Operational Control Procedures Bhel

OPERATIONAL CONTROL PROCEDURES
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - EASTERN REGION

DOC. NO. : PSER:HSEOM:005:02
REV. NO. : 02

START REDUCING THE USE OF PLASTIC ENVIRONMENTAL CONSERVATION


DOC NO. :
PSER:HSEOM:005:02

REV NO. : 02 EFF DATE : 15.06.2005

PREPARED BY

REVIEWED BY

APPROVED BY

ISSUED TO :

COPY NO. :

DATE OF ISSUE :

ISSUED BY

( NAME, DESGN./DEPT.) ( SIGN. )

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR : EASTERN REGION

Doc. No.: PSER:HSEOM:005:02

OPERATIONAL CONTROL PROCEDURES Rev. No. : 02
Eff. Date : 15.06.2005
TABLE OF CONTENTS Page 1 of 2

Sl.
No
Title
No. of
Pages
OCP
No.
Rev.
Status
1. Table of Contents 1 02
2. Amendment Records Sheet 1 02
3. Abbreviations 1 02
4. OCP for General Safety Measures 2 00 00
5. OCP for Safe Handling of Chemicals 3 01 02
6. OCP for Electrical Safety 2 02 02
7. OCP for Energy Conservation 3 03 02
8. OCP for Safe Welding and Gas Cutting Operation 2 04 02
9. OCP for Fire Safety 3 05 02
10. OCP for Safe use of Hand Tools 3 06 02
11. OCP for First Aid 1 07 02
12. OCP for Food Safety at Canteen 2 08 02
13. OCP for Safety in use of Cranes 3 09 02
14. OCP for Storage & Handling of Gas Cylinders 2 10 02
15. OCP for Manual Arc Welding 3 11 02
16. OCP for Safe use of Helmets 2 12 02
17. OCP for Good House Keeping 2 13 02
18. OCP for Safe Excavation 2 14 02
19. OCP for Working at Height 2 15 02
20. OCP for Safe filling of Hydrogen in Generator 2 16 02
21. OCP for Illumination 2 17 02
22. OCP for Handling & Erection of Heavy Metals 2 18 02
23. OCP for Safe Acid Cleaning 4 19 02
24. OCP for Safe Oil Flushing 3 20 02
25. OCP for Safe Alkali Boil Out 4 21 02
26. OCP for Steam Blowing 3 22 02
27. OCP for Safe Working in Confined Area 2 23 02
28.
OCP for Safe Operation of Passenger Lift, Material Hoists
& Cages
3 24 02
29. OCP for Vehicle & Crane Maintenance 3 25 02
30. OCP for Radiography 4 26 02
31. OCP for Waste disposal 1 27 01
32. OCP for Mineral wool insulation 1 28 01
33. OCP for Working at night 1 29 01


OPERATIONAL CONTROL PROCEDURES Rev. No. : 02
Eff. Date : 15.06.2005
TABLE OF CONTENTS Page 2 of 2

34. OCP for Computer operation 1 30 01
35. OCP for Storage in open yard 1 31 01
36. OCP for Drilling ,reaming and grinding (machining)
operation
2 32 01
37. OCP for Stress relieving 1 33 01
38. OCP for Hydraulic test 1 34 01
39. OCP for Trail run of rotary equipment 1 35 01
40. OCP for Batching 1 36 01
41. OCP for Cable laying/tray work. 2 37 01
42. OCP for Spray insulation 2 38 01
43. OCP for Compressor operation 1 39 01
44. OCP for Gas distribution test 1 40 01
45. OCP for Cleaning of hotwell / deaerator 1 41 01
46. OCP for Electrical maintenance 2 42 01
47. OCP for Operation & Maintenance of AC plant and
system.
1 43 01
48. OCP for Material preservation 2 44 01
49. OCP for Electro-resistance heating 1 45 01
50. OCP for Blasting 1 46 01
51. OCP for Transformer charging 1 47 01
52. OCP for Safe handling of battery system 1 48 01
53. OCP for DG set 1 49 01
54. OCP for Sanitary Maintenance 1 50 01
55. OCP for Piling Rig Operation 1 51 01
56. OCP for Passivation 1 52 01
57. OCP for Safe EDTA Cleaning 4 53 00
58. OCP for Safe Chemical cleaning of Pre boiler system 4 54 00
59. OCP for Safe Boiler Light up 3 55 00
60. OCP for Safe Rolling and Synchronisation 3 56 00
61. OCP for Safe Full Loading of Unit 3 57 00

Doc. No. : PSER:HSEOM:005:02

Rev. No. : 02
Eff. Date : 15.06.2005
AMENDMENT RECORDS SHEET Page 1 of 1

Old Document New Document Sl.
No.

Date Page No. /
OCP No.
Revisi
on No.
Page No./
OCP No.
Revisi
on No.
Nature of Change Effective
Date

01. 25.11.02 - -
OCP No. 01
to 26ll
00 1
st
issue 25.11.02

02. 25.06.03
TOC, Amm
Records,
OCP No.
01 to 26
00
TOC, Amm
Records,
OCP No. 01
to 26
01
Revised after including
comments from DNV and
including new OCP Nos. 27
to 52
25.06.03

03. 15.06.05
TOC, Amm
Records,
OCP No.
01 to 26
01
TOC, Amm
Records,
OCP No. 01
to 26
02
Revised after unifying
amongst OCPs and including
new OCP Nos. 00, 53 to 57 in
commissioning area.
15.06.05
04. 15.06.05
OCP No.
27 to 52
00
OCP No. 27
to 52
01 - Do - 15.06.05



Rev. No. : 02
Eff. Date : 15.06.2005
ABBREVIATIONS
Page 1 of 1

ABBREVIATION EXPANSION

BARC Bhaba Atomic Research Centre
BFP Boiler Feed Pump
C G Centre of Gravity
Dept. Department
Doc. Document
Eff. Effective
ELCB Earth Leakage Circuit Breaker
ESP Electrostatic Precipitator
HOD Head of Department
HOS Head of Section
HQ Head Quarters
HR Human Resources
HSE Occupational Health, Safety and Environment
HSEOM HSE Operational Manual
ISO International Organization for Standardization
MA Management Appointee
MMD Measurement and Monitoring Devices
MOT Main oil tank
MR Management Representative
NDE Non Destructive Examination
O & M Operation and Maintenance
OCP Operational Control Procedure
OEM Original Equipment Manufacturer
OGA Overall general arrangement
OHSAS Occupational Health and Safety assessment Series
PPE Personal Protective Equipment
PSER Power Sector Eastern Region
Rev. Revision
RTO Road Transport Officer
SOX Site Operations (department code)
TOC Table of Content
WBM Water Bound Macadam

Doc. No.: PSER:HSEOM:005 : 02

Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 00 GENERAL SAFETY MEASURES Page 1 of 2

1. Purpose : To ensure safe environment at workplace

2. Scope : PSER HQ & Sites

3. Responsibility : Concerned HOD / Head/SOX

4. Performance criteria : Number of unsafe incidents reported

5. Cross reference : OHSAS : 18001 , ISO : 14001

6. Procedure :

S.no. Activity Responsibility
1.
Ensure use of Personal Protective Equipment like safety
shoes, safety helmets, safety belts, safety goggles, face
shield, earplugs, hand gloves etc. as per job requirement.
Concerned
Individual/
Supervisor
2 Openings in the floors must be covered. Supervisor
3
Install handrails on platforms and stairs as soon as these are
erected.
Temporary handrails should be provided on temporary
platforms.
Supervisor
4
Ensure scaffolding materials are of proven quality and
inspected by experienced supervisor.
Supervisor
5
Check that there are no hindrances on walkways and
sufficient headroom is available.
Supervisor
6 Warning signs should be displayed at unsafe places. Supervisor
7.
Ensure adequate and safe means of access and exit from all
work places.
Supervisor
8. Never block accesses and exits routes to work places. Supervisor
9. Due importance should be given to house keeping Supervisor
10.
Ensure adequate illumination of all the work places and
access / exit routes.
Supervisor
11.
Arrangement of emergency lighting is also called for to
ensure safety during power breakdown.
Head/SOX
12.
Hazardous activity area should be cordoned off using tapes
with red and white bands.
Supervisor
13. Provide one First Aid box each for every 150 workmen. Head/SOX
14.
One vehicle should always be stationed at work site along
with First Aid Box.
Head/SOX
15
Ensure adequate communication facilities between all work
places and the office of Site- In charge / Emergency control
room and fire station for handling emergency situation.
Head/SOX


Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 00 GENERAL SAFETY MEASURES Page 2 of 2

16.
Train adequate number of employees at work site in First
Aid and Fire Fighting.
Head/SOX
17.
Make it a habit that supervisors explain to the workers all
hazard potentials and safety measures needed in the work;
planned for the day.

Supervisor
18.
Display appropriate posters in locally understood languages
regarding safety at site.

HSE Coordinator

7 Records :

Record Title Record No. Location Responsibility Retention
Period

8 Verification, Corrective and Preventive Action :

HOD / Site Incharge shall ensure effective implementation of the above procedure. In case
of any deviation, shall take suitable corrective and preventive action.



Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 01 SAFE HANDLING OF CHEMICALS

Page 1 of 3

1. Purpose : To avoid any personal damage / harm from the effects of hazardous
chemicals

2. Scope : PSER Kolkata (HQs. and Sites)

3. Responsibility : Concerned HODs / Head/SOX

4. Performance criteria : No. of incidents / accidents on such cases

5. Cross reference : ISO : 14001, OHSAS : 18001

6. Procedure :

Sr. No. Activity Responsibility
1. Definition : Manufacture, Storage and import of Hazardous
Chemicals Rule 1989 under the Environment Protection
(EP) Act 1986 define ~Hazardous Chemicals' based on
toxicity, flammability and explosivity.
--
2. Legal requirements : The Factories Act and the Environment
Protection Act & the the Rules made under these acts
require :
Identification & Labeling, Obtaining Material Safety Data
Sheet & Disclosure of information to the workers.
Training & supervision
Safe storage, handling & disposal
Emergency planning and preparedness
Monitoring of work environment and health of workers
--
3. Obligation of workers under Factories Act : No worker in
factory shall willfully :
Misuse any appliance
Do anything likely to endanger himself or others
Neglect to make use of any appliance provided for
security, safety and health of employees
Refuse to undergo medical examination
Supervisor
4. Identification & Labeling :
Label the containers clearly with contents, name &
address of manufacture/ importer, physical and health
hazards & recommended PPEs
Know how to use the information provided on the labels
Do not handle any unlabelled container. Check with your
supervisor

Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 2 of 3

5. Storage :
Store chemicals in a cool, dry and well ventilated place
away from heat and ignition sources. Avoid storage in
open sun. Also refer MSDS.
Store reactive chemicals separately.
Do not refill empty containers with any chemical other
than the one originally contained. Use containers in first
in first out basis.
Keep flammable chemicals in closed containers
Store poisonous substances such as cyanides in licked
cabinets away from acids.
Supervisor
6. Handling :
Ensure electrical bonding and grounding while
transferring flammable chemicals from one container to
another
Follow strictly the approved procedures for loading /
unloading
Use PPEs as necessar
Handle containers with care, using appropriate trolleys
Keep cylinders upright with caps and chain them.
Watch for the posted signs indicating areas requiring
particular precautions and strictly adhere to them.
Supervisor
7. Disposal :
Don't pour acids/ alkalis in the drainage without proper
neutralization
Do not drain out toxic / flammable chemicals with water.
Collect it with absorbent materials for its safe disposal
Decontaminate the used containers not intended for re-
use and make up usable by puncturing before disposal
and follow them strictly
Supervisors
8. Handling Emergencies :
Know and understand precautions and procedures in
case of spillage/ leakage/ fire if any
Keep safety & emergency kits in working order and
accessible
Keep antidote ready and handy while handling toxic
chemicals
Get trained in first aid procedures
Drivers of vehicles transporting hazardous chemicals
should know the emergency procedure.
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 3 of 3

9. General :
Use no sparking tools and flame proof electrical
equipment in the area where flammable chemicals are
used stored
Follow established work permit systems
Periodically vent all drums containing volatile liquids, if
provision is available
Do not keep any food stuff or take meals in the area
where hazardous chemicals are stored / handled. Wash
hands before eating.
Do not use any solvent for cleaning hands. Use soap.
Maintain good house keeping standards and avoid
spillage.
Clean the floor immediately in case of any spillage.
Change contaminated clothes immediately.
Never take the chemicals away from the job for personal
use.
Identify hazardous chemicals at your workplace and
know their properties.
Supervisor

7. Records :

Period

8. Verification, Corrective and Preventive Action :




Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 02 ELECTRICAL SAFETY Page 1 of 2

1. Purpose : To avoid any personal damage / harm from the effects of electrical shock



4. Performance criteria : No. of such incidents / accidents on such cases

5. Cross reference : OHSAS : 18001

6. Procedure :

1. All parts of electrical installations shall be of standard
construction conforming to relevant IS codes .
HOD / Site Incharge
2. Install Earth trip device at main distribution board. HOD / Site Incharge
3. Earth all power cables Supervisor
4. Ensure earthing of all electrical construction equipment
at two locations on the body.
Supervisor
5. Certified electricians shall carry out all electrical
connections and wiring.
Supervisor
6. Ensure that all extension boards have earth wire
connected and only three pin metal clad industrial type
sockets are mounted on the board.
Supervisor
7. Never draw power from a socket by inserting wires into
the socket.
Supervisor
8. Always use metal clad three pin plug tops for drawing
power for electrical hand tools.
Supervisor
9. Use only three core flexible wire for electrical hand
tools. Connect earth wire properly to the body of the
hand tool as well as to the plug top.
Supervisor
10. Never use earth as neutral. Supervisor
11. Ensure that the flexible wires and power cables are
properly insulated and are laid so that the insulation
does not get damaged due to activities in the vicinity.
Supervisor
12. All cable terminations should be properly tightened. Supervisor
13. Cover all power cables running on surface to prevent
damage due to movement of materials and vehicles.
Supervisor
14. Install proper distribution boards at different locations to
avoid haphazard laying of electrical wires.

HOD / Site Incharge



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 02 ELECTRICAL SAFETY Page 2 of 2

15. Frequent inspections should be carried out to identify
damaged insulation, loose connections, improper
fuses; lack of earthing etc. and remedial action should
be initiated immediately.
Supervisor
16. Introduce permit system for electrical safety. While men
are at work on electrical lines or equipment for
maintenance/repair, main switch should be cut off and
fuses should be removed. Warning signs should be
displayed on the main switch.
HOD / Site Incharge

7. Records :

Record Title Record No. Location Responsibility Retention Period





Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 03 ENERGY CONSERVATION

Page 1 of 3

1. Purpose : To ensure that all energy conservation points are identified and response
plan established for all identified situation/ points.

2. Scope : Applicable to all areas where energy is in use in any form

3. Responsibility : Concerned HODs / Head/ SOX

4. Performance criteria : Record of present system and modified system over period
of time i.e. continuous improvement

5. Cross reference : ISO : 14001

6. Procedure :

A. Illumination :
1. Switch off tube lights, lamps, fans, etc when not required All staff
2. Prefer task lighting instead of uniform one all over Supervisor
3. Follow recommended illumination levels for area Supervisor
4. Use energy efficient lamps & luminaries HOD/ Site incharge
5. Keep all lighting equipment & reflectors clean Supervisor
6. Optimize use of natural lighting Supervisor
7. Prefer electronic ballast in place of conventional chokes Supervisor
8. Prefer Compact Fluorescent Lamps. Supervisor
9. Use current / voltage reducer Supervisor

B. At the work place
1. Use high efficiency and optimum size equipment Supervisor
2. Optimize use of plant utilities such as steam, cooling water,
compressed air, etc.
Supervisor
3. Monitor and control all plant parameters strictly Supervisor
4. Install monitoring instruments like flow meters, pressure &
temperature gauges, ammeter, etc. whwrever necessary
Supervisor
5. Carry out preventive maintenance and remove the scaling/
sedimentation regularly
Supervisor
6. Stop all leakage. Avoid unnecessary long distribution
pipelines
Supervisor
7. Use thermostatic controller for cooling tower fans Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 2 of 3

8. Optimize need of refrigeration and also the refrigeration
temperature
Supervisor
9. Don't use weak or broken insulation Supervisor
10. Check regularly all measuring MMD for their calibration Supervisor
11. Use gravity wherever possible for liquid flow. Supervisor

C. The Kitchen / Mess
1. Keep the entire cooking material ready before lighting the
stove
Supervisor
2. Let cold material attain room temperature before cooking Supervisor
3. Soak the grains and cereals before cooking them Supervisor
4. Avoid using excessive water before cooking Supervisor
5. Use utensils having broad bases. Use lid on cooking
utensils
Supervisor
6. Prefer small burner and light flame Supervisor
7. Ensure stable, bright and blue flame. Reduce flame when
boiling starts
Supervisor
8. Use only ISI mark stoves and kerosene wicks stove Supervisor
9. Use pressure cookers Supervisor
10. Cook different types of food simultaneously by using
separators
Supervisor
11. Avoid often re-heating of food, store food in insulated
containers.
Supervisor

D. On the road
1. Get the vehicle regularly serviced and engine tuned Driver
2. Maintain correct tyre pressure Driver
3. Clean air filter regularly Driver
4. Drive in correct gears and at optimum and uniform speed Driver
5. Keep your foot off the clutch and use it only when changing
gears
Driver
6. Avoid idle running of engine Driver
7. Make the vehicle lighter, reduce unnecessary load Driver
8. Plan your trips and route and avoid rush-hour traffic.

All staff



Rev. No. : 02
Eff. Date : 15.06.2005


Page 3 of 3

7. Records :

Period
Record for required
illumination level in
various work area
1 HOD office HOD 1 year
MMD calibration record 2 Concerned
area
Supervisor 1 year
Waste record on fuel / oil
leakage
3 Concerned
area
Supervisor 1 year
Preventive maintenance
record for various
equipment
Vehicle service record 5 Concerned
area
Supervisor 1 year





Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 04 SAFE WELDING AND GAS CUTTING
OPERATION

Page 1 of 2

1. Purpose : To ensure that all activities related to welding and gas cutting are safe

2. Scope : Applicable to all areas involving welding and gas cutting

3. Responsibility : Concerned Head/ SOX

4. Performance criteria Number of such incidents/ accidents reported


6. Procedure :

1 Use trolleys and cradles of adequate strength, as far as
possible, while moving the cylinders.
Supervisor
2 Always keep LPG and other liquefiable gas cylinders in upright
position and ensure that they are not knocked over
Operator
3 Check that the valves of the gas cylinders are lightly shut when
not in use.

Operator
4 Do not release gas from the cylinder unless pressure regulator
is fitted to its valve.
Operator
5 Use gas hoses specially designed for the purpose with standard
colour code.
Operator
6 Use proper clamps for hose connections, Check leakage from
hose connections before starting work. Never use steel wires for
clamping.
Operator
7 Take care that there are no kinks in the hoses and the hoses
are laid such that nobody steps on the hoses and these do not
get damaged due to activities in progress in the vicinity.
Operator
8 Use flame flash back arrestors to avoid back firing in flammable
gas cylinders.
Supervisor
9 Open the valve of oxygen gas first and then flammable gas for
lighting the torch.
Operator
10 Use friction gas lighters only for lighting the torch. Never use
matches or smoldering manila ropes or rags for lighting the
torch.
Operator
11 Protect the gas cylinders and hoses from welding sparks or gas
cutting sparks falling on them.
Operator
12 Ensure that the valve key is easily accessible to close the valve
immediately in case of emergency.
Operator



Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 04 SAFE WELDING AND GAS CUTTING
OPERATION

Page 2 of 2

13 Never crimp the hose for temporary shutting of gas. Always shut
the supply through pressure regulators.
Operator
14 Check the hoses daily for any visible damage. Discard the
hoses in which gas had backfired.

Supervisor
15 Remove the leaking cylinder of flammable gas immediately to
an open space where it is least dangerous to life and property.
Intimate the supplier of the cylinder.

Supervisor
16 Ensure use of aprons , gloves and other PPE as appropriate .

Supervisor

7. Records :

Period





Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 05 FIRE SAFETY

Page 1 of 3

1. Purpose : To ensure safety during any event of fire

2. Scope : PSER (HQs. and Sites)

3. Responsibility : Concerned HODs / Head/ SOX

4. Performance criteria Decreasing number of such incidents/ accidents

5. Cross reference : ISO 14001, OHSAS 18001

6. Procedure :

1 Ensure safe access to and means of escape from all site
locations
Site Incharge
2 Construct temporary building like site offices and materials
stores with non combustible materials.
Site Incharge
3 Keep adequate safe distance between temporary buildings.
Recommended safe distance of temporary sheds from main
buildings is approx 15M and 9M from each other
Site Incharge
4 Provide free space between each section of the stored
materials to allow access for fire fighting
Concerned HOS
5 Store inflammable materials separately Concerned HOS
6 Avoid using combustible materials for form work and
scaffolding.
Concerned HOS
7 Remove combustible packing material from the site
periodically to avoid accumulation of fire load.
Concerned HOS
8 Clean site frequently at least once a week. Concerned HOS
9 Display No smoking Posters in areas where inflammable
materials are stored.
Site HSE Coordinator
10 Dont light any fire in or around storage areas for cooking or
any other purpose.
Concerned HOS
11 Inspect the work place thoroughly where welding and gas
cutting operations are to be carried out and remove any
inflammable materials around, before starting work
Concerned HOS
12 Ensure that welding and gas cutting sparks do not fall on
combustible materials. In case it cannot be avoided, cover
the materials with metal sheet
Supervisor
13 In case, welding or gas cutting has to be done on a vesse,l
pipe or container, which contains or had earlier contained
flammable liquids; ensure purging inerting and issue work
permit before starting work
Concerned HOS



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 05 FIRE SAFETY Page 2 of 3

14 Ensure that there is no leakage of gases from hoses or hose
connections fitted with the gas cylinders before starting gas
cutting.
Supervisor
15 In case of electric welding, check that there are no loose
connections in welding cables and earth connection.
Supervisor
16 Do not leave electric circuits on or gas cutting torches
burning when not in use.
Supervisor
17 Inspect the area for smoldering materials after gas cutting
/welding. If found extinguish them.
Supervisor
18 Remove gas cylinders to stores when not in use. Operator
19 Place fire extinguishers in conspicuous locations as near as
possible to escape routes
20 Ensure that the fire extinguishers are clearly visible & easily
accessible and passage leading to them is free
21 Mark the type of extinguishers and the class of fire for which
these are meant, conspicuously at each location
22 Maintain the fire extinguishers in fully charged and operable
condition
23 Inspect the extinguishers monthly to ensure that they have
not been actuated or tampered with and to detect any
physical damage or corrosion
24 Recharge the extinguishers on expiry Site HSE Coordinator
25 Maintain effective communication system to site in charge
and fire safety officer from all fire hazard areas
Site Incharge
26 Display telephone numbers and residential addresses of site
in charge, Fire safety officer, security officer, Fire brigade,
doctor and police near each telephone
27 Post round the clock guards trained in fire fighting, at
vulnerable locations
Site Incharge
28 Form fire-fighting teams with site supervisors, sub
contractors, personnel and security guards. Impart adequate
training to the fire-fighting teams
Site Incharge
29 Conduct fire-fighting drills at least once in a quarter Site HSE Coordinator
30 Keep informed all the personnel at site in respect of
i) Raising an alarm in case of fire.
ii) Action to be taken in the event of fire.
iii) Safety measures for fire risk operations.
iv) Location of fire extinguishers and their use for
different kinds of fire.
Prepare emergency plan indicating individuals
responsibility in the event of fire and keep the
individual properly informed.
Guideline for selection of type, size and quantity of fire
extinguishers is annexed. However, exact requirement may
be determined in consultation with local fire authority and or
the underwriters



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 05 FIRE SAFETY Page 3 of 3

7. Records :

Period





Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 06 SAFE USE OF HAND TOOLS

Page 1 of 3

1. Purpose : To avoid any damage / injury to personnel during use of hand tools



4. Performance criteria decreasing number of such incidents/ accidents


6. Procedure :

1. Common causes of accidents due to Hand tools are :
Wrong tool for job
Fall of tool not stored properly
Wrong size of tool
Wrong method of handling/ carrying
Poorly maintained tool
Unauthorized modification of tool
Defect in tool
---
2. Important preventive measures are :
Use the right tool
Use a tool in good condition
Use the tool in right way
Keep tools in a safe place
Use appropriate PPE
Carry tools in tool box/bag
---
3. Safe work practices for commonly used hand tools :
3.1 Screw Driver :
Never use a screw driver as a chiesel, punch or wedge
Never pry with a screw driver
Do not carry the screw drivers in pockets
Never hold a job in your hand
Screw driver tip should match with the design and size of the slot
A damaged tip should be dressed
For electrical work, use screw driver with insulated handles.
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 2 of 3

3.2 Hammer :
Use a soft faced hammer to strike hardened steel surface
Use a heavy hammer for heavy jobs
Replace the loose wedge with a good steel or wooden one, never
use a nail
Replace the hammer if the face is damaged or has grown brittle
If the handle is greasy, clean it before using the hammer
Always replaced cracked, splintered or broken handle, never
repair them
Keep your eyes on the spot you are hitting
Use pliers to hold the work. Keep your hand out of the way
Supervisor
3.3 Chisel : [Steel wedges, Punches and similar tools]
Do not use mushroomed chisel
Dress the head whenever signs of cracking or speadinf appears
A chisel only large enough for one job should be selected so that
the blade is used rather than only one point or corner
Keep the cutting edge sharp and ground at right angle. A sharp
edge takes a good bite and does not slip easily. With a dull-edged
chisel you have to strike harder and there is more chance that the
hammer may miss and hit your hand.
Supervisor
3.4 Spanner / Wrench :
Use wrnch of right size.
Do not use worn wrench
Always get the jaws squarely on the nut
To prevent adjustable wrench from slipping, set the jaw up tight.
Pull towards the movable jaw.
Use a pipe wrench to remove worn nut
Always hold something solid with one hand and keep the wrench
under control.
Never slip a pipe over a wrench to get more leverage. Get a
bigger wrench.
Never use a wrench around a moving machinery.
Supervisor
3.5 Knife :
Use sharp knife-occasionally, touch it up with whet stone
Cut away from yourself - never towards any part of your body.
When the job is over, put the knife in sheath
If you are setting the knife down for only a moment, put it where it
won't be in the way and don't leave it where it might fall.
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 3 of 3

3.6 File :
Do not use a file without a handle
Do not use files as punches or drifts
It is dangerous to pry with a file. Files are brittle and break easily.
When they do, pieces fly around.
When a file gets clogged with metal it may slip. Keep it sharp, tap
it on edge once in a while to knock off the filings. When that does
not help, clean it with file card.
Files must not be twisted in slotted work
Supervisor
3.7 Pliers :
Do not use pliers as a substitute for wrenches
Be certain that pliers use for electrical work are insulated/
Supervisor
4. Use non-sparking tools in fire prone areas. Supervisor

7.0 Records :

Period

8.0 Verification, Corrective and Preventive Action :




Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 07 FIRST AID

Page 1 of 1

1. Purpose : To provide preliminary preventive medical help before reaching to doctor



4. Performance criteria : Adequacy of first aid service provided when in need


6. Procedure :

1. Identification of location for putting up first aid boxes HR
2. Making of emergency medicines / first aid materials in
consultation with doctor
HR
3. Making / display of important telephone numbers of
hospitals / ambulance / fire brigade / local police
HR
4. Impart first aid training to various categories of staff
during breathing problem / electric shock / cuts and
wounds/ burns / suffocation / eye injury / poisoning /
fracture
HR

7. Records :

Period
First Aid training records FA-01 HR Three years




Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 08 FOOD SAFETY AT CANTEEN

Page 1 of 2

1. Purpose : To avoid food borne illness


3. Responsibility : HRM Department

4. Performance criteria : Exception points at management reviews.


6. Procedure :

Sr. Activity Responsibility
1 Legal Requirements :
Analysis of food samples by public analysts
Restriction on dose of irradiation for onions, potatoes,
spices, mangoes, rice, dried fruits, and meat products.
Restriction on use of synthetic food colours in cakes/fruit
drinks
Canteen
Committee/Canteen
Contractor
2 Necessary steps at the time of procurement of raw materials
for canteen :
To insist the contractor to buy Agmark/ISI certified products
viz. Cooking oil/Veg oil/packed spices etc.
Canteen Committee
3 Check for expirty or best before date Canteen Committee
4 Storage of raw materials :
1.Refrigerate perishable foods quickly after procurement.
2.store leftovers at temperature either below 10 degree C or
above 60 degree C.
3.Keep raw meat, poultry eggs, seafood and their juices
away from ready to-eat foods
Contractor/Canteen
Committee.
5 Protection of food from insects. Contractor
6 To avoid contact between raw foodstuffs and cooked foods
through hands, flies, utensils or unclean surfaces.
Contractor
7 Food preparation
- to keep the food preparation premises meticulously clean.
Canteen Contractor



Rev. No. : 01
Eff. Date : 15.06.2005

OCP No. : 08 FOOD SAFETY AT CANTEEN

Page 2 of 2

8 Avoid Biological Bacteria :
-Wash hands thoroughly before start preparing or serving
food and after every interruption, esp. if you have used the
toilet.
-Wash fruits and vegetables thoroughly using plenty of safe
water particularly if they were eaten raw
-Cut vegetables and fruits first, then raw meat and poultry.
-Wash cutting boards and utensils with hot soapy water
after cutting raw meat and poultry products and before
slicing vegetables
Canteen Committee/
Contractor
9. Checking of Electric Boiler at kitchen Electrician
10 Checking of Aquaguard/refrigerator HRM
11 Impart training about biological bacteria to canteen
staff/workers
Canteen Contractor

7 Records

Record Title Record No. Location Responsibility Retention time

8. Verification, Corrective and Preventive Action ;

HOD / Site Incharge shall ensure effective implementation of the above procedure. In
case of any deviation, shall take suitable corrective and preventive action.



Rev. No. : 02
Eff. Date : 15.06.2005

OCP No. : 09 SAFETY IN USE OF CRANES

Page 1 of 3

1. Purpose : To avoid damage / personal injury during usage of cranes

2. Scope : PSER Sites

3. Responsibility : Concerned Site Incharges



6. Procedure :

1 Try to locate the crane on as solid and level ground as
possible.
Operator
2 Ensure that the earth is properly compacted if the crane is
required to move or work in back-filled area.
Supervisor
3 In case there is doubt about bearing capacity of the earth,
place 1 thick metallic plates or wooden sleepers under the
crawler or tires to distribute load
Operator
4 Deploy only trained and experienced operators with valid
license to operate the cranes
Supervisor
5 Read the instruction manual of the crane thoroughly and
keep the crane operator informed
Supervisor
6 Keep the machine in good operating condition especially
clutches, brakes and controls
Concerned HOD
7 Ensure that boom and hoist cut off limit switches are
operational
Supervisor
8 Before starting the crane, see that all the guards of moving
parts are properly fitted
Operator
9 Shut off the engine when clearing, adjusting or lubricating
the machine
Operator
10 Do not over lubricate the parts. Clean overflowing lubricants Supervisor
11 Keep the crane boom length as short as possible for
maximum lifting capacity and greater safety
Operator
12 Do not work with the boom to close to the vertical, because
a sudden release of the load may throw the boom back over
the cab
Operator
13 Depute only trained and experienced riggers for slinging the
materials to be lifted
Supervisor
14 Ensure that only one person gives signals to the crane
operator
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005


Page 2 of 3

15 Before lifting load, be sure about the weight of the material.
When lifting near capacity load, calculate entire load
carefully including hook block and slings; and check it
against rated lifting capacity
Operator
16 Test the host brake by raising the load a few inches and
holding it should hold easily
Operator
17 Dont pull sideways on the boom not even a little hit Lift
straight up on every load
Operator
18 Never move a crane away from the load while handling near
capacity loads, to avoid boom failure or machine damage
Operator
19 Ensure the soundness and capacity of the slings being used Supervisor
20 Before lifting or moving load, warn the surrounding
personnel by sounding horn
Operator
21 Swing the load very slowly and carefully. Avoid sudden jerks Operator
22 Never swing load over ground crew Operator
23 Always watch the load and the signals from the signalman Operator
24 While loading or unloading a truck, never swing the load
over the truck cabin
Operator
25 Never allow any person to stand under the load being lifted Supervisor
26 Ensure that the reverse horn is operational. Crane helper
should guide the crane operator while reversing the crane
Supervisor
27 Let the crane run idle for a little while, after the crane has
done heavy work. Do not stop the engine abruptly
Operator
28 Do not move the crane with boom at very high angle,
especially on uneven terrain. This may result in the boom
being thrown back over the cab
Operator
29 When the load is to be lifted to a higher elevation, tie the
load with a manila rope to guide the load while in the air, so
that it does not strike any building or structure during
swinging
Supervisor
30 Always keep the boom at least 6 feet from overhead wires Operator
31 If the boom hits overhead wires accidentally, stay on the
crane until the boom is cleared or the current is cut off. Do
not allow any one on the ground to touch the crane. In case
it is absolutely necessary to leave the cabin, jump out; dont
step down
Operator
32 Do not leave the cabin with engine running or load in the air Operator



Rev. No. : 02
Eff. Date : 15.06.2005


Page 3 of 3

7. Records

Record Title Record No. Location Responsibilit
y
Retention time
Crane fitness
certificates
CR 01 Respective
Site
Site
Incharge
Till deploymeny
of crane
Maintenance records /
TCs of wires. slings
CR 02 -do- Site
Incharge
Till deploymeny
of wires/ slings




Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 10 STORAGE AND HANDLING OF GAS
CYLINDERS
Page 1 of 2

1. Purpose : To avoid damage / personal injury during storage and handling of gas
cylinders


3. Responsibility : Concerned Site Incharges



6. Procedure :

S No. Activity Responsibility
1 While procuring gas cylinders, check that every cylinder is labeled with
the name of the gas and the name and address of the person by whom
the cylinder was filled
Indentors
2 Check that a warning is attached to every cylinder containing
permanent or liquefiable gas
Supervisor
3 Do not change colour of the cylinder Supervisor
4 The cylinder should not be filled with any gas other than the one it now
contains
Supervisor
5 No flammable material should be stored in the vicinity of the cylinder or
in the same room in which it is kept
Supervisor
6 No oil or similar lubricant should be used on the valves or other fitting of
the cylinder
Supervisor
7 Please look for next date of test, which is marked on a metal ring
inserted between the valve and the neck of the cylinder, and if this date
is over, do not accept the cylinder
Supervisor
8 Use trolleys and cradles of adequate strength, as far as possible, while
moving the cylinders
Supervisor
9 Handle the cylinders carefully and dont allow the cylinders to fall upon
one another or subjected to any shock
Handling staff
10 Dont slide or drop the cylinders Handling staff
11 Always keep LPG and other liquefiable gas cylinders in an upright
position and see that they cannot be knocked over
Handling staff
12 Secure the cylinders used in horizontal position so that they cannot
roll.
Handling staff
13 Store the cylinders in a cool, dry and well ventilated place under cover
and away from open flames or any potential source of heat
Handling staff
14 Never store the cylinders in sun Handling staff
15 Storage room should be of fire resistant construction Site Incharge



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 10 STORAGE AND HANDLING OF GAS
CYLINDERS
Page 2 of 2

S No. Activity Responsibility
16 Keep the cylinders containing flammable gases separated from
other gas cylinders by an adequate distance
Supervisor
17 Keep the filled cylinders segregated from the empty cylinders Supervisor
18 Check that the valves of the gas cylinders are tightly shut Handling staff
19 Repairing of gas cylinders is not permitted Supervisor
20 Remove the leaking gas cylinders to an open space where it is least
dangerous to life and property and inform the supplier
Supervisor
21 Dont posses more than the following quantity of gas without a valid
license
Supervisor
Liquefied Petroleum Gas 100 Kg
(Flammable)

Disssolved Acetylene 15 Cylinders
(Flammable)

Oxygen,Argon,Nitrogen,Carbon dioxide 50 Cylinders
(Non-flammable ,non-toxic gases)
(Total)

Chlorine 50 Cylinders
(toxic gases)

Hydrogen 125 Kg or 15 cylinder
(Flammable but non-toxic gases) (Whichever is less)

7. Records :

Procurement /
inspection records
GC - 01 Site Indenting dept. Till consumption
of cylinder


HOD / Site Incharge shall ensure effective implementation of the above procedure. In case of
any deviation, shall take suitable corrective and preventive action.
.



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 11 MANUAL ARC WELDING Page 1 of 3

1. Purpose : To avoid damage / personal injury during Manual Arc Welding


3. Responsibility : Concerned Head/SOX


5. Cross reference : OHSAS : 18001, ISO : 14001

6. Procedure :

ELECTRICAL HAZARDS

1 All electrical equipment and the work-pieces should be
grounded
Supervisor
2 Work piece should be grounded from a separate connection. Supervisor
3 Work lead should not be grounded by mistake Supervisor
4 The work area, equipment and clothing should be kept dry at
all times.
Supervisor
5 Dry gloves and rubber soled shoes should be worn Welder
6 The welder should stand on a dry board or insulated platform Welder
7 Cables and connections should be kept in god condition Supervisor
8 Worn, damaged or bare cables should not be used Supervisor
9 In case of electric shock, the power should be turned off
immediately and non-conducting materials should be used to
pull the victim from the live contact. A physician should be
called and CPR continued until breathing has been restored ,
or until a physician has arrived.
Supervisor

FUMES & GASES

1 Sufficient ventilation, exhaust at the arc, or both should be
used to keep fume and gases from breathing zones and the
general work area.

Supervisor



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 11 MANUAL ARC WELDING
Page 2 of 3

NOISE

1 Ear muffs or earplugs may be used Supervisor

BURN PROTECTION

1 Worker should wear protective clothing made of fire
resistance material
Supervisor
2 Pant cuffs or clothing with open pockets or other places on
clothing that can catch and retain molten metal or sparks
should not be worn.
Supervisor
3 High top shoes or leather leggings and fire resistance gloves
should be worn
Supervisor
4 Helmets or hand shields that provide protection for the face,
neck and ears should be worn
Supervisor

5 Clothing should be kept free of grease and oil. Supervisor
6 Consumable materials should not be carried in pockets.

Welder
7 Appropriate eye protection should be used at all times Supervisor
8 Goggles or equivalent also should be worn to give added eye
protection
Supervisor
9 Insulated gloves should be worn at all times when in contact
with hot items or handling electrical equipment.
Supervisor

FIRE PREVENTION

1 Welding should not be done in atmospheres containing
dangerously reactive or flammable gases, vapours , liquid or
dust.
Supervisor
2 All combustible materials should be removed from the welding
place.
Supervisor



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 11 MANUAL ARC WELDING Page 3 of 3

RADIATION

1 Welding arcs should not be viewed except through welding
filter plates
Welder
2 The casual passers by or welding operations should be
protected by the use of screens, curtains or adequate
distance from aisles, walkways, etc
Supervisor
3 Exposed skin should be protected with adequate gloves and
clothing as specified.
Supervisor

SAFETY MEASURES IN RADIOGRAPHY

1 Permission from M/s BARC, Mumbai for use of radiography
source.
Site Incharge
2 Deployment of supervisor duly certified by M/s BARC,
Mumbai
Site Incharge
3 Deployment of certified Radiographer Site Incharge
4 Review the periodic dosage report of personnel engaged in
radiographic operation
Site incharge
5 Ensure availability of necessary radiation survey meters. Site Incharge
6 Ensure Members of Public are removed to safe distances
while performing radiography
Supervisor
7 Suitable warning lamps/warning boards to be displayed and
area of radiography to be cordoned off.
Supervisor
8 Only personnel certified by the site in-charge shall perform
NDE
Site Incharge

7. Records :






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 12 SAFE USE OF HELMETS Page 1 of 2

1. Purpose : To ensure safety during work at risk zone

2. Scope : PSER (HQs & Sites)

3. Responsibility Concerned HOD / Head/SOX



6. Procedure :

1 Ensure use of Safety Helmet by all the employees working at site
and the persons visiting the site for protection against head
injury
Concerned
Supervisors
2 Safety helmets shall conform to IS: 2925. Safety Coordinator
3 Safety helmet should be compatible with working requirements
e.g.
Site Incharge
3.1 Helmet with chinstrap is useful for the person working in windy
condition or repeated bending or looking upward.
Site HSE
coordinator
3.2 Helmet with head load ring is useful for the person carrying head
load.
Check the helmet regularly for any signs of damage of
deterioration. Replace the helmet immediately in case positive
signs of damage or deterioration are evident.

Wear the helmet right way round. It does not give proper
protection when worn back to front.

Dont wear the helmet sloping up or down as it may
significantly reduce the protection it may provide.

Adjust the headband and the chinstrap so that there are no
chances of the helmet falling down.

Clean the helmet and its seat band regularly and change the
sweatband when required.

Never store the helmet in direct sunlight or excessive heat.
Long-term exposure can weaken the shell quickly.

Keep stock of helmets for visitors at site. Inspect the helmet
before handing it over to a visitor.
Site HSE
coordinator



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 12 SAFE USE OF HELMETS Page 2 of 2

7. Records






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 13 GOOD HOUSE KEEPING Page 1 of 2

1. Purpose : To ensure proper placing and stacking of material at sites


3. Responsibility Concerned Site Incharges



6. Procedure :

1 Unload the materials where it is required. Materials normally
tend to be dumped wherever space is open or where riggers
find it most convenient to unload. This lead to poor storage,
poor house keeping and damage to materials
Site Incharge
2 Stack the raw materials like cement etc. as per standard
code to avoid deterioration of materials and to ensure safety
of personnel handling the materials
Site Incharge
3 Keep the materials orderly and well stacked Supervisor
4 While stacking the materials, ensure that there is no
hindrance in passages for movement of people
Supervisor
5 Dispose of bands, binders and other packing materials as
soon as supplies are unwrapped
Supervisor
6 Place adequate number of suitable scrap bins, biodegradable
waste bins and non biodegradable waste bins in work area
Supervisor
7 Remove waste /scrap, generated during erection activities
regularly from working area
Supervisor
8 Clean the work places and passages that are slippery due
to oil or water spillage. Sand or saw dust can be used for
cleaning oil
Supervisor
9 Secure loose or light materials on open roofs and open
floors against wind
Supervisor
10 Always keep the elevated working platforms free from
unwanted tools, materials and scrap
Supervisor
11 Never throw materials or scrap from elevated locations to
lower elevations. Take suitable measures to lower such items
safely
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 13 GOOD HOUSE KEEPING Page 2 of 2

7. RECORDS


8. VERIFICATION, CORRECTIVE AND PREVENTIVE ACTION ;




Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 14 SAFE EXCAVATION Page 1 of 2

1. Purpose : To avoid damage / personal injury during excavation work at sites


3. Responsibility Concerned Head/SOX

4. Performance criteria : No. of such incidents / accidents on such cases.


6. Procedure :

1 Ensure proper barricading by ribbon/ rigid poles of the
excavated area
Head of Section
2 Proper side slopes of the excavation as per the type of
soil should be maintained
Head of Section
3 If the side slopes cannot be provided due to space
constraints/ nearby structures
Head of Section
i)Before excavation sheet piling must be done to prevent
the collapse of earth.
Head of Section
ii)Shoring and shuttering to be done Head of Section
iii) As soon as the job is completed, immediate back
filling to be done
Head of Section
iv) Excavation below existing foundation must be
avoided
Head of Section
4 Under water excavation to be done with proper
mechanical means.
Head of Section
5 A temporary coffer dam to be constructed when
excavation is done by the side of water reservoir
Head of Section
6 No personnel be allowed within the swing area of
mechanical excavator when work is in progress.
Head of Section
7 In case of running plant permission must be obtained
from client for excavation.
Site Incharge
8 Before excavation in running plant, under ground pipes
and cables to be de-energised
Site Incharge
9 Proper lighting to be arranged when the excavation is
carried out at night
Head of Section
10 Excavated earth to be dumped/ stored in a designated
place only.
Head of Section



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 14 SAFE EXCAVATION Page 2 of 2

11 Surplus earth to be transported and disposed in the
area provided by client. A written permission to be
obtained.
Head of Section
12 Disposal and transportation of surplus earth to be done
in a proper vehicle so that earth does not spill out.
Head of Section
13 Muck and slush generated from piling to be transported
in a closed container.
Head of Section

7. Records






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 15 SAFE WORKING AT HEIGHT Page 1 of 2

1. Purpose : To avoid damage / personal injury during working at height at sites



4. Performance criteria : No. of such incidents / accidents on such cases.


6. Procedure :

1 SAFE USE OF SCAFFOLDS
1.1 Provide scaffolds for all works that cannot be safety performed from
floor level
Supervisor
1.2 Ensure that the scaffold materials are of adequate strength for the
purpose it is to be used
Supervisor
1.3 Check scaffold components for damage and defect before use Supervisor
1.4 Avoid using combustible materials for scaffolds Supervisor
1.5 For platforms, use planks of grade 1 quality at least 2 thick and 10
wide; free from all defects such as loose knots and splits
Supervisor
1.6 Erect scaffolds level and plumb Supervisor
1.7 Use diagonal braces for stability of scaffolds Supervisor
1.8 Planks used for platforms should overhang the supports by 150
300 mm
Supervisor
1.9 Hold the planks together by splicing at the bottom Supervisor
1.10 Secure the platform firmly with the scaffold Supervisor
1.11 Minimum width of platforms 2 M above floor level should be 900mm Supervisor
1.12 Provide guardrails 1.5M high, consisting of top rail and mid rail for
platforms higher than 2 M from floor level
Supervisor
1.13 Provide toe guards at the platform edges to eliminate hazard of tools
or other objects falling from the platform
Supervisor
1.14 Inspect the erected scaffolds regularly, if the scaffolds are to be used
for a long period of time
Site HSE
coordinator
1.15 Keep the platforms free from any unnecessary obstruction material,
rubbish and oil spillage
Supervisor
1.16 Use safety belt properly anchored to a permanent structure while
working on a platform higher than 2 M from floor level
Supervisor
1.17 Do not allow persons to work from scaffold during storm or high
winds
Supervisor
1.18 Do not use braces for climbing up or down a structure or a platform.
A safe and convenient means of access should be provided to all
platform levels
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 15 SAFE WORKING AT HEIGHT Page 2 of 2

2.0 SAFE USE OF LADDERS.

2.1 Use portable ladders for flights up to 4 M only Supervisor
2.2 Provide fixed ladders for flights above 4 M Supervisor
2.3 Place the ladder at an angle of 75 degrees (approx) from the
horizontal
Supervisor
2.4 Extend ladder at least 1 M above the top landing Supervisor
2.5 Secure top and bottom of the ladder firmly to prevent displacement Supervisor
2.6 Ensure that the width of the ladder is not less than 300 mm and
distance between rungs is not more than 300 mm
Supervisor
2.7 Provide landings of minimum size 600 x 600 mm at intervals not
more than 6 M for fixed ladders. Check the ladders daily for any
defects
Site HSE
coordinator
2.8 Ensure that the areas around base and top of the ladder are clear.
Getting on and off the ladder is more hazardous than using it. Use a
mudsill if the ladder is to rest on soft, loose or rough soil
Supervisor
2.9 Do not use ladders of conducting material near power lines Supervisor
2.10 Stand no higher than the fourth rung from the top for carrying out
any job standing on a ladder
Supervisor
2.11 Always face the ladder while climbing up or down Supervisor
2.12 Maintain three point contact while climbing up or down a ladder i.e.
two hands and one foot or two feet and one hand on the ladder at all
the times.
Avoid climbing up or down a ladder while carrying anything in hands.
Lift tools, equipment and materials with a rope
Supervisor

7. Records






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 16 SAFE FILLING OF HYDROGEN IN
GENERATOR
Page 1 of 2

1. Purpose : To ensure safety during Hydrogen Filling in / Emptying from Generator at
site.


3. Responsibility : Safety / Commissioning /Operation Department



6. Procedure :

1 To ensure that open flame ( welding, gas-cutting, smoking etc.)
is never used in the vicinity of the generator and the Hydrogen
system ( consisting of Seal oil/Gas/ waste gas systems/
Hydrogen cooler pipeline/ waste fluid system) as soon as
Generator is declared to be under commissioning/ it is in
operation.
Commissioning
IN-charge/
concerned Safety
Coordinator
2 To ensure that Filling and emptying the Generator is done
preferably with the Generator at rest. Else Consumption of
CO
2
/H
2
increases due to the whirling motion between the
medium to be displaced and the medium admitted. This may
increase the probability of an accident.
Commissioning
IN-charge/
concerned Safety
Coordinator
3 To ensure that ,If situation demands, Filling emptying should be
done at the most when Generator is at turning/barring gear
speed. At normal speed of 3000 rpm consumption of CO
2
/H
2
will
be enormous and hence should never be allowed.
Commissioning
IN-charge/
concerned Safety
Coordinator
4 To ensure that manufacturers recommendation/write-up/ O&M
manual is available at site and the process is performed exactly
in line with manufacturer' recommendation. Ensure that , these
recommendations are properly understood by the persons who
are actually executing/supervising the subject activity.
Commissioning
IN-charge/
concerned Safety
Coordinator
5 To ensure that adequate cylinders of CO
2
/H
2
is available (to be
checked before start of activity ). In case Gasses are provided
with pipelines then ensure that adequate quantity at appropriate
pressure is available. Ensure that Air filling lines are in service
and compressor is running. Air is available with proper dryness.
Concerned user



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 16 SAFE FILLING OF HYDROGEN IN
GENERATOR
Page 2 of 2

6 To ensure that Seal oil system is put in auto ( never allow this
operation while seal oil system is in manual mode) mode and all
the interlocks are checked.
Commissioning
IN-charge/
concerned Safety
Coordinator
7 To ensure that Bearing vapour exhauster is put in service ( auto
mode)
Operation in-
charge
8 To ensure that CO
2
Flash evaporator is filled with heat transfer
liquid upto lower edge of the riser. Ensure that this equipment is
commissioned and its protection/interlocks are checked.
Operation in-
charge
9 To ensure that the rubber flexible hose which connects air line
with compressed air filter ( at Generator gas unit) is
disconnected as soon as CO
2
/H
2
filling/ emptying activity starts
Operation in-
charge
10 To ensure that all shutoff valve and three way valves in the gas
valve rack at the gas dryer and in the bottle rack are closed
before start of Filling operation.
Operation in-
charge
11 To ensure that only Flame proof lamps are used in the
Hydrogen filling area / Gas room for illumination purpose.
Commissioning
IN-charge/
concerned Safety
Coordinator
12 To ensure that Hydrogen Cylinders are handled properly at the
time of its unloading and fitting with manifold. Hydrogen cylinder
manufacturers norms should be followed. While fitting these
cylinders spanners/keys of proper sizes should only be chosen.
Ensure that cylinder valves and caps are never hit/ hammered (
which may cause spark and fire)
Commissioning
IN-charge/
13 To ensure that filled cylinders are always stored vertically up ,
Empty cylinders are properly marked and stacked separately.
Commissioning
IN-charge/

7. Records :






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 17 ILLUMINATION Page 1 of 2

1. Purpose : To ensure adequate lighting at work places during working.

2. Scope : PSER HQs & Sites

3. Responsibility : Concerned HOD/ Head/SOX


5. Cross reference : OHSAS :18001

6. Procedure :

1 Provide adequate illumination at all work places and their
approach passages/corridors. Refer recommended values of
illumination for different locations
HOD(HRM) / Site
Incharge
2 Ensure that artificial lighting do not cause excessive glare or
disturbing shadows
HOD(HRM) / Site
Incharge
3 Provide suitable guards for the lamps where necessary to
prevent danger, if lamp breaks
HOD(HRM) / Site
Incharge
4 Use 24volt supply for hand-held lamps, especially in
confined spaces. Lamp guards are necessary for hand-held
lamps
HOD(HRM) / Site
Incharge
5 Provide emergency lighting to minimize danger in case of
power failure
HOD(HRM) / Site
Incharge



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 17 ILLUMINATION Page 2 of 2

6
Recommended values of illumination
S. No. Location Illumination
(Lux)
A. Construction Area
1. Outdoor areas like store yards, entrance and exit roads 20
2. Platforms 50
3. Entrances, corridors and stairs 100
4. General illumination of work area 150
5. Rough work like fabrication, assembly of major items 150
6. Medium work like assembly of small machined parts 300
rough measurements etc.
7. Fine work like precision assembly, precision 700
measurements etc.
8. Sheet metal works 200
9. Electrical and instrument labs 450

B. Office

1. Outdoor area like entrance and exit roads 20
2. Entrance halls 150
3. Corridors and lift cars 70
4. Lift landing 150
5. Stairs 100
6. Office rooms, conference rooms, library reading tables 300
7. Drawing table 450
8. Manual telephone exchange 200

HOD(HRM) / Site Incharge

7. Records :





Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 18 HANDLING & ERECTION OF HEAVY
METALS
Page 1 of 2

1. Purpose : To avoid damage / personal injury during handling and erection of heavy
metals.





6. Procedure :

1
Ensure proper maintenance of all the lifting machinery and
tackles. Record of maintenance carried out should be available
Site Incharge
2
Inspect daily, before start of work, all such equipment and record
in a Daily Inspection Register
Concerned HOS
3
Test certificates of all the lifting machinery and tackles should be
maintained. Testing shall be done periodically s recommended by
the manufacturer
Site Incharge
4
Maximum safe working load shall be conspicuously marked on all
the lifting machinery and tackles
Concerned HOS
5
Ensure that the lifting machinery and tackles are not loaded
beyond maximum safe working load
Concerned HOS
6
Before lifting with a winch ensure proper anchoring of the winch
and the pulleys. The pulleys must be checked thoroughly for any
defects
Concerned HOS
7
Do not tie or attach lifting devices such as chain pulley blocks,
max-pull or wire rope slings to the floor grills, working platforms
or guardrails
Supervisor
8
When load is being lifted with lifting machinery, warn the persons
in the vicinity by sounding horns/ whistle
Supervisor
9
Do not allow any body to stand under the load being lifted Supervisor
10
Never allow any person to ride on the loads being lifted Supervisor
11
Deploy only trained and authorized operators for operating the
lifting machinery
Supervisor
12
Ensure that only skilled riggers are engaged for slinging the
material to be handled
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 18 HANDLING & ERECTION OF HEAVY
METALS
Page 2 of 2

13
Use of safety helmet, safety shoes and hand gloves by the riggers
must be ensured
Supervisor
14
Only one person should give signals to the operator to lifting the
machinery
Supervisor
15 Ensure proper illumination of the area where material handling is
in progress
Supervisor
16 Never carry out any welding in the boiler structure during drum
lifting operation. This can damage wire ropes used for lifting of
drum
Supervisor

7. Records :






Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 19 SAFE ACID CLEANING Page 1 of 4

1. Purpose : To promote safety of power station personnel including customer, own and
subcontractors by setting out the general requirements while conducting acid
cleaning activity and the specific requirements to avoid danger from specific
hazards.


3. Responsibility : Concerned Head/SOX / Commissioning Head

4. Performance criteria : No. of incidents / accidents on such cases reported.


6. Procedure :

1 Identification of hazardous locations:
Chemical storage area solid and liquid
Main boiler ground level, economiser floor and drum level
Acid transfer station consisting of acid transfer pump, acid
tanker and piping network
Acid cleaning pumping station consisting of mixing tank and
acid circulation pump and piping network of chemical solution,
steam and water
Connected piping routing from acid cleaning station to main
boiler and neutralization pit
Effluent discharge / neutralization pit
Power supply DOL/ star- delta switching station
Nitrogen cylinder storage area and Nitrogen blanketing station
Supervisor
2 Identification of hazardous chemicals / gas:
i) Hydrochloric acid
ii) Rodine
iii) Ammonium Bifluoride
iv) Citric acid
v) Hydrazine Hydrate
vi) Ammonium Hydroxide
vii) Trisodium phosphate
viii) Disodium phosphate
ix) Bleaching powder
x) Hydrated lime or soda ash
xi) Nitrogen gas
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005

3 Identification of safety equipment:
For Personnel -
i) Gum boots 12 pairs
ii) Rubber gloves 12 pairs
iii) Rubber or polythene aprons 12 nos
iv) Helmets 12 nos
v) Safety goggles (plain glass) 12 nos
vi) Ear muffs 12 nos
vii) Face masks(transparent, plastic) 12 nos
First aid box (containing dilute ammonium hydroxide, 50%
sodium bicarbonate solution, eye lotion, bandages, smelling
salts, Iodine, burnol, cotton and any other medicine prescribed
by plant medical unit doctor)
Water shower
Ambulance
Supervisor
4 For plant equipment
i) Lime powder and bleaching powder for neutralising
the chemicals leaking from pipes and pumps
ii) Flushing water jet
iii) Nitrogen
iv) Tarpaulin and tin/asbestos sheet
v) Fire extinguisher / tender
vi) Ladder, temporary platform/scaffolding
Supervisor
5 For Environment
i) Lime 20 Ton or Soda ash 10 T
ii) Bleaching powder 5 Ton
iii) Neutralising pit at a safe location: 300 m
3
volume
Supervisor
6 Pollution control acceptance criteria:
Effluent discharge from neutralizing pit pH value should be 8.
Concerned
HOS
7 Communication methodology -
i) Control room with telephone, PA system and walki
talki. Medical attendant's full time presence is
necessary.
ii) Plant hospital to be sounded in advance for any
possible injury prior to start of activity.
Site Incharge
8 Work instructions explaining proper storage/ stacking, handling of
hazardous chemicals/gas to be pasted at identified hazardous
locations as identified in a)
Concerned
HOS
9 Notice board display and cordoning of identified hazardous
locations to prevent entry of personnel other than authorized
working personnel
Concerned
HOS



Rev. No. : 02
Eff. Date : 15.06.2005

10 Prevention of any welding/ gas cutting at the time of acid
circulation. Possibility of localized explosion remains due to
presence of hydrogen in acid fumes
Concerned
HOS
11 For working in electrical switchboard, related electrical safety
procedure is to be followed
Concerned
HOS
12 For any repair/maintenance work in between the stages of
chemical cleaning, related site safety procedure is to be followed
with respect to handling, repair and maintenance equipment
Concerned
HOS
13 Working area should be cleared off all debris, scrap and non-
related materials. Safe access to acid cleaning equipment is to be
ensured. Tin sheet roof is to erected over acid cleaning & transfer
pumping station, nitrogen blanketing station, electrical switchboard
to prevent rain water falling over equipment
Concerned
HOS
14 To prevent surrounding plant equipment from any possible
damage, tarpaulin, tin sheet/asbestos sheet is to be used as
guard
Concerned
HOS
15 Any area suspected to be contaminated by chemicals due to
leakage or any other reason should be washed with copious
quantity water to dilute same and neutralized with lime before
leading to drain
Concerned
HOS
16 Makeshift covered store is to be utilized for storing the chemicals
near to working area.
Total area including workstations, passages, main boiler,
staircases, neutralizing pit, road should be sufficiently illuminated
with floodlight. In addition, hand lamps are to be made available
Concerned
HOS
17 All personnel handling the chemicals mentioned in step b) during
shifting, pouring in mixing tank & neutralizing pit and attending/
guarding the leaking chemicals should wear protective clothing and
gadgets mentioned in step c).
Concerned
HOS
18 Any person affected by acid or other chemicals should be treated
with flushed water first. If the affected area is considerable he
should be given a total shower bath. Cut or burn injury should be
treated with proper medicine. For any inhalation of vapour, the
affected person should be taken to fresh air and administer artificial
respiration. For any eye injury due to chemicals first wash with
water and then apply eye lotion. For any injury of severe nature, he
should be transferred to hospital after applying necessary first aid.
Trained medical attendants services should be utilized while
attending to the injured personnel.
Concerned
HOS



Rev. No. : 02
Eff. Date : 15.06.2005

19 All the effluent from boiler after chemical cleaning should be
neutralized in neutralizing pit wherever necessary for maintaining
pollution norm. Acidic water should be neutralized with lime or
soda ash. Effluent with Hydrazina and ammonia should be treated
with bleaching powder
Concerned
HOS
20 For any fire incident, applicable procedure is to be followed for
extinguishing.
Site HSE
coordinator

7. Records:

RECORD NO. TITLE AREA RETENTION
PERIOD

8. Verification, Corrective and Preventive Actions :




Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 20 SAFE OIL FLUSHING Page 1 of 3
1. Purpose : To promote safety of power station personnel including customer, BHEL
and sub contractors by setting out the general requirements while
conducting Oil Flushing activity and the specific requirements to avoid
danger from specific hazards.





6. Procedure :
i) Oil storage area.
ii) Turbo-generator floor, ground level , MOT level.
iii) Oil Pump station
iv) Oil Centrifuge area.
v) Oil Piping from MOT to TG Bearings.
vi) Impure oil tank area.
Supervisor
2 Identification of hazards & risks.
i) Slip due to leakage/spillage of lube oil causing
physical injury & land contamination.
ii) Dermal contact during handling causing skin irritation
or dermal acne.
iii) Fire causing physical injury or property damage.
Supervisor
3 Identification of hazardous gas:
i) Oil Vapour
----
4 Identification of safety equipments:
For Personnel
iii) Helmets 12 nos
iv) Safety goggles (plain glass) 12 nos
v) Face masks(transparent, plastic) 12 nos
vi) First aid box (containing dilute ammonium hydroxide,
50% sodium bicarbonate solution, eye lotion, bandages,
smelling salts, Iodine, burnol, cotton and any other medicine
prescribed by plant medical unit doctor)
For plant equipment
i) Flushing water jet
ii) Fire extinguisher / tender.
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005

Disposal of waste oil should be done cautiously without spilling it
on the ground. The waste oil should be kept into either barrels or
Dirty oil tank.
Supervisor
6 Communication methodology
i) Control room with telephone, PA system and walki talki.
Medical attendents full time presence is necessary.
ii) Plant hospital to be sounded in advance for any possible
injury prior to start of activity.
Site Incharge
oil are to be pasted at identified locations as identified in a).
Site HSE
coordinator
working personnel.
Site HSE
coordinator
9 Prevention of any welding/ gas cutting at the time of Oil Flushing.
Possibility of fire hazards is there due to presence of oil vapours.
Supervisor
procedure is to be followed.
Supervisor
11 For any repair/maintenance work during the process of Oil
Flushing,, related site safety procedure is to be followed with
respect to handling, repair and maintenance of equipment.
Concerned
HOS
related materials. Safe access to Oil Flushing area is to be
ensured..
Supervisor
13 Any area contaminated with oil due to leakage or any other
reason should be covered with sand to avoid slippage as well as
fire hazard.
Supervisor
14 Total area should be sufficiently illuminated with floodlight. In
addition, hand lamps are to be made available.
Concerned
HOS
15 All personnel handling oil should wear protective clothing and
Supervisor
16 Any person affected by inhalation of oil vapour should be taken to
fresh air and administer artificial respiration. For any eye injury due
to oil ingress first wash with water and then apply eye lotion. For
any injury of severe nature, he should be transferred to hospital
after applying necessary first aid. Trained medical attendants
services should be utilised while attending to the injured personnel.
Site HSE
coordinator
17

For any fire incident, applicable procedure is to be followed for
extinguishing.
Site HSE
coordinator



Rev. No. : 02
Eff. Date : 15.06.2005

7. Records:

Period





Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 21 SAFE ALKALI BOIL OUT Page 1 of 4

1. Purpose : To promote safety of power station personnel working under customer,
BHEL and sub contractors by setting out the general requirements while
conducting Alkali Boil-out activity and the specific requirements to avoid





6. Procedure :


Chemical cleaning pumping station consisting of mixing tank
and Chemical Circulating pump and piping network of
chemical solution, steam and water
Connected piping routing from Chemical cleaning station to
main boiler and neutralization pit

Supervisor
2 Identification of hazardous chemicals / gas:

Hydrazine Hydrate
Ammonium Hydroxide
Trisodium phosphate
Disodium phosphate

Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005

3 Identification of safety equipments:
For Personnel -
iv) Helmets 12 nos
vi) Ear muffs 12 nos
Water shower
Ambulance
Supervisor
Flushing water jet
Tarpaulin and tin/asbestos sheet
Fire extinguisher / tender
Ladder, temporary platform/scaffolding
Concerned HOS
5 For Environment
i) Acid for neutralization : 1 Ton.
ii) Neutralising pit at a safe location: 300 m3 volume
Concerned HOS
6 a) Pollution control acceptance criteria:
Effluent discharge from neutralizing pit should have pH
value of 8.
Site Incharge
7 b) Communication methodology -
talki. Medical attendants full time presence is
necessary.
Site Incharge
Site HSE
coordinator
working personnel.
Site HSE
coordinator
10 Prevention of any welding/ gas cutting at the time of Alkali Boilout Supervisor


Rev. No. : 02
Eff. Date : 15.06.2005

procedure is to be followed.
Concerned HOS
with respect to handling, repair and maintenance equipment.
Concerned HOS
related materials. Safe access to Chemical cleaning equipment is
to be ensured.

Supervisor
14 Tin sheet roof is to erected over Chemical cleaning pumping
station, electrical switch board to prevent rain water falling over
equipment.

Concerned HOS
guard.

Supervisor
quantity water to dilute same and neutralised with acid before
leading to drain.
Supervisor
17 Makeshift covered store is to be utilised for storing the chemicals
Concerned HOS
18 Total area including workstations, passages, main boiler,
staircases, neutralising pit, road should be sufficiently illuminated
with floodlight. In addition, hand lamps are to be made available.

Supervisor
guarding the leaking chemicals should wear protective clothing
and gadgets mentioned in step c).

Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005

20 Any person affected by acid or other chemicals should be treated
affected person should be taken to fresh air and administer
artificial respiration. For any eye injury due to chemicals first wash
with water and then apply eye lotion. For any injury of severe
nature, he should be transferred to hospital after applying
necessary first aid. Services of trained medical attendants should
be utilised while attending to the injured personnel.

Site HSE
coordinator
21 All the effluent from boiler after chemical cleaning should be
neutralised in neutralizing pit wherever necessary for maintaining
pollution norm. Alkaline water should be neutralized with acid.
Effluent with Hydrazine and ammonia should be treated with
bleaching powder.

Concerned HOS
extinguishing.
Site HSE
coordinator

7. Records :

Period





Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 22 SAFE STEAM BLOWING Page 1 of 3

1. Purpose : To promote safety of power station personnel working under customer,
BHEL and sub contractors by setting out the general requirements while
conducting Steam Blowing activity and the specific requirements to avoid



4. Performance criteria : .No. of such incidents / accidents on such cases.


6. Procedure :


i) Boiler Drum elevation housing MS Stop valve and
Safety valves.
ii) Temporary piping for steam blowing.
iii) Steam Exhaust area.

Supervisor
2 Identification of hazards & risks

i) Noise leading to hearing impairment.
ii) Release of heat from un-insulated portions of steam
lines causing heat syncope.
iii) Leakage of steam causing steam burns.
Supervisor

For Personnel -
a) The entire area of Boiler and surrounding covering at
least 100 Meters from the steam exhaust pipe
should be totally cordoned off with barriers and
display boards.

Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005

b) Following items should be made available before steam
blowing:
i) Safety Boots 12 pairs
ii) Asbestos gloves 12 pairs
iii) Helmets 12 nos
iv) Safety goggles (plain glass) 12 nos
v) Ear muffs 12 nos
vi) Face masks(transparent, plastic) 12 nos
vii) First aid box (containing dilute ammonium
hydroxide, 50% sodium bicarbonate solution, eye
lotion, bandages, smelling salts, Iodine, burnol,
cotton and any other medicine prescribed by plant
medical unit doctor)

Fire extingusher / tender
Ladder, temporary platform/scaffolding
Supervisor
5 For Environment
Pollution control acceptance criteria for noise level.
Site Incharge
talki. Medical attendants full time presence is
necessary.
Site Incharge
working personnel.
Site HSE
coordinator
8 Prevention of any welding/ gas cutting at the time of steam blowing Concerned
HOS
9 For any repair/maintenance work in between the stages of steam
blowing, related site safety procedure is to be followed with respect
to handling, repair and maintenance of equipment.
Concerned
HOS
10 Working area should be cleared off all debris, scrap and non-related
materials.
Supervisor
11 Total area including workstations, passages, main boiler, staircases,
, road should be sufficiently illuminated with floodlight. In addition,
hand lamps are to be made available.
Site Incharge
extinguishing.
Site HSE
coordinator



Rev. No. : 02
Eff. Date : 15.06.2005

7. Records :

Period





Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 23 SAFE WORKING IN CONFINED AREA Page 1 of 2

1. Purpose : To define procedure for working in confined area and response plan
established for the same.

2. Scope : PSER HQs and Sites (applicable areas)


4. Performance criteria : Accident and health record of employees

5. Cross reference : ISO : 14001 , OHSAS : 18001

6. Procedure :

1. Confined space risk assessment for each job / area HOD
2. Issue of confined space work entry permit Supervisor
3. Check if isolation of confined space is required and from what i.e.
water / gas/ steam/ chemicals/ mechanical/ electrical drives

Supervisor
4 Tags fixing at isolation point/ confined area location, detailing type
of location/ confinement and workmen inside
Supervisor
5. Check if ventilation in confined space is adequate or not, provide
for appropriate ventilation before entry if so required
Supervisor
6 Check if atmospheric test is required, do the same for Hydrogen
Sulphide ppm, Toxic gas ppm, Explosives, etc.

Supervisor
7 Prepare Emergency & rescue procedures. Whenever accident
occurs which requires an emergency rescue be attempted, the
stand-by and rescue person is to be contacted immediately.

Supervisor
8 Management approval to enter confined space to ensure that
confined space is safe for entry and for doing the work and that all
persons on the job have been briefed
Supervisor



Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 23 SAFE WORKING IN CONFINED AREA Page 2 of 2

9 All personnel entering and working in the confined space must
sign before they entry to confined space that they have been
advised of the safety precautions to be taken while working in the
confined space covered by the permit and that they have been
trained to work in confined spaces and consider this site safe to
enter. After coming out of the confined space they should also
sign exit statement and intimate that they have now left this
confined space and that they are aware that should they re-enter
it, they are required to sign again.

Supervisor
10 Permit cancellation after work completion : It should clearly
indicate status of work i.e. completed or suspended, all personnel
have exited the confined space, signed off, all equipment
removed and the confined space may now be secured and this
permit cancelled.
Check whether PPE has been taken and are being used : Such as
Respiratory protection, Rescue or access equipment, Eye
protection, Essential requirements such as Fire Extinguishers,
First Aid Kit, Torch, Routine protection items and any other safety
precautions.
Supervisor

7 Records :

Record Title Record
No.
Location Responsibility Retention period
Entry permit issue and exit
statement record
Record for items/
equipment taken and
brought back from
confined space
2 Concerned
HOS
HOS 1 year
Accident detail record 3 HOD office HOD 1 year


of any deviation, take corrective/ preventive action.


Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 24 SAFE OPERATION OF PASSENGER LIFT,
MATERIAL HOISTS & CAGES
Page 1 of 3

1. Purpose : To ensure safe operation of Passenger lift, Material Hoists and cages

2. Scope : PSER HQs and Sites (applicable areas)



5. Cross reference : ISO : 14001 , OHSAS : 18001

6. Procedure :

1 COMMON CAUSES OF FAILURE : ---
1.1 A HUMAN ERROR :
[i] Deploying untrained and in-experience operator -
[ii] Negligence to go through instruction manual and using the
skill of experience only
[iii] Absence of periodical maintenance .
[iv] Keeping moving parts un guarded
[v] Over lubrication.
[vi] Over loading [beyond safe load].
[vii] Improper way of shutting doors.
[viii] Use of improper D shackles .
[ix] Ignorance about the location of C G of an item.
[x] Smoking inside the lift.
[xi] Not ensuring the soundness and capacity of slings, chain
pulley, pully block, Hook chook etc. being used .
[xii] Operating without signal man .
[xiii] Leaving the lift cabin with engine in running condition .
---
1.2 B. MACHINE ERROR [other error]
[i] Torn and old slings .
[ii] Improper Earthing .
[iii] Leakage of oil in the lifting drum .
[iv] Short circuit .
[v] Power cut.
[vi] Failure of locking arrangement .
[vii] Friction heat / spark in engine.
[viii] Static spark in engine.
---
1.3 C. BASIC PREVENTIVE MEASURES.



Rev. No. : 02
Eff. Date : 15.06.2005
Page 2 of 3

2 Try to locate the equipment / structure / frame on as solid and
level ground as possible
Supervisor
3 Ensure that the earth is properly compacted where the basic
structure is erected
Supervisor
3 Ensure about he proper reinforcement Supervisor
4 Deploy only trained and experienced operators with valid license
to operate the lift, J ib crane, hoist and cages
Supervisor
5 Read the instruction manual of the equipment thoroughly and
keep the operator informed
Supervisor
6 Keep the machinaries in good operating condition especially
clutches, brakes and controls, slings, manila ropes
Supervisor
7 Ensure that boom and hoist cut off limit switches are operational Supervisor
8 Before starting the lift see that all the guards of moving parts are
properly fitted
Operator
9 Shut of the engine when cleaning, adjusting or lubricating the
machine
Operator
10 Do not over lubricate the parts. Clean overflowing lubricants Supervisor
11 Keep on checking the condition of strands of slings and manila
ropes regularly
Supervisor
12 Depute only trained and experienced riggers for slinging the
materials / cages to be lifted
HOS
13 Ensure that only one person gives signals to the operator Supervisor
14 Before lifting load, be sure about the weight of the material. When
lifting near capacity load, calculate entire load carefully including
hook ,block and slings, and check it against rated lifting capacity
Operator
15 Test the hoist brake by raising the load a few inches and holding it
should hold easily
HOS
16 Never allow any person to stand within the periphery of the J ib
crane or beside the straight and stressed slings connected
between the load and Hook chook or the place where cage is
being lifted
Supervisor
17 Before lifting or moving load, warn the surrounding personnel by
sounding horn / whistle
Operator
18 Swing the load very slowly and carefully .Avoid sudden jerks Operator
19 Never swing load over ground crew Operator
20 Always watch the load and the signals from the signalman Operator
21 Never allow any person to stand under the load ( cage) being lifted Operator



Rev. No. : 02
Eff. Date : 15.06.2005
Page 3 of 3

22 Let the machine of the lift run idle for a little while, after the lift has
done heavy work. Do note stop the engine abruptly
Operator
23 When the load is to be lifted to a higher elevation, tie the load with
a manila rope to guide the load while in the air, so that it does not
strike any building or structure during swinging
Supervisor
24 Do not leave the cabin with engine running or load in the air Operator

7 Records :

Record Title Record
No.





Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 25 VEHICLE & CRANE MAINTENANCE Page 1 of 3

1. Purpose : To ensure proper maintenance of vehicles & cranes during usage to avoid
pollution & adverse environmental impacts beyond permissible limits

2. Scope : PSER HQs and Sites


4. Performance criteria : Exception reports on such incidents


6. Procedure : VEHICULAR POLLUTION & PROCEDURE FOR FITNESS TESTING
OF CONSTRUCTION EQUIPMENT'S

INTRODUCTION:

The exhaust fumes coming out of the tail ;pipe of vehicles, contain many polluting
substances which is a major contributor for environmental damage and diseases. One
research study says that 2.5 million people are estimated to die prematurely each year
from pollution related ailments. It is estimated that currently our country is losing over 10
% of its G.D.P. in costs associated with damage to the environment and degradation of
the countrys natural resources.

Air pollution and other health hazards caused by vehicles have reached an alarming
proportion in the country. The vehicle population in the country has grown from 0.3 million
(1951) to 25.34 million (1993) and contributing now around 50 to60% of the total air
pollution in the cities. This is mainly contributed by cars. Two wheelers, three wheelers as
they have old and III maintained engines, in chich nearly 30% of the fuel remains
unburned.

VEHICULAR POLLUTANTS

The main pollution omitted in the automobile exhaust gases are carbon monoxide (CO),
load aerosol, nitrogen oxides, sulphur oxides and heterogenous groups of hydrocarbons
Apart from this smoke (o.01 to 1 micron), Mists (2 to 200 micron) and ;particulate matter
(1 to 200 micron) are also formed due to incomplete combustion and solid impurity
contents of the fuel. In particular the diesel operated vehicles emit more toxic pollutants.



Rev. No. : 02
Eff. Date : 15.06.2005

EFFECTS OF POLLUTANTS

Human Health :

- Carbon Monoxide : Hinders oxygen supply from blood into the tissues as a combines with
the iron in the hemoglobin and thereby replacing oxygen in the hemoglobin, leading to
variety of ailments.
- Respirable particulate matter : 0.2 to 10 micron size of particulate matter can go directly
into the lungs causing bronchial ;problems and allergic asthma.
- Lead : It attacks the blood, kidneys and central nervous system. It can cause anemia,
kidney failure, permanent brain damage and finally death also.
- Environment : The ;pollutants such as SO
2
& NOx form acid rain and affect sometimes,
vegetation, soil surfaces ; darken sky through formation of smoke leading to limited visibility
and corrode metals. The ;plants are damaged by acute injury in which pollutants attack the
cells resulting in chronic effects related to disruption of chlorophyll synthesis and thereby
affecting the net yield of crops/ fruits.

SOURCES OF VEHICULAR POLLUTION

Vehicular emissions originate from changes in driving cycle (transient of steady state).
Engine conditions (injection and aspiration) techniques, maintenance, total mileage), fuel
composition (sulphur content, aromaticity, volatility), incomplete combustion and air/fuel/
ratio. Main ;places where ;pollution originates from the vehicle include engine crankcase ,
exhaust system, the carburetor and the fuel tank. The emission of particulate matter
increases with decrease in air/fuel ration, increase in load and temperature. Malfunction of
engine devices, especially fuel injection system, increases the omission of the main
exhaust components.

POLLUTION CONTROL MEASURES
Following measures may be adopted to reduce the emission:

- Modification of engine design to improve - Thermal reactors for complete
fuel combustion efficiency oxidation of CO & HC
- Exhaust gas recirculation for ensuring - Catalytic converter to reduce
complete combustion emissions for unburned HC and CO
- Use of particle traps for removing - Use of unleaded gasoline
particulate matter
- Use of low sulphur diesel - Use of low smoke lube oil for 2-stroke
and mixed lubricating engines.
- Use of alternate & cleaner fuels (CNG - Adopting cleaner vehicle standards.
LPG,Methanol etc),
- Improvement in traffic congestion - Introduction of efficient rapid mass
transport systems.
- Implementation of strict inspection/ - Driving vehicles at 50-60 KMPH
maintenance programmes. Range
- Avoiding idling at the traffic junctions/signals



Rev. No. : 02
Eff. Date : 15.06.2005

Type of vehicle CO HC No
Diesel driven
2/3 wheeler petrol
driven(Reference
mass R in kg)
Rs. 150
150<Rs.350
Rs.350
14g/KWH

12g/km
12.18(R-150)/200
3g/km
3.5g/KWH

8g/km
8+4(R-150)/200
12g/km
8g/KWH

- Limits for petrol driven vehicles :-

Reference Mass rw in kg
- Co (g/km) HC (g/km)
Rw<1020
1020<rw s 1250
1250<rws 1470
1470<rw s 1700
1700<rw s 1930
1930<rw s2150
rw<2150
14.3
16.5
18.8
20.7
22.9
24.9
27.1
2.0
2.1
2.1
2.3
2.5
2.7
2.9

PUC Check: All vehicles (one year after 1
st
registration) need to undergo the Pollution Under
Control (PUC) test at the testing facilities authorised by RTO periodically and ensure the compliance
with the emission limits. Compliance to BHARAT II or III norm may be adhered to if required
contractually/Statutory obligation.

CRANE MAINTENANCE: All cranes are to be maintained by authorized maintenance agency of
OEM. Records of maintenance are to be kept in each crane history cards. Disposal of wastes
generated during crane maintenance are to be disposed as per waste disposal procedure.(ref OCP
no 27). Care to be taken to collect lub oil/mobil in trays/bins during draining and refilling, to avoid
land contamination and avoid fire hazards.

7 Records :

Record Title Record
No.




Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 26 RADIOGRAPHY Page 1 of 4

1. Purpose : To ensure safety during radiography of welded joints at sites


3. Responsibility : Concerned Site Incharge

4. Performance criteria : Accident and health record of employees

5. Cross reference OHSAS : 18001, ISO : 14001

6. Procedure :

1. Exposure to penetrating radiation from Radioactive Isotopes and
other source is becoming more and more pronounced in the
construction field
---
2 A couple of decades ago, radioactive sources, used, were
comparatively mild and less encountered. With the growing
demand of weld joint inspection, metal thickness / flaw
determination, liquid level measurement in High temperature /
pressure process vessels etc., the use and application of the
radioactive sources specially, Y-radiation, has increased
considerably
---
3 However, the protection and procedure for work safety and
personnel protection have warranted very little basic changes
---
4 Atomic Energy authorities have been alert and alive to the
situation Well organized and efficient monitoring, controlled
operation and rescue / recovery system has been developed and
enforced. Some of these are
---
5.1 Authorized person obtains all Radioactive Isotopes from BARC
(Bhabha Atomic Research Centre, Mumbai) only
Site Incharge
5.2 Transportation and storage specifications and standards are
rigidly monitored and enforced by the authorities
Site Incharge
5.3 Any mishap, loss or damage is promptly attended to and rectified
by the authorities, immediately on receipt of information
Site Incharge
5.4 They promptly and formally collect all isotopes reaching their Half-
life stage
Site Incharge
5.5 Site requirements for the safe use of field personnel are as
follows:
a. Isotope storage a designated and certified location
should be maintained properly with prescribed warning
board and fencing.
Site Incharge



Rev. No. : 02
Eff. Date : 15.06.2005

b. Personnel using the Isotope must be medically checked
before being permitted to handle and found fit.

c. They must have a valid BARC certificate for safe handling
of Isotopes.

d. They must use a film Badge or Dosimeter as prescribed by
the authorities while working with Isotopes.

e. Isotope attached to a metal pencil should be removed from
storage only for the optimum period of work.

f. Isotope MUST not be taken out of the container lead pot
till actual exposure stage is reached. The exposure time
must be calculated beforehand.

g. Ensure radiation monitoring equipment is working, when
exposure is in progress.

h. On expiry of the exposure time, the source must
immediately be put back in the container.

i. All personnel working with radiation sources must maintain
the prescribed safe distance at all stages of work.

j. Isotopes Pencil must be handled by a Collimator or
monitoring rod of specified length, to avoid any unsafe
proximity to the operators body.

k. Isotopes or the pencil should never be touched by hand or
allowed to come in contact with body.

l. The area of work must be cordoned for a minimum radius of
10m for a Y-ray Isotope of about 3 C (S.A) and more as the
strength Specific Activity of the source, demands.

Specified warning Boards MUST be installed adequately around
the cordoned area.



Rev. No. : 02
Eff. Date : 15.06.2005

5.6 If an isotope is damaged or lost:
a) Immediately seal the working / suspected areas for all
traffic,
pedestrian or vehicle.
b) Do not remove any materials tools, containers, vehicles
anything from the suspected area.

Inform BARC Authorities Radiation Protection, Directorate of
Atomic Energy.
Site Incharge
Keep strict watch till the authorities arrive.

The authorities will locate and dispose off the offending isotope.

On no account site people or any other persons except BARC
designated personnel should attempt to recover the lost isotope.

Suspected over exposure of any personnel must be reported to
medical center immediately

5.7 On a routine basis:

All personnel attached to the radiography / radiometer crew
must have prescribed medical check ups.

Dosimeter / film badges must be returned to BARC for
processing. Safe exposure dosage for each individual over
different time stages fortnightly, monthly, annually are
predetermined and compared against actual exposures.

If a person is over exposed at any time he should be:

a) Taken off Radiograpy / Radiometry work.

b) Assigned other duties as advised by doctor. He has
no cause for panic.

A careful handling and strict observance of precautionary
measures renders isotope use totally safe.

Site Incharge



Rev. No. : 02
Eff. Date : 15.06.2005

7 Records :

Record Title Record
No.


case of any deviation, take corrective/ preventive action.


Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 27 WASTE DISPOSAL Page 1 of 1

1. Purpose : To define procedure for waste disposal and response plan establishment
for the same


3. Responsibility : Concerned HOS / Safety co-ordinator



6. Procedure :
Sr.no. Activity Responsibility
1 Identification of type of waste by certain characteristics that
they possess such as being corrosive, flammable, reactive or
toxic
Supervisor
2 Segregation of waste in different category depending on their
disposal mode and characteristics
Supervisor
3 Disposal Supervisor
4 Re-use or return- If the material can't be re-used at the facility
where it is waste, it may be useful at a nearby facility.
Alternatively, the manufacturer may accept return of unused
product.
HOD
5 Recycle- Can the waste be returned to the manufacturers for
recycle
HOD
6 Reject- Waste may be properly disposed of at provincially
licensed landfills or by licensed haulers at licensed waste
facilities. In this regard handling and disposal advice" sheets
are to be developed .These sheets will recommend a disposal
practice for various type of waste
HOD

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 28 MINERAL WOOL INSULATION Page 1 of 1

1. Purpose : To ensure safety of men & equipment during working with mineral wool
insulation.



4. Performance criteria : Number of unsafe incident during working with mineral wool
insulation.


6. Procedure :
1 Ensuring uses of PPEs during handling and application of
insulation as listed below
Supervisor
2 Cordoning of the area before start of insulation Supervisor
3 Scaffolding should be proper so that no accident occurs during
work
Supervisor
4 Covering of all adjacent equipments with suitable means like
tarpaulin, plastic sheets, Aluminum sheets etc. to avoid
damage to other equipments wherever required
Concerned
Engineer
5 Proper storage of mineral wools to be done ( like storing ins.
Mat. At clean and dry place with proper cover, oil soaked ins.
Should not be used,)
Concerned
Engineer
6 Cleaning of all waste and adjacent equipments after completion
of insulation
Supervisor
7 All wastes to be dumped at a predetermined isolated place to
avoid land nuisance and pollution which will be disposed of by
customer
Supervisor
8 Proper PPEs to be during rolling and cutting of sheet Supervisor
9 Drilling machine cable and drill bit should be in healthy
condition
Supervisor

7.0 Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 29 WORKING AT NIGHT Page 1 of 1

1. Purpose : To define procedure for working at night and response plan establishment
for the same

2. Scope : Applicable to all area where work of night is involved


4. Performance criteria : Accident and health record of personnel working in present
system and modified system


6. Procedure :

1 Identify work area for night shift only when it become
unavoidable , or else plan to complete the job in maximum
two shift or even by early / late working
Supervisor
2 Do not plan heavy complex job for night shift Supervisor
3 Plan less load for night shift people Supervisor
4 Suitable (good) compensation for night shift as it damage
person health due to Living and working "out of synch" with
circadian(body) rhythms -- as well as constantly shifting them --
places stress on ones body, potentially leading to the health
problems such as stomach related ailment, high blood
pressure, heart disease etc
HOD
5 Same person should not continue in night shift for long period
in short and long run
HOD
6 Woman should be avoided in night shift as it leads to ill effect
on womens reproductive health such as Miscarriage,
conception , premature birth, Low birth weight etc.. apart from
other human problems
HOD

7. Records :

Record Title Record No. Location Responsibility Retention Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 30 SAFE COMPUTER OPERATION Page 1 of 1

1. Purpose : To ensure safe working during operation of computers



4. Performance criteria : No. of incidents/ accidents reported


6. Procedure :

1 Body Posture :
1.1 While working on computer sit properly , so that your back
remains straight.
Computer
Operator
1.2 Place the monitor at the level of your eyes so that it is not
strenuous for your neck.
Computer
Operator
1.3 Keep the mouse and keyboard in such a position so that while
working your hands may rest against some support.
Computer
Operator
2. Eyes :
2.1 Place the monitor at the level of your eyes and adjust the
brightness and contrast , so that it is comfortable for the eyes.
Computer
Operator
2.2 Take small breaks and close/blink your eyes while working
continuously on a computer.
Computer
Operator
3. Disposal of Waste:
3.1 Unusable computer stationery should be disposed of in the
bins kept in different places.
Computer
Operator
3.2 .All non-biodegradable wastes like unusable/used cartridges,
CDs and floppies are to be disposed of in the Special Bin kept
at EDP Centre.
Computer
Operator

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 31 STORAGE IN OPEN YARD Page 1 of 1

1. Purpose : To ensure safety during storage and handling of material in open
storage yard.



4. Performance criteria No. of incidents / accidents in the area


6. Procedure :
1 The open store should be approachable by trucks/ trailers and
the roads to be min. of WBM grade.
Site Incharge
2 There should be sufficient space to place the vehicles at the
store area.
Site Incharge
3 The area should be leveled ground as far as possible. MM Incharge
4 The materials should be kept above the ground level preferably
on sleepers.
MM Incharge
5 The storage area should not be at low laying and water soggy. MM Incharge
6 The drainage system should be proper and it should be
connected to main drain of the plant.
MM Incharge
7 The store should be cleaned time to time and the vegetation
growth to be cut regularly.
MM Incharge
8 The materials having specified shelf life are to be issued in
first in first out basis.
MM Incharge
9 The wooden boxes/ polythene sheets / other inflammables are
to be kept away from the materials.
MM Incharge
10 The material handling should be by mechanical means as far
as possible.
MM Incharge
11 The area to be properly grid marked for easy identification of
materials and the grids marks to be displayed.
MM Incharge

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 32 DRILLING, REAMING AND
GRINDING (MACHINING) OPERATION
Page 1 of 2

1. Purpose : To ensure safety of men and equipment during machining operations
like drilling, reaming , grinding, etc.



4. Performance criteria : Number of un-safe incidents during such operations


6. Procedure :

1. Ensure proper power connection to these drilling, reaming &
grinding equipment by way of appropriate plugs and wires.
Supervisor
2 Ensure proper selection of drilling, reaming & grinding machines
depending upon type of job to be executed.
Supervisor
3 Ensure proper selection of tools (like drilling / reaming bits,
grinding wheels, etc.) depending upon type of job to be carried
out
Operator
4 Ensure proper electrical earthing of these machines / equipment
before starting the job.
Operator
5 Ensure proper fixing / attachment / tightening of drilling / reaming
bits / grinding wheels with their respective machines before start
of the job
Operator
6 Ensure that the job / item o to be drilled / reamed / grinded is
rigidly held and firmly secured before such activities are started.
Supervisor
7 Ensure usage of goggles, gloves, aprons and other PPEs as
appropriate.
Supervisor
8 Ensure minimum time gap (intermittently) in the process of
continuous use of these machines (as prescribed by
manufacturer) to avoid damage to equipment / electrical hazard.
Supervisor
9 Ensure proper cooling of drill bit / reamers by use of appropriate
coolant to avoid over-heating of tools.
Operator
10 Ensure that sub-standard or worn out tools (drilling / reaming
bits, grinding wheels) are not used.
Supervisor
11. Use caution signage / adequate cordoning as appropriate for
other workers to avoid any personal injury
Supervisor
12. Ensure proper cleaning and disposal of the debris / chips
generated in the process.
Supervisor


Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 32 DRILLING, REAMING AND
GRINDING (MACHINING) OPERATION
Page 2 of 2

7.0 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 33 STRESS RELIEVING Page 1 of 1

1. Purpose : To ensure safety of men & equipment during stress relieving.



4. Performance criteria : Number of unsafe incident during stress relieving


6. Procedure :

1. Ensure the adequacy of ceramic beads on the heating coil to
avoid fire / over heating of asbestos wrapper.
Concerned
Supervisor
2 Correct variety of thermal chalk (temperature indicating
crayon) is to be used for the particular temperature range.
Concerned
Supervisor
3 Use only calibrated temperature recorder.

Concerned
Supervisor
4 Proper disposition of thermocouple should be ensured
before starting stress relieving so that proper recording of
heating & cooling is done
Concerned
Supervisor
5 All electrical connections are to be done by certified
electrician. Power cable running on surface should be
guarded against any damage due to material movement.
Cable termination should be properly tightened to avoid
sparking & fire.
Concerned
Supervisor
6 Removal of track welds to be ensured from the surface of
item being stress relieved other wise insulation will be
disturbed and any recording will be inadequate.

Concerned
Supervisor

7.0 Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 34 HYDRAULIC TEST Page 1 of 1

1. Purpose : To ensure safety of men & equipment during hydraulic test of boilers and
to avoid ill effect on environment.



4. Performance criteria : Number of unsafe incidents during the event


6. Procedure :

1. Cordon off the entire boiler before starting the hydraulic test. Concerned HOS
2 Ensure proper functioning of hydrostatic pump and verify the
related test certificates
Concerned HOS
3 Ensure proper calibration certificate for all the pressure
gauges used during the process.
Concerned HOS
4 Ensure deployment of adequate no. of experienced personal
during the test.
Concerned HOS
5 Ensure gradual increase in the medium pressure. Concerned HOS
6 Observe for any leakage/seepage through weld joints, valve
glands, etc.
Concerned HOS
7. Ensure supply voltage of 24 V DC only for the hand lamps
used in the process.
Concerned HOS
8 Use appropriate PPEs like helmet, gloves, safety shoes
during the test.
Concerned
Supervisor
9 Ensure gradual release of pressure after completion of the
test.
Concerned HOS

7 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 35 TRIAL RUN OF ROTARY EQUIPMENT Page 1 of 1

1. Purpose : To ensure safety of men & equipment during trial run of rotary
equipment.





6. Procedure :

1. Ensure that proper alignment has been done between the
driving & driven equipment and the same is recorded
Concerned HOS
2 Clean all debris, scrap iron, temporary support etc. from the
casing and equipment platform
Concerned HOS
3 Ensure IR value of motor and lubrication of bearings as per
drg/ instruction manual
Concerned HOS
4 There should not be any oil spillover on or near the
equipment platform, staircases etc (This is dangerous from
the view point of human movement as well as fire hazard).
Concerned
Supervisor
5 Remove all the lubricant drum from the work place to the
earmarked place of storage yard.
Concerned
Supervisor
6 During the trial run of the rotary equipment, keep a vigil on
the bearing temperature, amperage, vibration & noise. If
anything unusual is noticed, equipment should be stopped
immediately and attended.
Concerned HOS

7.0 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 36 BATCHING Page 1 of 1

1. Purpose : To ensure safety of men & equipment during batching operation and
obviate undesirable effects on environment.





6. Procedure :

1. Ensure that only experienced operators run the batching
machine
Concerned
Engineer
2 Avoid prolonged exposure/inhalation of dust or cement
powder.
Supervisor
3 Follow the maximum weight limit for men and women
workers while lifting the mixed concrete
Supervisor
4 Follow instructions on electrical safety like ELCB operated
equipment, proper cable termination, use of 24V hand
lamps. etc.
Supervisor
5 Adequate safety measures (including job-instructions) are
taken for the workmen pouring aggregates and cement in the
batching machine
Supervisor

7 Records :

Period





Rev. No. : 01
Eff. Date : 15.06.2005
OCP No.: 37 CABLE LAYING/TRAY WORK Page 1 of 2

1. Purpose : To ensure safe working during cable laying and tray work





6. Procedure :

Sr.no: Activity Responsibility
1 Ensure that the civil embedment are as per drg. Concerned HOS
2. Ensure clearance is available from civil dept for
the cable trench/area concerned.
Concerned HOS
3. Ensure availability of cable schedule Concerned HOS
4. Ensure welding of supports for trays are done
using proper PPE .
Welding Incharge
5. For welding in plants, where hydrocarbon has
been charged, hot job permit to be obtained from
administrative authority.
Welding Incharge
6. Ensure that proper fasteners are used without
wastage.
HOS (electrical)
7. Ensure proper PPE like safely shoe, gloves are
used for handling of trays.
HOS (electrical)
8 After erection of trays, ensure proper earthing of
same is done as per drg.
HOS (electrical)
9. Take physical measurement of tray routes of
different section for arriving at exact cable length
required. Avoid wastage.
HOS (electrical)
10. Use jack to lift the cable drum and manual drawal
of cables to be done.
HOS (electrical)
11. For HT cables, use roller drums to avoid damage
to the cables.
HOS (electrical)
12. For cable laying between panels/switchgear
already electrically powered up, electrical work
permit shall be obtained from administrative
authority.
HOS (electrical)



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No.: 37 CABLE LAYING/TRAY WORK Page 2 of 2

13. Use cable tags made from aluminium flats and
ensure visibility of tags.
HOS (electrical)
14. Dress cables by using cable wrap belts/straps. HOS (electrical)
15. For cable termination work, it is to be ensures that
equipment at both ends are electrically isolated as
per work permit provision.
HOS (electrical)
16. Store cut piece cables in store yard till disposed as
scrap.
HOS (electrical)

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 38 SPRAY INSULATION Page 1 of 2

1. Purpose : To ensure safety of men & equipment during spray insulation



4. Performance criteria : Number of unsafe incident during spray insulation


6. Procedure :

1 Cables should be with out any defects used for the mixing
device and m/c should be properly grounded without any
electrical defect to avoid electrical fault / hazard.
Concerned
Engineer
2 Ensuring uses of PPEs as listed below Concerned
Engineer
3 Cordoning of the area before start of insulation Concerned
Engineer
4 Scaffolding should be proper so that no accident occurs
during work
Supervisor
5 Covering of all adjacent equipments with suitable means like
tarpaulin, plastic sheets, Aluminium sheets etc. to avoid
damage to other equipments
Concerned
Engineer
6 Proper handling and storage of mineral wools and chemicals
required for spray insulation to be done ( like storing ins.
Mat. At clean and dry place with proper cover, oil soaked ins.
Should not be used, PPE to be used while handling etc.)
Concerned
Engineer
7 Proper storage and handling of cement and paints is to be
done (like cement is to be kept in dry & covered place,
cements to covered, paint and thinner should be kept in
shade and away from heat, PPE to be used while handling)
Concerned
Engineer
8 Cleaning of all waste and adjacent equipments after
completion of insulation
Concerned
Engineer
9 All wastes to be dumped at a predetermined isolated place
to avoid land nuisance and pollution which will be disposed
of by customer
Concerned
Engineer


Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 38 SPRAY INSULATION Page 2 of 2

PPE to be used during handling and application of spray insulation:

a) Rubber hand gloves
b) Mask (mouth and nose combined)
c) Clear goggles to protect eye
d) Dungaree with head gear
e) Gumboot
f) Helmet
g) Safety belt (while working at height)

7.0 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 39 COMPRESSOR OPERATION Page 1 of 1

1. Purpose : To avoid damage / personal injury / sound pollution throughout the
operating hours .



4. Performance criteria : Exception points at management review


6. Procedure :

1. Ensure lubrication / cooling water system of the compressor
before starting
supervisor /
operator
2 Periodic draining of air receiver to avoid accumulation of water
thereby reducing chances of water ingress in the system .

--- do ---
3 Ensure Suction Filter healthiness . ---- do ---
4 Ensure sequential change of air dryer ---- do ---
5 Ensure correct Automatic loading / unloading --- do ---
6 Periodic checking of suction valves ---- do ---
7 Ensure Belt tightness & proper belt guards ---- do ---
8 Monitor operating parameters ---- do ---
9 General House keeping to be maintained .
Safety
1. Use of ear muffles for the persons working near
Compressor .
2. Measurement of noise level at regular intervals & to
be maintained with in limit . (90 d)

---- do ---

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 40 GAS DISTRIBUTION TEST Page 1 of 1

1. Purpose : To ensure safety of men & equipment during gas distribution test of
ESP


3. Responsibility : Concerned Engineer / HOS / Safety coordinator

4. Performance criteria : Number of unsafe incident during gas distribution test
of ESP


6. Procedure :
1. Obtain work permit from the unit control room for working
inside the ESP if the unit has already been commissioned.
Concerned
Engineer
2 Ensure that all the transformers of the fields are put off and
disconnecting switches are isolated.
Concerned
Engineer
3 Ensure that the collecting / emitting rapping mechanisms are
put off
Concerned
Engineer
4 Ensure that all the fields are discharged. Concerned
Engineer
5 Ensure Sl. No. 2 & 3 above by removing the keys from the
interlock system
Concerned
Engineer
6 Ensure that all scraps are removed from the inside of ESP
so that the passage is kept clean.
Concerned
Engineer
7 Ensure that the workmen engaged for taking readings Are
properly educated about the condition inside the ESP during
the GD test.
Concerned
Engineer
8 Ensure availability of 24 V hand lamps for illumination of
inside.
Concerned
Engineer
9 Ensure proper box-up of the ESP after the test is completed.

Concerned
Engineer

7.0 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 41 CLEANING OF HOTWELL /
DEAERATOR
Page 1 of 1

1. Purpose : To ensure safety of men & equipment during cleaning of hotwell /
deaerator.



4. Performance criteria : Number of unsafe incident during cleaning of hotwell /
deaerator.


6. Procedure :
1. Ensure availability of proper platform for opening of man-
hole door and that water is completely drained out.
Concerned HOS
2 Proper lighting is to be arranged during cleaning.

Concerned
Engineer
3 Supply of lighting has to be from 24 V DC source for safety
of personnel.
Concerned
Engineer
4 Arrange adequate portable fans for proper ventilation of the
hotwell / deaerator.
Concerned
Engineer
5 Ensure that deaerator temperature is brought down to
ambient temperature before entry of personnel into the
deaerator.
Concerned
Supervisor
6 Proper isolation is to be ensured from water and steam side
and work permit is to be issued.
Concerned
Engineer
7 CEP / BFP breakers are to be racked out and work permit is
to be issued.
Concerned
Engineer
8 Uses of appropriate PPEs like hand gloves and dungry
clothes are to be ensured.

Concerned
Supervisor

7.0 Records :

Period





Rev. No. : 01
Eff. Date : 15.06.2005
OCP No.: 42 ELECTRICAL MAINTENANCE Page 1 of 2

1. Purpose : To ensure safe working during electrical maintenance





6. Procedure :

1 Raise work permit for carrying electrical
maintenance work mentioning required
isolations, precautions.
HOS (Electrical)
2. Obtain sanctioned work permit and ensure that
required isolations are carried out.
HOS (Electrical)
3. For HT system, ensure power incomers are
racked out , control supply switched off and fuse
removed.
HOS (Electrical)
4. Electrical isolations are to be confirmed as per
scheme applicable.
HOS (Electrical)
5. Earthing of HT feeders may be carried out with
feeder earthing truck, as and where available as
an added safety.
HOS (Electrical)
6. Use PPE like electrical gloves of correct voltage
rating, safety shoe, rubber mats for carrying out
the work.
HOS (Electrical)
7. Display caution tags at the electrical isolation
points (viz. DO NOT OPERATE, MEN AT
WORK, DANGER etc)
HOS (Electrical)
8. Where ever lockable EPBs are available , same
to be locked in OFF position with Do not
operate tag.
HOS (Electrical)
9. All electrical equipment ,like cables, motors,
generators after isolation to be earthed by
earthing rods/ cables.
HOS (Electrical)
10. Carry out maintenance work. HOS (Electrical)


Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. 42 : ELECTRICAL MAINTENANCE Page 2 of 2

11. Before recharging the system, ensure all
earthings are removed.
HOS (Electrical)
12. Ensure all connections are restored. HOS (Electrical)
13. Fill up work permit stating completion of work
and return permit.
HOS (Electrical)
14. Remove all isolations and restore system for
normal operation.
HOS (Electrical)

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 43 OPERATION AND MAINTENANCE OF
A/C PLANT & SYSTEM .
Page 1 of 1

1. Purpose : To ensure proper / controlled atmosphere in the work area where cool
atmosphere is required for the safety and improved efficiency of
personnel and plant .



4. Performance criteria : Regular monitoring of temp / humidity level in the area
under A/C system .


6. Procedure :
1. Switch on the system about 45 min before the office hour so
that working may be commenced in proper atmosphere and
the system to be switched off immediately after office hours
Head /BMC
2 The temp / humidity level of the area where A/C atmosphere
exists must be monitored at regular interval . Dry and wet
bulb thermometer provided to be monitored regularly .
HR / Site Incharge
3 Carryout preventive and routine maintenance regularly HR / Site Incharge
4 Monitor & Control all plant parameters strictly
5 Arrest all leakages and spillage of lubricants .
6 Proper ventilation of the A/C plant room . Exhaust fan
provided must be in continuous service.

7 Proper lighting of the plant room .
8 House keeping of the A/C plant room HR / Site Incharge
9 As the refrigerant gas is highly pollutant, care must be
taken to avoid gas leakage .

10 Record of operation readings to be maintained .

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 44 MATERIAL PRESERVATION Page 1 of 2

1. Purpose : To ensure safety of men & equipment during preservation of material.



4. Performance criteria : Number of unsafe incident during material preservation.


6. Procedure :

1. Location of material (as per grid plan co-ordinates) are to be
recorded in stock register so that unnecessary re-handling is
avoided.
Store keeper
2 Illumination in the preservation area is to be adequate so
that preservation activities (like cleaning and painting,
greasing of machined surface etc) are done properly.
Concerned HOS
3 Grading of soil in open storage area should be sound so that
movement of cranes and trailers are safe and trouble free.
Concerned HOS
4 When material handling is done for preservation work at
open yard, weeds/ grass etc are to be cleaned to reduce the
chances of insect bites to the workmen
Concerned
supervisor
5 During surface cleaning before preservation painting,
workmen are to use nose mask to avoid inhalation of rust
and dust. Also, during handling of mineral wool, use of nose
mask and other PPEs as appropriate, is essential.
Concerned
supervisor
6 When greasing is done on sharp machined surfaces, care
must be taken so that workmen do not get injury in hand.
Use appropriate PPEs.
Concerned
supervisor
7 While doing preservation of electrical equipment (like HT
motor, etc) where space heaters are to be used, certified
electrician's services are to be taken. Strict vigil is to be kept
when the space heater is on to remove the chances of fire
hazard.
Concerned HOS /
supervisor


Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 44 MATERIAL PRESERVATION Page 2 of 2

7.0 Records :

Period





Rev. No. : 01
Eff. Date : 15.06.2005
OCP No.: 45 ELECTRO RESISTANCE HEATING Page 1 of 1

1. Purpose : To ensure safe working during electro resistance heating


3. Responsibility : Concerned Engineer/HOS/Safety Coordinator



6. Procedure :

1 Ensure that the workmen directly involved in the work are
aware of the safety measures required for the job.
Concerned Engineer
1 Ensure adequacy of ceramic beads on the heating coil to
avoid fire/over heating of the wrapper
Concerned Engineer
2 Verify for correctness of the thermal chalk to be used for
the particular heating range.
Concerned Engineer
3. Use only calibrated temperature recorder Concerned Engineer
4. All electrical connections are to be done by certified
electrician. Power cable running on surface should be
guarded against any damage due to material movement.
Cable termination should be done properly to avoid
sparking/fire.
Concerned Engineer
5. The area should be cordoned to so that other workmen
not directly involved in the job become cautious.
Concerned Engineer
6. Ensure that electrical connections are switched off and
the job attained normal temperature before removal of
cordoning
Concerned Engineer

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 46 BLASTING
Page 1 of 1

1. Purpose : To define procedure for safe blasting and response plan establishment
for the same

2. Scope : Applicable to all area where work of blasting is involved


4. Performance criteria : Accident and health Record of personnel working in
present system and modified system over period of
time ie. Continuous improvement


6. Procedure :
1 Identify the area which will be effected by blast Supervisor
2 Evacuate entire area in the vicinity for man and animal by
proper information to all concern about timing and extent
Supervisor
3 Educate the local and other effected person in the vicinity
about blasting
Supervisor
4 Siren to be blown before blast and after blast in different mode
and should be known to all
Supervisor
5 Check the area after blast for various damage or note
observation if any
Supervisor
6 In case of accident, proper care to be taken, in case of damage
to other things extent of damage to be assessed
Supervisor

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 47 TRANSFORMER CHARGING
Page 1 of 1

1. Purpose : To ensure safe working during electrical charging of transformers





6. Procedure :

1 Ensure that erection of transformer is complete as per the
OGA drg.
HOS (Electrical)
2. Ensure that all pre-commissioning checks are completed
(Dielectric strength of oil, IR value of both windings).
HOS (Electrical)
3. Ensure that electrical protection checking of the upstream
and downstream switchgear are completed.
HOS (Electrical)
4. Ensure that the earthing of the transformer is completed as
per drawing.
HOS (Electrical)
5. Ensure that fencing of the transformer is completed and
same is earthed.
HOS (Electrical)
6. Ensure that fire fighting system, as applicable is in place. HOS (Electrical)

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 48 SAFE HANDLING OF BATTERY SYSTEM Page 1 of 1

1. Purpose : To ensure safe working during handling of battery system





6. Procedure :
1. Study the O&M manual of Battery manufacturer to identify the
chemicals used and their hazards.
HOS (Electrical)
2. During handling of battery, ensure availability of clean water
either from running tap or in pot (tank/drum/bucket).
HOS (Electrical)
3. Ensure use of PPE like rubber hand gloves, masks etc for
handling of battery.
HOS (Electrical)
4. Before placing of cells in battery room, ensure civil work
completion like floor tiles, exhaust fan running etc.
HOS (Electrical)
5. Carry out erection of the cells as per drawing. HOS (Electrical)
6. For maintenance free battery, arrange for charging of cells
after assembly.
HOS (Electrical)
7. For cells requiring acid or alkali solution to be charged after
erection, ensure availability of weigh bridge, mixing pot, funnels
etc. as per manufacturers guide lines.
HOS (Electrical)
8. Organize job meeting at site before start of the chemical filling
activity and explain the potential hazards of the operation and
immediate rescue action to be carried out.
HOS (Electrical)
9. Do not use any excess quantity of water & chemical. Chemical
to be used in exact amount for commissioning of cells.
HOS (Electrical)
10. Carry out electrical charging of the battery with battery charger. HOS (Electrical)

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 49 DG SET Page 1 of 1

1. Purpose : To define procedure for safe operation of diesel generator set





6. Procedure :

1 Qualified and suitably trained person to handle the machine HOD
2 O & M crew to follow the manual of OEM on all issue for
operation and maintenance
Supervisor
3 Calibration of various items to be done as per its
recommended chart
Supervisor
4 Sound proof chamber for DG set HOD
5 2 nos. of ventilator fan in the room for proper ventilation HOD
6 Extension of exhaust outside the building as per municipal
norms, at least 5 mtrs above the building
HOD
7 Clearance to be taken from all statutory bodies for operating
the machine such as pollution control board
HOD

7. Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 50 SANITARY MAINTENANCE Page 1 of 1

1. Purpose : To ensure safe maintenance of sanitary system in eco-friendly way



4. Performance criteria : No. of incidents / accidents in the area


6. Procedure :

1 The waste water from the bath-rooms and toilets are to
be properly drained.
Concerned supervisor
2 In no case the soak pit to be made near the under
ground tube well or the open well.
Concerned HOD / HOS
3 The bath rooms and toilets be cleaned every day. Concerned supervisor
4 The toilets must have proper ventilation systems. Concerned HOD / HOS
5 There should be sufficient spittoons and dustbins kept
in every floors.
6 There should be adequate ladies toilet for lady
employees.
Concerned HOD / HOS
7 The canteen and the kitchen are to cleaned every day
with proper disinfectants and fly proof nets are to be
provided in the doors and windows.
8 The kitchen wastes are to be properly disposed. Concerned supervisor
9 The drinking water is to be treated before use. Concerned supervisor

7. Records :

Period



Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 51 PILING RIG OPERATION Page 1 of 1

1. Purpose : To ensure safety of men & equipment during piling rig operation and
obviate undesirable effects on environment.





6. Procedure :

1. Ensure adequate caution signs for the area of operation Concerned
Engineer
2 The working persons in the vicinity should use ear plugs and
avoid prolonged exposure to the sound
Supervisor
3 Provide adequate access facilities to the working personnel Supervisor
4 Ensure that the necessary tools and tackles which are
engaged in operation, are in sound health.
Supervisor
5 As far as possible, the piling rig operation should be
completed within day time when working near residential
area or hospitals.
Concerned
Engineer

7 Records :

Period




Rev. No. : 01
Eff. Date : 15.06.2005
OCP No. : 52 PASSIVATION Page 1 of 1

1. Purpose : To ensure safety of men & equipment during boiler passivation and
also to avoid any ill effect on environment.



4. Performance criteria : Number of unsafe incidents during the event reported

5. Cross reference : OHSAS 18001 , ISO 14001

6. Procedure :

1. Cordon off the entire boiler area, effluent discharge area and
neutralizing pit
Concerned HOS
2 Use appropriate Personal Protective Equipment Concerned
Supervisor
3 Ensure that there is no leakage/seepage from boiler
pressure parts during the process
Concerned HOS
4 Before inspection of drum internals, ensure that the inside of
the drum has attained near-normal temperature and is free
of fumes.
Concerned
Supervisor
5 Use appropriate protective clothing, mask before entering
into the drum
Concerned
Supervisor
6 Ensure development of proper magnetite layer in the
sample pipe piece kept inside the mixing tank.
Concerned
Supervisor
7 Ensure complete neutralization in the effluent pit before de-
cordoning of the area.
Concerned
Supervisor
8 Ensure supply voltage of 24 V DC only for hand lamps use in
the process.
Concerned
Supervisor

7 Records :

Period




Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 53 SAFE EDTA CLEANING Page 1 of 4

subcontractors by setting out the general requirements while conducting
EDTA cleaning activity and the specific requirements to avoid danger from
specific hazards.



4. Performance criteria : No. of unsafe incident during EDTA Cleaning.


6. Procedure :

EDTA transfer station consisting of EDTA transfer pump, EDTA
tanker, EDTA storage tank and piping network
Chemical pumping station consisting of mixing tank and
chemical supply pump and piping network of chemical solution
& water
Connected piping routing from chemical pumping station to
main boiler and effluent pit
Effluent discharge / pit
Compressed piping network

Supervisor
2

Identification of hazardous chemicals / gas:
i) Ammoniated EDTA
ii) Hydrazine Hydrate
iii) Ammonium Hydroxide
iv) BHELMAX
v) BHELSOL

Supervisor



Rev. No. : 00
Eff. Date : 15.06.2005

3.

Identification of safety equipment:
For Personnel -
iv) Helmets 12 nos

Water shower
Ambulance

Supervisor/Site
HSE
Coordinator
ii) Tarpaulin and tin/asbestos sheet
iii) Fire extinguisher / tender
iv) Ladder, temporary platform/scaffolding
Supervisor/Site
HSE
coordinator
5 For Environment
i) Neutralising pit at a safe location: 500 m3 volume
ii) Compressed air piping network
Supervisor
/Site HSE
coordinator
Effluent discharge from neutralizing pit pH value should be 8.5 to 9.
Concerned
HOS
necessary.
Site Incharge
hazardous chemicals to be pasted at identified hazardous locations
as identified in a)
Concerned
HOS
working personnel

Concerned
HOS


Rev. No. : 00
Eff. Date : 15.06.2005

10 Prevention of any welding/ gas cutting at the time of EDTA
circulation.
Concerned
HOS
Concerned
HOS
Concerned
HOS
related materials. Safe access to EDTA cleaning equipment is to
be ensured. Tin sheet roof is to erected over EDTA transfer &
cleaning pumping station, electrical switchboard to prevent rain
water falling over equipment
Concerned
HOS
guard
Concerned
HOS
quantity water to dilute same before leading to drain
Concerned
HOS
Total area including workstations, passages, main boiler,
staircases, Effluent pit, road should be sufficiently illuminated with
floodlight. In addition, hand lamps are to be made available
Concerned
HOS
shifting, pouring in mixing tank & effluent pit and attending/
Concerned
HOS



Rev. No. : 00
Eff. Date : 15.06.2005

18 Any person affected by EDTA or other chemicals should be treated
affected person should be taken to fresh air and administer artificial
respiration. For any eye injury due to chemicals first flush with
water. The eyelids should be pushed apart using the thumb and
index finger. And then water washing jet should directed from the
side of eye for 5 10 minutes. After that apply eye lotion. In the
event of splashing of skin with chemicals the affected area should
be thoroughly washed. For any injury of severe nature, he should
be transferred to hospital after applying necessary first aid. Trained
medical attendants services should be utilized while attending to
the injured personnel.
Concerned
HOS
19 All the effluent from boiler after chemical cleaning should be stored
first in effluent pit. The organic EDTA chemical solution is having
pH of 8.5 to 9.0 and hence no treatment for pH adjustment is
required as it would meet the pH requirement for disposal.
Compressed air will be used to destroy the residual Hydrazina &
organics and the effluent will be disposed after aeration for 10
days. The organic chemical is completely biodegradable.
Concerned
HOS
extinguishing.
Site I/C/Site
HSE
coordinator

7. Records :

Period


Site Incharge shall ensure effective implementation of the above procedure. In case of any
deviation, shall take suitable corrective and preventive action.


Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 54 SAFE CHEMICAL CLEANING OF
PREBOILER SYSTEM
Page 1 of 4

acid cleaning activity and the specific requirements to avoid danger from
specific hazards.


3. Responsibility : Concerned Site Incharge / Commissioning Head



6. Procedure :

Main boiler ground level, economiser floor, feed control
station and drum level, Turbine area ground level,
intermediate floor, turbine floor
Chemical cleaning pumping station consisting of mixing tank
and chemical circulation pump and piping network of chemical
solution, steam and water
Connected piping routing from chemical pumping station to
economizer inlet NRV and neutralization pit

Site HSE
coordinator
2 Identification of hazardous chemicals:
i) SNID - PGN
ii) Hydrazine Hydrate
iii) Ammonium Hydroxide
iv) Bleaching powder

Site HSE
coordinator



Rev. No. : 00
Eff. Date : 15.06.2005
PREBOILER SYSTEM
Page 2 of 4

For Personnel -
iii) Asbestos gloves 8 pairs
iv) Helmets 12 nos
vi) Ear muffs 8 nos
Water shower
Ambulance
Site HSE
Coordinator
i) Bleaching powder for neutralising the hydrazine
solution leaking from pipes and pumps
ii) Flushing water jet
iii) Tarpaulin and tin/asbestos sheet
iv) Fire extinguisher / tender
v) Ladder, temporary platform/scaffolding
Site HSE
coordinator
5 For Environment
i) Bleaching powder 1 Ton
ii) Neutralising pit at a safe location: 300 m3 volume
Site HSE
coordinator
Effluent discharge from neutralizing pit pH value should be 8.
Concerned
HOS
necessary.
Site Incharge
Concerned
HOS



Rev. No. : 00
Eff. Date : 15.06.2005
PREBOILER SYSTEM
Page 3 of 4

working personnel
Concerned
HOS
Concerned
HOS
Concerned
HOS
related materials. Safe access to chemical cleaning equipment is to
be ensured. Tin sheet roof is to erected over chemical cleaning
pumping station, electrical switchboard to prevent rain water
falling over equipment
Concerned
HOS
guard
Concerned
HOS
quantity water to dilute same and neutralized with bleaching
powder (in case of hydrazine) before leading to drain
Concerned
HOS
Total area including workstations, passages, main boiler, trurbine
area, staircases, neutralizing pit, road should be sufficiently
illuminated with floodlight. In addition, hand lamps are to be made
available.
Concerned
HOS
Concerned
HOS
18 Any person affected by chemicals should be treated with flushed
water first. If the affected area is considerable he should be given a
total shower bath. Cut or burn injury should be treated with proper
medicine. For any inhalation of vapour, the affected person should
be taken to fresh air and administer artificial respiration. For any
eye injury due to chemicals first wash with water and then apply
eye lotion. For any injury of severe nature, he should be transferred
to hospital after applying necessary first aid. Trained medical
attendants services should be utilized while attending to the injured
personnel.
Concerned
HOS



Rev. No. : 00
Eff. Date : 15.06.2005
PREBOILER SYSTEM
Page 4 of 4

19 All the effluent from boiler after chemical cleaning should be neutralized
in neutralizing pit wherever necessary for maintaining pollution norm.
Effluent with Hydrazina should be treated with bleaching powder.
Concerned HOS
extinguishing.
Site HSE
coordinator

7. Records:

Period





Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 55 SAFE BOILER LIGHT UP
Page 1 of 3

boiler light up activity and the specific requirements to avoid danger from
specific hazards.





6. Procedure :

Fuel oil storage area, unloading and pressuring pumping station
Main boiler ground level, firing floor, drum level
Deaerator and BFP area
Chemical dozing system
ID/FD/AH area
Boiler fill pumping station
Compressed air piping network
Atomising steam piping network
Fuel oil piping network
HT, LT and DC switchgear

Site Supervisor

2

3.

i) Tri Sodium Phosphate
ii) Di Sodium Phosphate
iii) Hydrazine Hydrate
iv) Ammonium Hydroxide

Identification of safety equipment:
For Personnel -
iv) Helmets 12 nos

Site Supervisor

Site Supervisor


Rev. No. : 00
Eff. Date : 15.06.2005
Page 2 of 3

Water shower
Ambulance
Site supervisor
Site supervisor
5 For Environment
i) DM plant effluent pit

Site supervisor
Effluent discharge from boiler pH value should be 7.5 to 9.
Site engineer
talki.

Site engineer
hazardous chemicals to be pasted at identified hazardous locations
as identified
Site engineer
working personnel
Site engineer
10 Prevention of any welding/ gas cutting at the time of boiler light up. Site engineer
Site engineer
Site engineer
related materials. Safe access to all equipment is to be ensured.
Site engineer
guard
Site engineer
Site engineer
16 Total area including workstations, passages, main boiler,
staircases, road should be sufficiently illuminated with floodlight. In
addition, hand lamps are to be made available
Site engineer


Rev. No. : 00
Eff. Date : 15.06.2005
Page 3 of 3

17 All personnel handling the chemicals during shifting, pouring in
metering/mixing tank and attending/ guarding the leaking
chemicals should wear protective clothing and gadgets mentioned
in step 3.

Site supervisor
18 Any person affected by cut or burn injury should be treated with
proper medicine. Person affected by chemicals should be treated
with flushed water. For any inhalation of vapour, the affected
person should be taken to fresh air and administer artificial
water and then eye ointment will be applied. For any injury of
severe nature, he should be transferred to hospital after applying
necessary first aid. Trained medical attendants services should be
utilized while attending to the injured personnel.
Site engineer
19 All the effluent from boiler should be led to drain only after ensuring
its proper pH.
Site engineer
extinguishing.
Site
engineer/HSE
Coordinator

7. Records:

Period

8. Verification, Corrective and Preventive Actions

.


Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 56 SAFE ROLLING & SYNCHRONISATION
Page 1 of 3

1. Purpose : To promote safety of power station personnel including customer, own
and subcontractors by setting out the general requirements while
conducting rolling & synchronization activity and the specific requirements
to avoid danger from specific hazards.



4. Performance criteria : No. of unsafe incident reported during rolling &
synchronisation.


6. Procedure :

Main turbine & generator--- turbine floor, MOT room, seal oil system
Condenser , Ejector and CEP area
ID/FD/AH/ESP area
Compressor and compressed air piping network
PRDS and auxiliary piping network
HT, LT and DC switchgear, battery room
Switchyard , generator bus duct, transformer, DG set
CW pump house
Cooling Tower
Hydrogen/CO
2
filling room and piping network
Air conditioning system

Site engineer
2

v) Hydrogen
vi) Carbon dioxide
vii) Sulphuric acid

Site Supervisor



Rev. No. : 00
Eff. Date : 15.06.2005
Page 2 of 3

3. Identification of safety equipment: refer OCP no.12
For Personnel -
iv) Helmets 12 nos

First aid box (containing dilute ammonium hydroxide, 50% sodium
bicarbonate solution, eye lotion, bandages, smelling salts, Iodine,
burnol, cotton and any other medicine prescribed by plant medical
unit doctor) Refer OCP. No.07
Water shower
Ambulance
Site supervisor
Site supervisor
5 For Environment
Site supervisor
Effluent discharge from boiler/turbine- pH value should be 7.5 to 9.
Leaking oil will be collected and stored in separate drum.
Site engineer
i) Control room with telephone, PA system and walki talki.
ii) Plant hospital to be sounded in advance for any possible
injury prior to start of activity.
Site engineer
hazardous chemicals to be pasted at identified hazardous locations as
identified in 1. Refer OCP no. 10.
Site engineer
9 Notice board display and cordoning of identified hazardous locations to
prevent entry of personnel other than authorized working personnel
Site engineer
10 Prevention of any welding/ gas cutting at the time of boiler light up. Refer
OCP no. 04
Site engineer
11 For working in electrical switchboard, related electrical safety procedure
is to be followed. Refer OP no. 02 & 42
Site engineer
12 For any repair/maintenance work during the activity, related site safety
procedure is to be followed with respect to handling, repair and
maintenance equipment
Site engineer
13 Working area should be cleared off all debris, scrap and non-related
materials. Safe access to all equipment is to be ensured. Refer OCP no.
13.
Site engineer
14 To prevent surrounding plant equipment from any possible damage,
tarpaulin, tin sheet/asbestos sheet is to be used as guard
Site engineer
15 Any area suspected to be contaminated by chemicals due to leakage or
any other reason should be washed with copious quantity water to dilute
same before leading to drain

Site engineer


Rev. No. : 00
Eff. Date : 15.06.2005
Page 3 of 3

16 Total area including workstations, passages, main boiler, turbine,
generator, rotating equipments, staircases, road should be sufficiently
illuminated with floodlight. In addition, hand lamps are to be made
available. Refer OCP no. 17
Site engineer
metering/mixing tank and attending/ guarding the leaking chemicals
should wear protective clothing and gadgets mentioned in step 3. Refer
OCP no. 01
Site supervisor
18 Any person affected by cut or burn injury should be treated with proper
medicine. Person affected by chemicals should be treated with flushed
water. For any inhalation of vapour/gas, the affected person should be
taken to fresh air and administer artificial respiration. For any eye injury
due to chemicals first flush with water and then eye ointment will be
applied. For any injury of severe nature, he should be transferred to
hospital after applying necessary first aid. Trained medical attendants
services should be utilized while attending to the injured personnel.
Site engineer
19 All the effluent from boiler and turbine should be led to drain only after
ensuring its proper pH.
Site engineer
21 For safety during hydrogen filling, refer related OCP no. 16 Site engineer
22 For safety during running of rotating equipments, refer related OCP no.35 Site engineer
23 For safety during running compressor, refer related OCP no. 39 Site engineer
24 For transformer charging refer related OCP no. 47 Site engineer
25 For handling battery system refer related OCP no.48 Site engineer
26 For safety during air conditioning system operation, refer related OCP
no.43
Site engineer
27 For running DG set, refer related OCP no. 49 Site engineer
extinguishing.
Site
engineer/HSE
Coordinator

7. Records :

Period




Rev. No. : 00
Eff. Date : 15.06.2005
OCP No. : 57 SAFE FULL LOADING OF UNIT
Page 1 0f 3

unit full loading activity and the specific requirements to avoid danger from
specific hazards.



4. Performance criteria : No. of unsafe incident during Full Loading.


6. Procedure :

Main turbine & generator--- turbine floor, MOT room, seal oil
system
Coal bunker, feeder and milling system area
Condenser , Ejector and CEP area
ID/FD/AH/ESP area
Compressor and compressed air piping network
PRDS and auxiliary piping network
HT, LT and DC switchgear, battery room
Switchyard , generator bus duct, transformer, DG set
CW pump house
Cooling Tower
Hydrogen/CO
2
filling room and piping network
Air conditioning system

Site engineer
2

v) Hydrogen
vi) Carbon dioxide
vii) Sulphuric acid

Site Supervisor



Rev. No. : 00
Eff. Date : 15.06.2005
Page 2 0f 3

3 Identification of safety equipment: refer OCP no.12
For Personnel -
iv) Helmets 12 nos

by plant medical unit doctor). Refer OCP. No.07
Water shower
Ambulance
Site supervisor
Site supervisor
5 For Environment
Site supervisor
Effluent discharge from boiler/turbine- pH value should be 7.5 to 9.
Leaking oil will be collected and stored in separate drum.
Site engineer
talki.
Site engineer
hazardous chemicals/gas/ fuel oil/ coal to be pasted at identified
hazardous locations as identified in 1. Refer OCP no. 10.
Site engineer
working personnel
Site engineer
10 Prevention of any welding/ gas cutting at the time of full loading
activity. Refer OP no. 04
Site engineer
procedure is to be followed. Refer OP no. 02 & 42.
Site engineer
12 For any repair/maintenance work during the activity, related site
safety procedure is to be followed with respect to handling, repair
and maintenance equipment
Site engineer
related materials. Safe access to all equipment is to be ensured.
Refer OCP no. 13.
Site engineer
guard
Site engineer


Rev. No. : 00
Eff. Date : 15.06.2005
Page 3 0f 3

Site engineer
16 Total area including workstations, passages, main boiler, turbine,
generator, rotating equipments, staircases, road should be
sufficiently illuminated with floodlight. In addition, hand lamps are to
be made available. Refer OCP no. 17.
Site engineer
metering/mixing tank and attending/ guarding the leaking
chemicals should wear protective clothing and gadgets mentioned
in step 3. Refer OCP no. 01
Site supervisor
18 Any person affected by cut or burn injury should be treated with
proper medicine. Person affected by chemicals should be treated
with flushed water. For any inhalation of vapour/gas, the affected
person should be taken to fresh air and administer artificial
water and then eye ointment will be applied. For any injury of
severe nature, he should be transferred to hospital after applying
necessary first aid. Trained medical attendants services should be
utilized while attending to the injured personnel.
Site engineer
19 All the effluent from boiler and turbine should be led to drain only
after ensuring its proper pH.
Site engineer
20 Mill inserting arrangement is to be made available to take care of
exigencies arising out of fire inside mill and feeder
Site engineer
21 For safety during hydrogen filling, refer related OCP no. 16 Site engineer
22 For safety during running of rotating equipments, refer related OCP
no.35
Site engineer
23 For safety during running compressor, refer related OCP no. 39 Site engineer
24 For transformer charging refer related OCP no. 47 Site engineer
25 For handling battery system refer related OCP no.48 Site engineer
26 For safety during air conditioning system operation, refer related
OCP no.43

27 For running DG set, refer related OCP no. 49
extinguishing. Refer OCP no. 05
Site engineer

7. Records :

Period



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