Hse Manual Rev 03

KPC HSE MANUAL
Titte
GEN-HSE.OOO1 03 20th Apri[, 2018 2of30 HSEQ
Document No. Revision Date of lssuance Page lssuing department
APPROVAL
M. Yasir Mohiuddin DGM HSEQ (Management

Representative)
REVIEWED BY M. Yasir Mohiuddin DGM HSEQ (Management

Representative)
Nowshad Alam Director KPC
DISTRIBUTION LIST:
1. Director KPC
2. GM Operations
3. GM E&I
4. GM Mechanical
5. GM Performance & projects
6. DGM Operations
7. DGM Mechanical
8. DGM I&C
9. DGM Material
10. KPC Managers
Edition Version No. Page Amended lssue Date Effective Date

KPC HSE MANUAL
Titte
GEN.HSE-OOO1 03 20th April, 2018 3of30 HSEQ
Document No. Revision Date of lssuance Page lssuing department
FOREWARD
The Management of KPC herewith gives the approva[ for the attached HSE Manuat.
This Occupational Heatth and Safety Manuat describes the Health and Safety Management
System devetoped and estabtished on the basis of l5O 45001-2018 and ISO 14001:2015 which
are imptemented in248 MW KPC to prevent work-retated injury and il,t heatth to workers and
to provide safe and heatthy workptaces to etiminate hazards and minimize HSE risks by taking
effective preventive and protective measures.
The manuat describes the 248 MW KPC K-Etectric poticies, the procedures and practices that
have been imptemented and maintained to ensure that the objective of continual
improvement is achieved.
The directions contained in this HSE System Manual are mandatory for personnel of att
departments of KPC and interested parties.
Nowshad Atam
Director KPC

K-ELECTRIC
KORANGI POWER COMPLEX

HSE MANUAL

KPC HSE MANUAL
Title
GEN-HSE-0001 03 20th April, 2018 2 of 30 HSEQ
Document No. Revision Date of Issuance Page Issuing department
APPROVAL

NAME DESIGNATION SIGNATURE
PREPARED BY M. Yasir Mohiuddin DGM HSEQ (Management

Representative)
REVIEWED BY M. Yasir Mohiuddin DGM HSEQ (Management

Representative)
APPROVED BY Nowshad Alam Director KPC
DISTRIBUTION LIST:
1. Director KPC
2. GM Operations
3. GM E&I
4. GM Mechanical
5. GM Performance & projects
6. DGM Operations
7. DGM Mechanical
8. DGM I&C
9. DGM Material
10. KPC Managers

Edition Version No. Page Amended Issue Date Effective Date

KPC HSE MANUAL
Title
FOREWARD
The Management of KPC herewith gives the approval for the attached HSE Manual.
This Occupational Health and Safety Manual describes the Health and Safety Management
System developed and established on the basis of ISO 45001-2018 and ISO 14001:2015 which
are implemented in 248 MW KPC to prevent work-related injury and ill health to workers and
to provide safe and healthy workplaces to eliminate hazards and minimize HSE risks by taking
effective preventive and protective measures.
The manual describes the 248 MW KPC K-Electric policies, the procedures and practices that
have been implemented and maintained to ensure that the objective of continual
improvement is achieved.
The directions contained in this HSE System Manual are mandatory for personnel of all
departments of KPC and interested parties.
________________________________
Nowshad Alam
Director KPC

KPC HSE MANUAL
Title

KPC HSE MANUAL
Title
Contents
1. PLANT PROFILE: .................................................................................... 6
2. SCOPE: ............................................................................................... 9
3. MANUAL REVISIONS: ............................................................................... 9
4. CONTEXT OF THE ORGANIZATION: ........................................................... 10
5. Leadership AND WORKER PARTICIPATION: .................................................... 11
5.1. Leadership and Commitment: .................................................................. 11
5.2 HSE POLICY ....................................................................................................................................................... 12
5.3. ORGANIZATION ROLES, RESPONSIBILITIES AND AUTHORITIES: .............................................. 12
5.4. CONSULTATION AND PARTICIPATION OF WORKERS ..................................................................... 13
6. Planning: ........................................................................................... 14
6.1. Actions to address risks and Opportunities: .................................................. 14
6.1.1. General ............................................................................................. 14
6.1.2 ................................................................................................................................................. 14
7. Support: ................................................................................................ 20
8 OPERATION ........................................................................................ 23
8.1 OPERATIONAL PLANNING AND CONTROL .......................................................................................... 23
8.1.1 GENERAL ......................................................................................................................... 23
9 PERFORMANCE EVALUATION .................................................................... 25
10 IMPROVEMENT ..................................................................................... 28

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1. PLANT PROFILE:
1.1. GEOGRAPHICAL DESCRIPTION:
248 MW Korangi Power Complex (KPC) site is located at Southwest of the Korangi
Creek, Karachi. GPS Coordinates of the site are Latitude 24.7866 N and Longitude
67.1372 E. The site is 7.5 m above mean sea level. To the North of Plant is an old
fishing village Ibrahim Haidri. On South, the plant shares a boundary wall with Pakistan
Air Force Base Korangi Creek. The plant is within a walled area occupying 38 acres.
The plant is easily accessible from main Korangi Industrial Area.
1.2. TECHNICAL DESCRIPTION:
The gross installed capacity of the plant is 248 MW at ISO conditions. Total plant
auxiliary power consumption is approximately 7.5%. The plant is connected to the K-
Electric grid through a Gas Insulated Switchgear with 100% redundant 248 KV link
(called KCR KPC Circuit 1 and Circuit 2).
1.3. ENGINES AND GENERATING UNITS:
There are four GE LM6000 PC-Sprint Gas turbines. Two gas turbines exhaust is fed to
an HRSG which in turn produces steam for one steam turbine. In this way, two GT's,
one HRSG and one ST constitutes one block and overall complex can be viewed as two
blocks. Each Gas Turbine is rated at 48.408 MW at ISO, the old steam turbine (operated
by GT 03 and 04) is rated at 26 MW and the new steam turbine (operated by GT 01 and
02) is rated at 28 MW. Each Gas turbine has a inlet air chilling system supplied by
McQuay. Steam turbines have been manufactured by GE Thermodyn.
1.4. FUEL SYSTEM:
Gas Turbines have dual fuel system (Natural Gas and Diesel). Fuel gas is supplied by
Sui Southern Gas Company Limited (SSGCL) through a pipeline. The Plant
approximately consumes 42 MMSCFD at base load operation. The gas is compressed
using 4 GE high speed reciprocating gas compressors from 2.2 bar (g) to 45 Bar (g) to
meet the Gas Turbine requirement.
1.5. HRSG (HEAT RECOVERY STEAM GENERATION):

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Each Heat recovery steam generator (HRSG) (Make: IEG/Metka) is unfired, non-reheat,
water-tube low-pressure casing type, with forced circulation both in HP and LP
evaporating system. The HRSG is designed for continuous operation and recovers heat
of the Gas Turbine’s exhaust to generate superheated steam (at HP and LP pressure
levels).
1.6. COOLING WATER SYSTEM:
Plant cooling water system consists of a primary and secondary cooling system.
Primary circuit is once through and uses Sea water as cooling medium. Secondary
circuit is a closed system with de-min water as the cooling medium.
1.7. TREATED WATER (DE-MINERALIZED WATER) PLANT:
Plant produces its de-mineralized water through two GE Reverse Osmosis units. Sea
water is used as a source. The total production of the unit 01 is 50m3/hr while that of
unit 02 is 30 m3/hr. Main consumers of de-min water are close-circuit cooling water
system, Sprint and De-NOX systems of Gas turbines and HRSG. The de-min water is
stored in four demin tanks having capacities 500m3, , and .
1.8. PLANT AIR SYSTEM:
Plant has 02 x 100% Screw type Ingersoll Rand Air Compressors, air dryers and plant
air piping to meet the requirements of pneumatic actuators in gas turbines,
compressors and firefighting deluge system. There is an adequate storage capacity to
meet the emergency shutdown requirements.
1.9. FIRE DETECTION & FIGHTING SYSTEM:
The Fire detection and fighting system at KPC consists of:
‐ A Fire & Gas detection system and a CO2 based fire suppression system for Gas
Turbines
‐ Following Addressable fire detection systems:
 Notifier by Honeywell.
 ZP3 four loop system
 ZP3 single loop system

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 MZX system
‐ Following conventional fire detection systems:
 Gent by Honeywell (8 zone)
 Gent by Honeywell (2 zone)
 Ziton System for EDG
 Ziton System for server room
 Ziton System for Management Block
 Kilsen
‐ FM200 based suppression systems at Old switchgear room and its basement, old
battery room and GIS cable basement
‐ NOVEC 1230 based suppression system at new switchgear room, new battery
and UPS room and new ST MCC.
‐ Foam based suppression system at new ST lube oil skid.
‐ A water based firefighting system with 02 each jockey pump (23 m3/hr), 01
each Motor driven pump (480 m3/hr), and 01 diesel engine fire water pump
(690 m3/hr). The water storage for the system is specifically used for
firefighting purposes with storage capacity of 5000 m3 of raw water. Fire water
network consists of fixed fire hydrants and deluge systems for transformers and
liquid fuel storage tanks.
2. ELECTRICAL SYSTEM:
The plant has two, 115/ 57.5/ 57.5 MVA, 3 winding, 11.5kv/248 KV step up
transformers for the gas turbines. Old Steam turbine has its own 33.1 MVA, 11 kV /
248 kV, 2 winding step up transformer while new steam turbine has its own 40 MVA,
11 kV / 248 kV, 2 winding step up transformer. The transformers have on-load tap
changers.
The station has four 6.6kV buses. Two 6.6kV buses for auxiliary power are fed through
two 18.5 MVA, 11.5/6.6 kV transformers and these buses can be coupled together

KPC HSE MANUAL
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when needed. Rest of the two 6.6kV buses are fed through 5 MVA, 11.5/6.6 kV
transformers and these buses can be coupled together when needed.
Low voltage equipment is fed through six low voltage buses. The buses are fed through
four 6.6 /0.4 KV transformer.
The plant has two UPS's in back to back configuration and two 110 VDC chargers with
their own battery banks for equipment of 1st commissioning phase. Moreover, two
UPS's in parallel configuration and two 110 VDC chargers with their battery banks for
2nd commissioning phase, ie New Steam Turbine.
3. CONTROL SYSTEM:
The plant is operated from the Central Control room. Gas Turbines are operated
through a Woodward Micronet control system. Excitation system for generator is
EX2100 by GE. Online vibration monitoring system by Bentley Nevada (BN3500) is
available.
Steam turbine control system is of GE Fanuc and has online vibration monitoring by
Bentley Nevada 3500.
Balance of Plant equipment and boiler is operated by a Distributed Control System

Experian PKS by Honeywell.
2. SCOPE:
This manual covers the Occupational Health, Safety & Environment Management System
(ISO 45001:2018) for 248 MW Combined cycle power plant K-ELECTRIC Karachi and
applicable to all employees, functional departments and contractors within the scope.
3. MANUAL REVISIONS:
HSE Manual is distributed on a “Controlled” or “Uncontrolled” copy basis, and records of
Quality System Manual holders and amendments are maintained by the Document & Data
Control Cell. Controlled copies of this manual are identified by mark showing “Controlled
Copy”.
Controlled Manuals are issued to personnel with the approval of Management
Representative and Director KPC. Amendments and revisions are issued to Manual
holders of controlled copy by Document & Data Control Cell. It is the responsibility of

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recipient to sign the DDL and DDC Representative to collect the obsolete
pages/documents.
Uncontrolled copies are not updated in case of amendment and revision.
Proposed changes to manual and documented procedures are initiated by using

prescribed forms. Document Review Committee is responsible for the review and
approval of the manual.
4. CONTEXT OF THE ORGANIZATION:
4.1. UNDERSTANDING ORGANIZATION AND ITS CONTEXT:
a) KPC shall determine external and internal issues that are relevant to its purpose
and that affect its ability to achieve the intended result(s) of HSE Management
system based on ISO-45001:2018
b) KPC shall monitor and review information about these external and internal issues.
4.2. UNDERSTANDING THE NEEDS AND EXPECTATIONS OF WORKER AND

OTHER INTERESTED PARTIES
Due to their effect or potential effect on KPC's ability to consistently generate electricity
and applicable internal, statutory and regulatory requirements, KPC shall determine:
The interested parties that are relevant to HSE. Major interested parties have been
identified as LDC, Procurement, Business Finance, GE, Thermodyne, Siemens, Honeywell,
SSGC and various local spare-parts suppliers and services providers.
The requirements of these interested parties relevant to HSE have been identified as
well. Major requirements include correct information exchange during ordering, correct
data for fault analysis, timely supply of services and spares, timely payment for obtaining
allocated fuel quota and meet / exceed expectation of sole consumer, namely, LDC and
so on.
As deemed necessary, KPC Management shall conduct thorough review about interested
parties and their interests relevant to HSE.

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4.3. DETERMINING THE SCOPE OF HSE:

This manual covers the Occupational Health and Safety Management System (ISO
45001:2018) for 248 MW Combined cycle power plant K-ELECTRIC Karachi and applicable
to all employees and functional departments within the scope
4.4. HSE MANAGEMENT SYSTEM:

KPC shall establish, implement, maintain and continually improve a HSE, including the
processes needed and their interactions, in accordance with the requirements of ISO
45001:2018.
Being a combined cycle power plant, the required inputs are air, sea water and natural
gas. These are consumed by Gas turbines, steam turbines and the auxiliaries to produce
electricity.
Operations department conducts the day to day operations required for electricity
production. Performance department keeps an eye on identified KPIs of plant equipment
and apparatus and maintenance is notified to address any observed issues, hampering
plant capacity or proper function, through SAP PM Module.
The record of KPI’s is maintained by Performance Department. These records are
regularly analyzed by Plant Management in daily coordination meeting to ensure that
Plant processes are smooth and being carried out as planned.
5. LEADERSHIP AND WORKER PARTICIPATION:
5.1. LEADERSHIP AND COMMITMENT:

KPC leadership shall committed to establish, document, implement and continually
improve the Occupational Health and Safety Management System (HSE) based on ISO-
45001:2018 standard and provide evidence of this commitment through:
a) Taking overall responsibility and accountability for the prevention of work related injury and
ill health
b) Directing and supporting persons to contribute to the effectiveness of the HSE management
system
c) Accountability for the effectiveness of HSE.
d) Establishing HSE Policy and Objectives.
e) Integration of HSE requirements into KPC’s business processes
f) Promoting the use of the process approach and risk based thinking.
g) Ensuring that the resources needed for the HSE are available.

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h) Communicating the importance of effective HSE management and of conforming to the HSE
requirements.
i) Ensuring that the HSE achieves its intended results.
j) Engaging, directing and supporting persons to contribute to the effectiveness of the HSE.
k) Promoting continual improvements.
l) Protecting workers from reprisals when reporting incidents, hazards, risks and opportunities
m) Ensuring the organization establishes and implements a process(s) for consultation and
participation of workers
n) Ensuring the establishment and functioning of health and safety committee.
o) Supporting other relevant Management Roles to demonstrate their leadership as it applies to
their areas of responsibility.
5.2 HSE POLICY

KPC management shall establish, implement and maintain an HSE policy that:
a) includes a commitment to provide safe and healthy working conditions for the
prevention of work-related injury and ill health and is appropriate to the purpose, size
and context of the organization and to the specific nature of its HSE risks and HSE
opportunities;
b) provides a framework for setting the HSE objectives;
c) includes a commitment to fulfil legal requirements and other requirements;
d) includes a commitment to eliminate hazards and reduce HSE risks
e) includes a commitment to continual improvement of the HSE management system;
f) Includes a commitment to consultation and participation of workers, and, where they
exist, workers’ representatives.
The HSE Policy shall;
a) be available as documented information;

b) be communicated within the organization;
c) be available to interested parties, as appropriate;
d) be relevant and appropriate.
5.3. ORGANIZATION ROLES, RESPONSIBILITIES AND AUTHORITIES:
KPC top management shall ensure that the responsibilities and authorities for relevant
roles within the HSE management system are assigned and communicated at all levels
within the organization and maintained as documented information. Workers at each
level of the organization shall assume

KPC HSE MANUAL
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Top management shall assign the responsibility and authority for:
a) ensuring that the HSE management system conforms to the requirements of this
document;
b) Reporting on the performance of the HSE management system to top management.
5.4. CONSULTATION AND PARTICIPATION OF WORKERS
KPC shall establish, implement and maintain a process(s) for consultation and
participation of workers at all applicable levels and functions, and, where they exist,
worker’s representation in the development, planning, implementation, performance
evaluation and actions for improvement of the HSE management system.
KPC Shall;
a) Provide mechanisms, time, training and resources necessary for consultation and
participation;
b) Provide timely access to clear, understandable and relevant information about
the HSE management system;
c) Determine and remove obstacles or barriers to participation and minimize those
that cannot be removed;
d) Emphasize the consultation of non-managerial workers on the following:
i. determining the needs and expectations of interested parties;

ii. establishing the HSE policy;
iii. assigning organizational roles, responsibilities and authorities, as
applicable;
iv. determining how to fulfil legal requirements and other requirements;
v. establishing HSE objectives and planning to achieve them;
vi. determining applicable controls for outsourcing, procurement and
contractors
vii. determining what needs to be monitored, measured and evaluated;
viii. planning, establishing, implementing and maintaining an audit
programme(s);
ix. ensuring continual improvement;
e) Emphasize the participation of non-managerial workers in the following:
i. determining the mechanisms for their consultation and participation;

ii. identifying hazards and assessing risks and opportunities;
iii. determining actions to eliminate hazards and reduce HSE risks;

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iv. determining competence requirements, training needs, training and

evaluating training;
v. determining what needs to be communicated and how this will be done;
vi. determining control measures and their effective implementation and use
vii. Investigating incidents and nonconformities and determining corrective
actions;
6. PLANNING:
6.1. ACTIONS TO ADDRESS RISKS AND OPPORTUNITIES:
6.1.1. GENERAL
KPC top management shall consider the issues identified in 4.1 and their requirements
as referred in 4.2 and determined the risks and opportunities that need to be
addressed to:
a) Give assurance that the HSE can achieve its intended result(s).
b) Enhance desirable effects.
c) Prevent, or reduce, undesirable effects.
d) Achieve continual improvement.
When determining the risks and opportunities for the HSE management system and its
intended outcomes that need to be addressed, KPC shall take into account:
a) hazards
b) HSE risks and other risks
c) HSE opportunities and other opportunities
d) Legal requirements and other requirements
The organization, in its planning process, shall determine and assess the risks and
opportunities that are relevant to the intended outcomes of the HSE management
system associated with changes in the organization, its processes or the HSE
management system. In the case of planned changes, permanent or temporary, this
assessment shall be undertaken before the change is implemented
The organization shall maintain documented information on:
a) Risks and opportunities;

b) The process and actions needed to determine and address its risks and opportunities
to the extent necessary to have confidence that they are carried out as planned.
6.1.2 HAZARD IDENTIFICATION AND ASSESSMENT OF RISKS AND OPPORTUNITIES

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a) HAZARD IDENTIFICATION
KPC shall establish, implement and maintain a process for hazard identification that is
ongoing and proactive. The process shall take into account, but not be limited to;
a) How work is organized, social factors (including workload, work hours,

victimization, and harassment and bullying) leadership and the culture
b) Routine and non-routine activities and situations, including hazards arising
from;
i. Infrastructure, equipment, materials, substances and the physical
conditions of the work place
ii. Product and service design, research, development, testing,
production, assembly, construction, service delivery, maintenance
and disposal
iii. Human factors;
iv. How the work is performed
c) Past relevant incidents, internal or external to the organization, including

emergencies, and their causes;
d) Potential emergency situations;
e) People, including consideration of;
i. Those with access to the work place and their activities, including
workers, contractors, visitors and other persons;
ii. Those in the vicinity if the work place who can be affected by the
activities of the KPC
iii. Workers at a location not under the direct control of KPC
f) Other issues, including consideration of;
i. The design of worker areas, processes, installations,

machinery/equipment, operating procedures and work organizations,
including their adaptation to the needs and capabilities of the workers
involved;
ii. Situations occurring in the vicinity of the workplace caused by work-
related activities under KPC control
iii. Situations not controlled by KPC and occurring in the vicinity if the
workplace that can cause injury and ill health to persons in the
workplace

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g) Actual or proposed changes in organization, operations, processes, activities and the

HSE management system
h) Changes in knowledge of, and information about, hazards
b) ASSESSMENT OF HSE RISKS AND OTHER RISKS TO THE HSE MANAGEMENT

SYSTEM
KPC shall establish, implement and maintain a process to;
a) assess HSE risks from the identified hazards, while taking into account the
effectiveness of existing controls;
b) Determine and assess the other risks related to the establishment,
implementation, operation and maintenance of the HSE management
system.
The methodology(ies) and criteria for the assessment of HSE risks shall be defined with
respect to their scope, nature and timing to ensure they are proactive rather than
reactive and are used in a systematic way. Documented information shall be
maintained and retained on the methodology and criteria.

c) ASSESSMENT OF HSE OPPORTUNITIES AND OTHER OPPORTUNITIES FOR
THE HSE MANAGEMENT SYSTEM
KPC shall establish, implement and maintain a process (es) to assess:
a) HSE opportunities to enhance HSE performance, while taking into account planned
changes to the organization, its policies, its processes or its activities and:
i. opportunities to adapt work, work organization and work environment to

workers;
ii. opportunities to eliminate hazards and reduce HSE risks;
b) Other opportunities for improving the HSE management system.
6.1.3 DETERMINATION OF LEGAL REQUIREMENT AND OTHER REQUIREMENTS
KPC shall establish, implement and maintain a process to:

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a) determine and have access to up-to-date legal requirements and other requirements
that are applicable to its hazards, HSE risks and HSE management system;
b) determine how these legal requirements and other requirements apply to the
organization and what needs to be communicated;
c) Take these legal requirements and other requirements into account when
establishing, implementing, maintaining and continually improving its HSE
management system.

KPC shall maintain and retain documented information on its legal requirements and
other requirements and shall ensure that it is updated to reflect any changes.
6.1.4 PLANNING ACTION
KPC shall plan:
a) Actions to:
i. Address these risks and opportunities

ii. Address legal requirements and other requirements
iii. Prepare for and respond to emergency situations
b) How to:
i. Integrate and implement the actions into its HSE management system
processes or other business processes;
ii. Evaluate the effectiveness of these actions
KPC shall take into account the hierarchy of controls and outputs from the HSE
management system when planning to take action.
When planning its actions, KPC shall consider best practices, technological options and
financial, operational and business requirements.
f) ASPECT AND IMPACT ANALYSIS
To establish a plan at 220 MW combined cycle power plant for developing

environmental management program for achieving the environmental objectives and
targets through the identification of environmental aspects and their impacts and
determination of significance of the impacts associated with the aspects.
For the identified aspects past, present and potential impacts (positive and negative)
are determined which are classified as one or more of the following:

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a) Water pollution
b) Air pollution
c) Noise pollution
d) Heat rejection
e) Risk of fire
f) Personnel safety
g) Health hazard
h) Depletion of natural resources
i) Land contamination
j) Conservation of resources etc.,
The significant aspects will be selected for setting up objectives/ for operational
control based on the following four factors:
a) All Aspects is falling under the category Emergency

b) All Aspects concerned with Legal issues
c) All Aspects whose severity rating is greater than 4 (> 4)
d) All Aspects whose significant score is greater than the average of maximum and
minimum significant scores.
Management Representative shall identify the members of core team and conduct
environment review considering the:
a) Use of materials and other resources

b) Use of Energy
c) Spillages / Leakages
d) Discharges / Disposals / Emissions
e) CCPP of noise/ vibration
f) CCPP of heat
g) Risk of fire Present
h) Emergency preparedness practices
i) Present safety practices
j) Customer and community / interested parties requirements
k) Evaluation of legal and other requirements
l) Identification of existing procedures dealing with contractual activities
A documented procedure HSE-SOP-0017 has been developed that details the

procedure for Aspect & Impact analysis.

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6.2 HSE OBJECTIVES AND PLANNING TO ACHIEVE THEM
6.2.1 HSE OBJECTIVES

The organization shall establish HSE objectives at relevant functions and levels in
order to maintain and continually improve the HSE management system and HSE
performance
The HSE objectives shall:
a. be consistent with the HSE policy;

b. be measurable (if practicable) or capable of performance evaluation;
c. Take into account:

i. applicable requirements;
ii. the results of the assessment of risks and opportunities
iii. the results of consultation with workers and, where they exist, workers’
representatives;
d) be monitored;
e) be communicated;
f) be updated as appropriate.
6.2.2 PLANNING TO ACHIEVE HSE OBJECTIVES:
When planning how to achieve HSE objectives, KPC shall determine;
a) What will be done

b) What resources will be required
c) Who will be responsible
d) When it will be completed
e) How the results will be evaluated, including indicators for monitoring
f) How the actions to achieve HSE objectives will be integrated into the business
processes
KPC top management shall maintain and retain documented information on the HSE
objectives and plans to achieve them.

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7. SUPPORT:
7.1 RESOURCES:
The Management of KPC shall determine and provide the resources needed for the
establishment, implementation, maintenance and continual improvement of the HSE
management system.
7.2 COMPETENCE:
KPC shall;
a) Determine the necessary competence of workers that affects or can affect its HSE
performance;
b) Ensure that workers are competent (including the ability to identify hazards) on the
basis of Appropriate education, training or experience;
c) where applicable, take actions to acquire and maintain the necessary competence,
and evaluate the effectiveness of the actions taken;
d) Retain appropriate documented information as evidence of competence.
7.3 AWARENESS:
Worker shall be made aware of;
a) The HSE policy and HSE objectives;

b) Their contribution to the effectiveness of the HSE management system, including
the benefits of improved HSE performance;
c) The implications and potential consequences of not conforming to the HSE
management system requirements;
d) incidents and the outcomes of investigations that are relevant to them;
e) Hazards, HSE risks and actions determined that are relevant to them;
f) the ability to remove themselves from work situations that they consider present an
imminent and serious danger to their life or health, as well as the arrangements for
protecting them from undue consequences for doing so.

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7.4 COMMUNICATION:
7.4.1 GENERAL
The Management of KPC shall establish, implement and maintain the process (es) needed
for the internal and external communications relevant to the HSE management system,
including determining;
a) On what it will communicate;

b) When to communicate;
c) With whom to communicate:
i. Internally among the various levels and functions of the KPC;

ii. among contractors and visitors to the workplace;
iii. among other interested parties;
d) How to communicate
KPC shall take into account diversity aspects (e.g. gender, language, culture, literacy,
disability) when considering its communication needs.
KPC shall ensure that the views of external interested parties are considered in
establishing its communication process.
When establishing its communication process, KPC shall:
a) Take into account its legal requirements and other requirements;

b) Ensure that HSE information to be communicated is consistent with information
generated within the HSE management system, and is reliable.
KPC shall respond to relevant communications on its HSE management system and retain
documented information as evidence of its communications, as appropriate.
7.4.2 INTERNAL COMMUNICATION
KPC shall;
a) Internally communicate information relevant to the HSE management system among
the various levels and functions of the KPC, including changes to the HSE
management system, as appropriate;
b) Ensure its communication process (es) enables workers to contribute to continual
improvement.
7.4.3 EXTERNAL COMMUNICATION

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KPC shall externally communicate information relevant to the HSE management system,
as established by the KPC’s communication process (es) and taking into account its legal
requirements and other requirements.
7.5 DOCUMENTED INFORMATION
7.5.1 GENERAL
KPC HSE management system shall include;
a) Documented information required by this document;

b) Documented information determined by the KPC as being necessary for the
effectiveness of the HSE management system.
7.5.2 CREATING AND UPDATING
When creating and updating documented information, KPC shall ensure appropriate:
a) Identification and description (e.g. a title, date, author or reference number);

b) Format (e.g. language, software version, graphics) and media (e.g. paper,
electronic);
c) Review and approval for suitability and adequacy.
7.5.3 CONTROL OF DOCUMENTED INFORMATION
Documented information required by the HSE management system and by this document
shall be controlled to ensure:
a) it is available and suitable for use, where and when it is needed;

b) It is adequately protected (e.g. from loss of confidentiality, improper use or loss of
integrity).
For the control of documented information, the KPC shall address the following activities,
as applicable:
a) Distribution, access, retrieval and use;

b) Storage and preservation, including preservation of legibility;
c) Control of changes (e.g. version control);
d) Retention and disposition.

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Documented information of external origin determined by KPC to be necessary for the

planning and operation of the HSE management system shall be identified, as
appropriate, and controlled.
8 OPERATION
8.1 OPERATIONAL PLANNING AND CONTROL
8.1.1 GENERAL
KPC shall plan, implement, control and maintain the processes needed to meet
requirements of the HSE management system, and to implement the actions determined
in by:

a) Establishing criteria for the processes;
b) Implementing control of the processes in accordance with the criteria;
c) Maintaining and retaining documented information to the extent necessary to have
confidence that the processes have been carried out as planned;
d) Adapting work to workers.
8.1.2 ELIMINATING HAZARDS AND REDUCING HSE RISKS
The KPC shall establish, implement and maintain a process (es) for the elimination of
hazards and reduction of HSE risks using the following hierarchy of controls:
a) Eliminate the hazard;

b) Substitute with less hazardous processes, operations, materials or equipment;
c) Use engineering controls and reorganization of work;
d) Use administrative controls, including training;
e) Use adequate personal protective equipment.

8.1.3 MANAGEMENT OF CHANGE
The KPC shall establish a process(es) for the implementation and control of planned
temporary and permanent changes that impact HSE performance, including:

a) New products, services and processes, or changes to existing products, services and
processes, including:

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i. Workplace locations and surroundings;

ii. Work organization;
iii. Working conditions;
iv. Equipment;
v. Work force;

b) Changes to legal requirements and other requirements;
c) Changes in knowledge or information about hazards and HSE risks;
d) Developments in knowledge and technology.
KPC shall review the consequences of unintended changes, taking action to mitigate any
adverse effects, as necessary.

8.1.4 PROCUREMENT
8.1.4.1 GENERAL

KPC shall establish, implement and maintain a process (es) to control the procurement
of products and services in order to ensure their conformity to its HSE management
system.

8.1.4.2 CONTRACTORS

KPC shall coordinate its procurement process (es) with its contractors, in order to
identify hazards and to assess and control the HSE risks arising from:

a) The contractors’ activities and operations that impact the organization;
b) KPC internal activities and operations that impact the contractors’ workers;
c) The contractors’ activities and operations that impact other interested parties in
the workplace.
KPC shall ensure that the requirements of its HSE management system are met by
contractors and their workers. The KPC’s procurement process (es) shall define and
apply occupational health and safety criteria for the selection of contractors.
8.1.4.3 OUTSOURCING
KPC shall ensure that outsourced functions and processes are controlled, its
outsourcing arrangements are consistent with legal requirements and other
requirements and with achieving the intended outcomes of the HSE management

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system. The type and degree of control to be applied to these functions and processes
shall be defined within the HSE management system.
8.2 EMERGENCY PREPAREDNESS AND RESPONSE
KPC shall establish, implement and maintain a process (es) needed to prepare for and
respond to potential emergency situations, including:
a) Establishing a planned response to emergency situations, including the provision of first

aid;
b) Providing training for the planned response;
c) Periodically testing and exercising the planned response capability;
d) Evaluating performance and, as necessary, revising the planned response, including after
testing and, in particular, after the occurrence of emergency situations;
e) Communicating and providing relevant information to all workers on their duties and
responsibilities;
f) Communicating relevant information to contractors, visitors, emergency response
services, government authorities and, as appropriate, the local community;
g) Taking into account the needs and capabilities of all relevant interested parties and
ensuring their involvement, as appropriate, in the development of the planned response.
KPC shall maintain and retain documented information on the process (es) and on the
plans for responding to potential emergency situations.
9 PERFORMANCE EVALUATION
9.1 MONITORING, MEASUREMENT, ANALYSIS AND PERFORMANCE EVALUATION
9.1.1 GENERAL
KPC shall establish, implement and maintain a process (es) for monitoring,
measurement, and analysis and performance evaluation.
KPC shall determine;
a) What needs to be monitored and measured, including;

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i. The extent to which legal requirements and other requirements are

fulfilled;
ii. Its activities and operations related to identified hazards, risks and
opportunities;
iii. Progress towards achievement of the KPC’s HSE objectives;
iv. Effectiveness of operational and other controls;
b) The methods for monitoring, measurement, analysis and performance evaluation, as

applicable, to ensure valid results;
c) The criteria against which the KPC will evaluate its HSE performance;
d) When the monitoring and measuring shall be performed;
e) When the results from monitoring and measurement shall be analyzed, evaluated and
communicated.
KPC shall evaluate the HSE performance and determine the effectiveness of the HSE
management system and shall ensure that monitoring and measuring equipment is
calibrated or verified as applicable, and is used and maintained as appropriate.
9.1.2 EVALUATION OF COMPLIANCE
KPC shall establish, implement and maintain a process (es) for evaluating compliance
with legal requirements and other requirements. KPC shall;
a) Determine the frequency and method(s) for the evaluation of compliance;

b) Evaluate compliance and take action if needed
c) Maintain knowledge and understanding of its compliance status with legal
requirements and other requirements;
d) Retain documented information of the compliance evaluation result(s).
9.2 INTERNAL AUDIT

9.2.1 GENERAL
KPC shall conduct internal audits at planned intervals to provide information on
whether the HSE management system:
a) Conforms to;

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i. KPC’s own requirements for its HSE management system, including the HSE
policy and HSE objectives;
ii. The requirements of this document;
b) Is effectively implemented and maintained.
9.2.2 INTERNAL AUDIT PROGRAM

KPC shall;
a) plan, establish, implement and maintain an audit programme(s) including the
frequency, methods, responsibilities, consultation, planning requirements and
reporting, which shall take into consideration the importance of the processes
concerned and the results of previous audits;
b) Define the audit criteria and scope for each audit;
c) Select auditors and conduct audits to ensure objectivity and the impartiality of the
audit process;
d) Ensure that the results of the audits are reported to relevant managers; ensure that
relevant audit results are reported to workers, and, where they exist, workers’
representatives, and other relevant interested parties;
e) Take action to address nonconformities and continually improve its HSE performance
f) Retain documented information as evidence of the implementation of the audit
programme and the audit results.
9.3 MANAGEMENT REVIEW

KPC top management shall review the organization’s HSE management system, at
planned intervals, to ensure its continuing suitability, adequacy and effectiveness.
The management review shall include consideration of:
a) The status of actions from previous management reviews;
b) Changes in external and internal issues that are relevant to the HSE management system,
including:
i. the needs and expectations of interested parties;

ii. Legal requirements and other requirements;
iii. Risks and opportunities;
c) The extent to which the HSE policy and the HSE objectives have been met;
d) Information on the HSE performance, including trends in:

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i. incidents, nonconformities, corrective actions and continual improvement;

ii. Monitoring and measurement results;
iii. Results of evaluation of compliance with legal requirements and other
requirements;
iv. Audit results;
v. Consultation and participation of workers;
vi. Risks and opportunities;
e) Adequacy of resources for maintaining an effective HSE management system;
f) Relevant communication(s) with interested parties;
g) Opportunities for continual improvement.
The outputs of the management review shall include decisions related to:
i. The continuing suitability, adequacy and effectiveness of the HSE

management system in achieving its intended outcomes;
ii. Continual improvement opportunities;
iii. Any need for changes to the HSE management system;
iv. Resources needed;
v. Actions, if needed;
vi. Opportunities to improve integration of the HSE management system with
other business processes;
vii. Any implications for the strategic direction of the organization.
KPC top management shall communicate the relevant outputs of management reviews
to workers, and, where they exist, workers’ representatives and shall retain
documented information as evidence of the results of management reviews.
10 IMPROVEMENT
10.1 GENERAL
KPC shall determine opportunities for improvement and implement necessary actions
to achieve the intended outcomes of its HSE management system.
10.2 INCIDENT, NONCONFORMITY AND CORRECTIVE ACTION

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KPC shall establish, implement and maintain a process (es), including reporting,
investigating and taking action, to determine and manage incidents and
nonconformities.
When an incident or a nonconformity occurs, KPC management shall:
a) React in a timely manner to the incident or nonconformity and, as applicable:
i. take action to control and correct it;

ii. Deal with the consequences;
b) Evaluate, with the participation of workers and the involvement of other relevant
interested parties, the need for corrective action to eliminate the root cause(s) of the
incident or nonconformity, in order that it does not recur or occur elsewhere, by:
i. investigating the incident or reviewing the nonconformity;
ii. determining the cause(s) of the incident or nonconformity;
iii. determining if similar incidents have occurred, if nonconformities exist,

or if they could
iv. Potentially occur;
c) Review existing assessments of HSE risks and other risks, as appropriate;
d) Determine and implement any action needed, including corrective action, in accordance
with the hierarchy of controls and the management of change;
e) Assess HSE risks that relate to new or changed hazards, prior to taking action;
f) Review the effectiveness of any action taken, including corrective action;
g) Make changes to the HSE management system, if necessary.

Corrective actions shall be appropriate to the effects or potential effects of the

incidents or nonconformities encountered.
KPC shall retain documented information as evidence of:

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i. the nature of the incidents or nonconformities and any subsequent actions

taken;
ii. The results of any action and corrective action, including their effectiveness.
KPC shall communicate this documented information to relevant workers, and, where
they exist, workers’ representatives, and other relevant interested parties.
10.3 CONTINUAL IMPROVEMENT

KPC shall continually improve the suitability, adequacy and effectiveness of the HSE
management system, by:
i. enhancing HSE performance;

ii. promoting a culture that supports an HSE management system;
iii. promoting the participation of workers in implementing actions for the
continual improvement of the HSE management system;
iv. communicating the relevant results of continual improvement to workers,

and, where they exist, workers’ representatives;
v. Maintaining and retaining documented information as evidence of

continual improvement.

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KPC HSE MANUAL

GEN-HSE.OOO1 03 20th Apri[, 2018 2of30 HSEQ

Document No. Revision Date of lssuance Page lssuing department

M. Yasir Mohiuddin DGM HSEQ (Management

REVIEWED BY M. Yasir Mohiuddin DGM HSEQ (Management

Nowshad Alam Director KPC

Edition Version No. Page Amended lssue Date Effective Date

GEN.HSE-OOO1 03 20th April, 2018 3of30 HSEQ

Document No. Revision Date of lssuance Page lssuing department

KORANGI POWER COMPLEX

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NAME DESIGNATION SIGNATURE

PREPARED BY M. Yasir Mohiuddin DGM HSEQ (Management

REVIEWED BY M. Yasir Mohiuddin DGM HSEQ (Management

APPROVED BY Nowshad Alam Director KPC

Edition Version No. Page Amended Issue Date Effective Date

GEN-HSE-0001 03 20th April, 2018 3 of 30 HSEQ

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1.2. TECHNICAL DESCRIPTION:

1.3. ENGINES AND GENERATING UNITS:

1.4. FUEL SYSTEM:

1.5. HRSG (HEAT RECOVERY STEAM GENERATION):

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1.6. COOLING WATER SYSTEM:

1.7. TREATED WATER (DE-MINERALIZED WATER) PLANT:

1.8. PLANT AIR SYSTEM:

1.9. FIRE DETECTION & FIGHTING SYSTEM:

The Fire detection and fighting system at KPC consists of:

‐ Following Addressable fire detection systems:

 ZP3 four loop system

 ZP3 single loop system

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‐ Following conventional fire detection systems:

 Gent by Honeywell (8 zone)

 Gent by Honeywell (2 zone)

 Ziton System for EDG

 Ziton System for server room

 Ziton System for Management Block

‐ Foam based suppression system at new ST lube oil skid.

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Balance of Plant equipment and boiler is operated by a Distributed Control System

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Uncontrolled copies are not updated in case of amendment and revision.

Proposed changes to manual and documented procedures are initiated by using

4. CONTEXT OF THE ORGANIZATION:

4.1. UNDERSTANDING ORGANIZATION AND ITS CONTEXT:

4.2. UNDERSTANDING THE NEEDS AND EXPECTATIONS OF WORKER AND

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4.3. DETERMINING THE SCOPE OF HSE:

4.4. HSE MANAGEMENT SYSTEM:

5. LEADERSHIP AND WORKER PARTICIPATION: