event) is classified as an injury; the same condition arising from exposure to industrial noise over a period of time would be classified as an illness. Similarly, irritation of throat from exposure of chlorine gas fumes could be classified as either an injury or an illness. If the exposure was instantaneous and occurred when a cylinder of gas ruptured, the case would be considered an injury. The case would be an illness if the employee was exposed to the agent over a period of time, such as working in an area were chlorine fumes from a bleaching process where present.
Injury (Traumatic). A wound or other condition of the body caused by external force including stress or strain. The injury is identifiable as to time and place of occurrence and member or function of the body affected, and is caused by a specific event or incident or series of events or incidents within a single day or work shift.
Near Miss: An incident where no ill health, injury, damage, or other loss occurs is also referred to as a “Near-Miss”. The term “Incident” also includes “NearMisses”. (defined as per OHSAS 18001) . Examples are
Non relieving of a relief valve at set pressure;
Relieving of relief valve before set pressure;
Non working of emergency appliance (eg. Non-working of fire fighting facilities) Non working of shutdown / trip systems; Violation of Safety regulation (eg. Working without valid work permit, working without proper PPE, working with improper tools, etc) Free falling of objects from height; Bursting/ disconnection of pressure hoses.
15.4 Procedure Following uniform procedure shall be adopted by L&T in case of an accident/ incidents/fire in the CPP-PNCP, IOCL Panipat. 1. Responsibility of reporting – L&T Site Engineer 2. Reporting - As per distribution given in the forms. 3. Method of reporting - e-mail / by fax / messenger. 4. Report Forms - There are four basic forms: 15.4.1 Reporting of Near Misses 1. Concerned site engineers/ supervisor shall send the original copy of the report to RCM / Site In-charge, EIL within 24hrs. of the occurrence. 2. EIL shall send the first copy of the report to Dy. Manager (Fire & Safety), IOCL through concerned IOCL Site – in-charge. 3. Record shall be maintained by L&T Site Safety Department. 15.4.2 Reporting of Loss Time / Fatality Accidents
1. Concerned site engineer shall inform to EIL & IOCL site engineer/ site incharge immediately through telephone or messenger. 2. He shall send the original copy of the report to RCM/ Site-Incharge, EIL within 1 hrs. of the occurrence. 3. He shall send the first copy of the report to Dy. Manager (Fire & Safety), IOCL through concerned IOCL Site – in-charge within 2 hrs of occurrence. 4. Injured person shall be allowed to join the duty only on production of Medical Fitness Certificate form authorized Medical practitioner. 15.4.3 Reporting of Fires (Major/ Minor) & Explosion
1. Concerned Site engineer shall send the original copy of the report to RCM/ Site In-charge, EIL within 24hrs. of the occurrence. 2. He shall send the first copy of the report to Dy. Manager (Fire & Safety), IOCL through concerned IOCL Site – in-charge. 3. Record shall be maintained by L&T Site Safety Department. 15.4.4 Investigation Report
1. For Near Miss: Near Miss Report shall be sent to EIL within 24 hrs of occurrences. Investigation for Lost Time/ Fatal accidents shall be carried out involving EIL/ IOCL. 2. For Major / Minor Fire: Minor fire report shall be sent to EIL within 24 hrs of occurrences. Major fire shall be investigated involving EIL/IOCL. 15.4.5 Recommendation Report L&T shall send status of recommendation of all the accidents /incidents / fires to EIL along with monthly safety report. 16.0 EMERGENCY PREPAREDNESS The site Emergency response Plan shall be submitted separately. The following facilities & systems shall be maintained at site. 16.1 Communication system
1. Safety Training/ Tool Box Talks shall be given to all concerned about the emergency assembly point, fire fighting equipment and its use. 2. Emergency related notices shall be displayed as required; 3. Separate area shall be identified as Emergency assembly point and its board shall be displayed ; 4. All important telephone numbers for use during an emergency shall be displayed at site. 5. Display of Safety Posters, Sign Boards. 6. Emergency drill shall be explained to all site employees. 16.2 Fire Fighting System
1. Sufficient fire fighting equipment such as extinguishers duly inspected shall be strategically placed during construction phase, near hot work and electrical; 2. Site personnel shall be trained for using correct type fire fighting equipment. 3. User shall obtain permission of IOCL prior to using hydrant or firewater for any other purpose. 16.3 First Aid facility
1. First Aid Boxes equipped with adequate supplies shall be maintained within each 300mts radius, which shall be regularly inspected and supplies replenished. 2. At least 5 % of the workforce shall be trained on first Aid. 3. A separate First aid center will be provided for Panipat site; 4. First Aid center will be manned by qualified first aider and equipped with first aid facilities to render emergency and first aid treatment; 5. The first aid center shall operate for during the working hours of the Project. 6. An Emergency Vehicle shall be provided as standby to exclusively to support first aid center. This vehicle shall be managed by First Aider manning the First Aid center/ Safety Personal/ Time Office/ Administration Officer and activated anytime when required in an emergency.
17.0 HSE Activity Plan A. Daily Activity
Sl No
Activity
Performer
Check
Review
Remarks
Tool Box Meeting (for Critical activities, change of conditions etc.)
Site supervisor/ in-charge Organize & deliver Safety Talks
SSO / Safety steward to witness the compliance.
RCM sample check.
The records of the tool box meeting shall be maintained with the topics covered & nos. of personnel attended.
HSE Induction Training
SSO/ Safety Steward
-
RCM sample check.
All workers prior entering the site shall undergo training. Gate pass shall be issued after completing training.
Inspection of scaffolding
Site Incharge / Competent Person
SSO to check RCM & countersign sample the report check
Prior to using the scaffold the inspection to be carried out & recorded.
Recording of the Near miss Incident. (Recording analysis and corrective action taken)
All personnel
SSO to verify & investigate
Effective implementation of this process shall take some awareness enhancement measures.
RCM to Sample check
B. Weekly / Fortnightly Activity at Site Sl No
Activity
Performer
Fortnightly inspection of Electrical installation
Electrical Supervisor/ Electrician
Compliance Reporting (Corrective Action Report for unsafe acts/ conditions inspections / audits etc.)
SSO
Inspection of the First Aid Box
First Aider
Check
Review
Remarks
SSO/ Steward to verify sample.
-
Fortnightly Checking of Electrical Installations & record the reading of ELCB trip.
RCM
-
SSO to provide a compliance report of the pending action points including the critical issues.
SSO/ Steward RCM to Witness & sample countersign check
All first Aid boxes to be checked of contents, emergency vehicle & arrangements.
C. Monthly Activity at Site
Sl No
Activity
Performer
Check
Review
Remarks
HSE Committee Meeting (L&T Internal)
RCM
SSO to facilitate
-
HSE committee members, workers & Contractor representative to attend, records to be maintained.
HSE Meeting with Contractors
RCM
SSO to facilitate
-
To discuss the HSE areas of concern & direct contractors for implementation.
Site HSE Audit (Internal)
RCM
-
RCM shall identify the multi disciplinary Team during the monthly HSE meeting report of the compliance to be reviewed in HSE Meeting.
Review of the Risk Site Analysis / JSA preparation in Engineers line with Activities of the Month.
SSO to verify compliance
RCM Sample check
Effective implementation of this process shall take some awareness enhancement measures. Review the compliance of PPE including Safety Belt / Harness.
PPE Inspection
SSO / Safety Steward
-
RCM sample check
Inspection of Fire Extinguisher
SSE / Safety Steward
SSO to witness & countersign.
RCM Sample check
All fire extinguishers to be identified & records to be correlated.
Site HSE Inspection by SSO SSO
RCM
-
General inspection of site on the HSE issues.
HSE Training / Refresher Training for Supervisor Level
SSO
RCM
-
The structure & schedule of training may be discussed & agreed during HSE Meeting.
Safety Promotional & Motivational Activities
SSO to organize
RCM
-
SSO to organize safety Promotional & motivational program, including competition, recognitions, awareness campaign etc.
Sl No
Activity
Reporting of the Monthly safety Stats
Performer
SSO
Check
Review
RCM
Remarks
-
4. Quarter/ Bi-Annual/ Yearly Activity at Site Sl No
Activity
Performer
Check
Review
Remarks
HSE Audit (External) (Every Quarter)
Team independent of project (head office)
SSO to facilitate.
-
The date of the Audit shall be finalized during the committee meeting and findings shall be reviewed.
Inspection of Crane & Lifting Accessories (Every Quarter)
P&M incharge
SSO/ Steward to Witness & countersign.
-
All lifting Equipment & accessories to be checked of its condition, certification & correlation.
Inspection of Construction Equipment & Machineries. (Every Quarter)
P&M incharge
SSO/ Steward to Witness & countersign.
-
All machineries & equipments including (Welding Machines, generator, Heavy machinery to be checked of its condition & recorded.
Inspection of Power tools (Every Quarter)
P&M incharge
SSO
-
Testing & certification of the Lifting Equipment (Yearly)
P&M Incharge
SSO to verify compliance
RCM Sample check
Correlating the certificate with the lifting equipments with proper identification.
E. Other HSE Activity at Site Including One Time Activities Sl No
Activity
Recording, Reporting & Analysis of the Incidents
Performer
SSO
Check
RCM
Review
GM
Remarks
Trend Analysis and inform to Management on the preventive measures.
