BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR - EASTERN · PDF fileoperational control...

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



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


AMENDMENT RECORDS SHEET Page 1 of 1

Old Document New Document Sl. No.

Date Page No. /

OCP No. Revision No.

Page No./ OCP No.

Revision No.

Nature of Change Effective Date

01. 25.11.02 - - OCP No. 01 to 26ll 00 1st 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 OPERATIONAL CONTROL PROCEDURES

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 S.no. Activity Responsibility

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.

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


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.

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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

Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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 : 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. : 02 ELECTRICAL SAFETY Page 1 of 2

1. Purpose : To avoid any personal damage / harm from the effects of electrical shock 2. Scope : PSER Kolkata (HQs. and Sites) 3. Responsibility : Concerned HODs / Head/SOX 4. Performance criteria : No. of such incidents / accidents on such cases 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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

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. : 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 : Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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


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

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. : 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 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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





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 : Sr. No. Activity Responsibility 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 Don’t 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

Sr. No. Activity Responsibility 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 Site HSE Coordinator

20 Ensure that the fire extinguishers are clearly visible & easily accessible and passage leading to them is free

Site HSE Coordinator

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





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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HODs / Head/SOX 4. Performance criteria decreasing number of such incidents/ accidents 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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 : Record Title Record No. Location Responsibility Retention

Period 8.0 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. : 07 FIRST AID

Page 1 of 1

1. Purpose : To provide preliminary preventive medical help before reaching to doctor 2. Scope : PSER Kolkata (HQs. and Sites) 3. Responsibility : Concerned HODs / Head/SOX 4. Performance criteria : Adequacy of first aid service provided when in need 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. No. Activity Responsibility 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


Period First Aid training records FA-01 HR Three years 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. : 08 FOOD SAFETY AT CANTEEN

Page 1 of 2

1. Purpose : To avoid food borne illness 2. Scope : PSER Kolkata (HQs. and Sites) 3. Responsibility : HRM Department 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 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

Sr. Activity Responsibility 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 4. Performance criteria : No. of such incidents / accidents on such cases 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. No. Activity Responsibility 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

Sr. No. Activity Responsibility 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 Don’t 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; don’t 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 2. Scope : PSER Sites 3. Responsibility : Concerned Site Incharges 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 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 don’t allow the cylinders to fall upon one another or subjected to any shock

Handling staff

10 Don’t 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 Don’t 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 : Record Title Record No. Location Responsibility Retention time Procurement / inspection records

GC - 01 Site Indenting dept. Till consumption of cylinder


.



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 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : ELECTRICAL HAZARDS

Sr. Activity Responsibility 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


NOISE

Sr. Activity Responsibility 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


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 :

Record Title Record No. Location Responsibility Retention time




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 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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. Don’t 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.




Rev. No. : 02 Eff. Date : 15.06.2005

OCP No. : 12 SAFE USE OF HELMETS Page 2 of 2

7. Records Record Title Record No. Location Responsibility Retention time




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 2. Scope : PSER Sites 3. Responsibility Concerned Site Incharges 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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 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. : 14 SAFE EXCAVATION Page 1 of 2

1. Purpose : To avoid damage / personal injury during excavation work at sites 2. Scope : PSER Sites 3. Responsibility Concerned Head/SOX 4. Performance criteria : No. of such incidents / accidents on such cases. 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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

Sr. Activity Responsibility 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





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 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX 4. Performance criteria : No. of such incidents / accidents on such cases. 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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


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

Sr. Activity Responsibility 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


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





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. 2. Scope : PSER Sites 3. Responsibility : Safety / Commissioning /Operation Department 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : Sr. Activity Responsibility 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 CO2/H2 increases due to the whirling motion between the medium to be displaced and the medium admitted. This may increase the probability of an accident.


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 CO2/H2 will be enormous and hence should never be allowed.


4 To ensure that manufacturer’s 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.


5 To ensure that adequate cylinders of CO2/H2 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

Sr. Activity Responsibility 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.


7 To ensure that Bearing vapour exhauster is put in service ( auto mode)

Operation in-charge

8 To ensure that CO2 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 CO2/H2 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.


12 To ensure that Hydrogen Cylinders are handled properly at the time of its unloading and fitting with manifold. Hydrogen cylinder manufacturer’s 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 : Record Title Record No. Location Responsibility Retention time




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 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS :18001 6. Procedure : Sr. Activity Responsibility 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


3 Provide suitable guards for the lamps where necessary to prevent danger, if lamp breaks


4 Use 24volt supply for hand-held lamps, especially in confined spaces. Lamp guards are necessary for hand-held lamps


5 Provide emergency lighting to minimize danger in case of power failure




Rev. No. : 02 Eff. Date : 15.06.2005

OCP No. : 17 ILLUMINATION Page 2 of 2

Sr. Activity Responsibility 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






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. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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

Sr. Activity Responsibility 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





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. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of incidents / accidents on such cases reported. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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


Sr. Activity Responsibility 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 m3 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


Sr. Activity Responsibility 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


Sr. Activity Responsibility 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.


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.

2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of incidents / accidents on such cases reported. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

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 – i) Gum boots 12 pairs ii) Rubber gloves 12 pairs 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


Sr. Activity Responsibility 5 Pollution control acceptance criteria:

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 attendent’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

7 Work instructions explaining proper storage/ stacking, handling of oil are to be pasted at identified locations as identified in a).


8 Notice board display and cordoning of identified hazardous locations to prevent entry of personnel other than authorized working personnel.


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

10 For working in electrical switchboard, related electrical safety 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

12 Working area should be cleared off all debris, scrap and non-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 gadgets mentioned in step c).

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.


17

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




Rev. No. : 02 Eff. Date : 15.06.2005


7. Records: Record Title Record No. Location Responsibility Retention

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 danger from specific hazards.

2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of incidents / accidents on such cases reported. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

Chemical storage area – solid and liquid Main boiler – ground level, economiser floor and drum level 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

Effluent discharge / neutralization pit Power supply DOL/ star- delta switching station

Supervisor

2 Identification of hazardous chemicals / gas: Hydrazine Hydrate Ammonium Hydroxide Trisodium phosphate

Disodium phosphate

Supervisor



Rev. No. : 02 Eff. Date : 15.06.2005


Sr. Activity Responsibility 3 Identification of safety equipments:

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



Supervisor

4 For plant equipment – 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 - i) Control room with telephone, PA system and walki

talki. Medical attendant’s full time presence is necessary.


Site Incharge





10 Prevention of any welding/ gas cutting at the time of Alkali Boilout Supervisor



Rev. No. : 02 Eff. Date : 15.06.2005


Sr. Activity Responsibility 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 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

15 To prevent surrounding plant equipment from any possible damage, tarpaulin, tin sheet/asbestos sheet is to be used as guard.

Supervisor

16 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 neutralised with acid before leading to drain.

Supervisor

17 Makeshift covered store is to be utilised for storing the chemicals near to working area.

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


Supervisor



Rev. No. : 02 Eff. Date : 15.06.2005


Sr. Activity Responsibility 20 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. Services of trained medical attendants should be utilised while attending to the injured personnel.


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



7. Records :

Record Title Record No. Location Responsibility Retention

Period 8. Verification, Corrective and Preventive Actions :




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 danger from specific hazards.

2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : .No. of such incidents / accidents on such cases. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

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

3 Identification of safety equipment:

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


Sr. Activity Responsibility 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)

4 For plant equipment – Fire extingusher / tender Ladder, temporary platform/scaffolding

Supervisor

5 For Environment – Pollution control acceptance criteria for noise level.

Site Incharge


talki. Medical attendant’s full time presence is necessary.


Site Incharge



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





Rev. No. : 02 Eff. Date : 15.06.2005



Period 8. Verification, Corrective and Preventive Actions : 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. : 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) 3. Responsibility : Concerned HOD / Head/SOX 4. Performance criteria : Accident and health record of employees 5. Cross reference : ISO : 14001 , OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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

Sr. Activity Responsibility 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

8. Verification, Corrective and Preventive Action : HOD / Site Incharge shall ensure effective implementation of the above procedure. In case 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) 3. Responsibility : Concerned HOD / Head/SOX 4. Performance criteria : No. of such incidents / accidents on such cases 5. Cross reference : ISO : 14001 , OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 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


Sr. Activity Responsibility 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, Jib 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 Jib 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


Sr. Activity Responsibility 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





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 3. Responsibility : Concerned HOD / Head/SOX 4. Performance criteria : Exception reports on such incidents 5. Cross reference : ISO : 14001 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 country’s 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 SO2 & 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 1st 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





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 2. Scope : PSER Sites 3. Responsibility : Concerned Site Incharge 4. Performance criteria : Accident and health record of employees 5. Cross reference OHSAS : 18001, ISO : 14001 6. Procedure : Sr. Activity Responsibility 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


Sr. Activity Responsibility 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 operator’s 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


Sr. Activity Responsibility 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




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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Exception points at management reviews. 5. Cross reference : ISO : 14001 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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incident during working with mineral wool insulation. 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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 : Record Title Record No. Location Responsibility Retention



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 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Accident and health record of personnel working in present system and modified system 5. Cross reference : OHSAS : 18001 6. Procedure : Sr.no. Activity Responsibility 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 one’s 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 women’s reproductive health such as Miscarriage, conception , premature birth, Low birth weight etc.. apart from other human problems

HOD

7. Records :




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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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 8. Verification, Corrective and Preventive Action :



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. 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria No. of incidents / accidents in the area 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of un-safe incidents during such operations 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility1. 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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incident during stress relieving 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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.


4 Proper disposition of thermocouple should be ensured before starting stress relieving so that proper recording of heating & cooling is done


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.


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.





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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incidents during the event 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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.


9 Ensure gradual release of pressure after completion of the test.

Concerned HOS




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incidents reported 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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).


5 Remove all the lubricant drum from the work place to the earmarked place of storage yard.


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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incidents reported 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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





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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : ISO : 14001, OHSAS : 18001 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

Sr.no: Activity Responsibility 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)





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 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incident during spray insulation 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : S.no. Activity Responsibility 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)




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 . 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Exception points at management review 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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 2. Scope : PSER Sites 3. Responsibility : Concerned Engineer / HOS / Safety coordinator 4. Performance criteria : Number of unsafe incident during gas distribution test of ESP 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incident during cleaning of hotwell / deaerator. 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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.


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.






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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 6. Procedure :

Sr.no. Activity Responsibility 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

Sr.no. Activity Responsibility 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 :





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 . 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Regular monitoring of temp / humidity level in the area under A/C system . 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : S.no. Activity Responsibility 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 : Record Title Record No. Location Responsibility Retention




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incident during material preservation. 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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.


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.


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 : Record Title Record No. Location Responsibility Retention




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 2. Scope : PSER Sites 3. Responsibility : Concerned Engineer/HOS/Safety Coordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 6. Procedure :

Sr.no: Activity Responsibility 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 Engineer4. 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 :



Doc. No.: PSER:HSEOM:005 : 02 OPERATIONAL CONTROL PROCEDURES 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 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Accident and health Record of personnel working in present system and modified system over period of time ie. Continuous improvement 5. Cross reference : OHSAS : 18001, ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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



Doc. No.: PSER:HSEOM:005 : 02 OPERATIONAL CONTROL PROCEDURES 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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 6. Procedure : Sr.no. Activity Responsibility 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 :





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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 6. Procedure : Sr.no. Activity Responsibility 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 :





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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents/ accidents reported 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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





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 2. Scope : PSER (HQs. and Sites) 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : No. of incidents / accidents in the area 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : Sr.no. Activity Responsibility 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. Concerned supervisor

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 :





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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incidents reported 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : S.no. Activity Responsibility 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




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. 2. Scope : PSER Sites 3. Responsibility : Concerned HOS / Safety co-ordinator 4. Performance criteria : Number of unsafe incidents during the event reported 5. Cross reference : OHSAS 18001 , ISO 14001 6. Procedure : S.no. Activity Responsibility 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.


5 Use appropriate protective clothing, mask before entering into the drum


6 Ensure development of proper magnetite layer in the sample pipe piece kept inside the mixing tank.


7 Ensure complete neutralization in the effluent pit before de-cordoning of the area.


8 Ensure supply voltage of 24 V DC only for hand lamps use in the process.






Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 53 SAFE EDTA 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 EDTA cleaning activity and the specific requirements to avoid danger from specific hazards. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of unsafe incident during EDTA Cleaning. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

Chemical storage area – solid and liquid Main boiler – ground level, economiser floor and drum level 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 Power supply DOL/ star- delta switching station

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

OCP No. : 53 SAFE EDTA CLEANING Page 2 of 4 Sr. Activity Responsibility 3.

Identification of safety equipment: For Personnel - i) Gum boots 6 pairs ii) Rubber gloves 6 pairs iii) Rubber or polythene aprons 6 nos iv) Helmets 12 nos v) Safety goggles (plain glass) 6 nos vii) Face masks(transparent, plastic) 4 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)


Supervisor/Site HSE Coordinator

4 For plant equipment – i) Flushing water jet 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

6 Pollution control acceptance criteria: Effluent discharge from neutralizing pit pH value should be 8.5 to 9.

Concerned HOS




Site Incharge

8 Work instructions explaining proper storage/ stacking, handling of hazardous chemicals to be pasted at identified hazardous locations as identified in a)

Concerned HOS


Concerned HOS



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 53 SAFE EDTA CLEANING Page 3 of 4 Sr. Activity Responsibility 10 Prevention of any welding/ gas cutting at the time of EDTA

circulation. Concerned HOS


Concerned HOS


Concerned HOS

13 Working area should be cleared off all debris, scrap and non-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


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 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, Effluent 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 & effluent pit and attending/ guarding the leaking chemicals should wear protective clothing and gadgets mentioned in step c).

Concerned HOS



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 53 SAFE EDTA CLEANING Page 4 of 4 Sr. Activity Responsibility 18 Any person affected by EDTA 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 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


Site I/C/Site HSE coordinator

7. Records :



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

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.

2. Scope : PSER Sites 3. Responsibility : Concerned Site Incharge / Commissioning Head 4. Performance criteria : Exception points at management reviews. 5. Cross reference : OHSAS : 18001 , ISO : 14001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

Chemical storage area – solid and liquid 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

Effluent discharge / neutralization pit Power supply DOL/ star- delta switching station


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




Rev. No. : 00 Eff. Date : 15.06.2005


Sr. Activity Responsibility 3 Identification of safety equipment:

For Personnel - i) Gum boots 8 pairs ii) Rubber gloves 8 pairs iii) Asbestos gloves 8 pairs iii) Rubber or polythene aprons 8 nos iv) Helmets 12 nos v) Safety goggles (plain glass) 8 nos vi) Ear muffs 8 nos vii) Face masks(transparent, plastic) 8 nos




4 For plant equipment – 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


5 For Environment – i) Bleaching powder 1 Ton ii) Neutralising pit at a safe location: 300 m3 volume


6 Pollution control acceptance criteria: Effluent discharge from neutralizing pit pH value should be 8.

Concerned HOS




Site Incharge


Concerned HOS



Rev. No. : 00 Eff. Date : 15.06.2005


Sr. Activity Responsibility 9 Notice board display and cordoning of identified hazardous

locations to prevent entry of personnel other than authorized working personnel

Concerned HOS


Concerned HOS


Concerned HOS

12 Working area should be cleared off all debris, scrap and non-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


Concerned HOS

14 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 bleaching powder (in case of hydrazine) before leading to drain

Concerned HOS

15 Makeshift covered store is to be utilized for storing the chemicals near to working area. 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


Sr. Activity Responsibility 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




Period





Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 55 SAFE BOILER LIGHT UP 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 boiler light up activity and the specific requirements to avoid danger from specific hazards. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : Exception points at management reviews. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

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.

Identification of hazardous chemicals / gas: i) Tri Sodium Phosphate ii) Di Sodium Phosphate iii) Hydrazine Hydrate iv) Ammonium Hydroxide

Identification of safety equipment: For Personnel - i) Gum boots 6 pairs ii) Rubber gloves 6 pairs iii) Rubber or polythene aprons 6 nos iv) Helmets 12 nos v) Safety goggles (plain glass) 6 nos

Site Supervisor Site Supervisor



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 55 SAFE BOILER LIGHT UP Page 2 of 3 Sr. Activity Responsibility 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)


Site supervisor


Site supervisor

5 For Environment – i) DM plant effluent pit

Site supervisor

6 Pollution control acceptance criteria: Effluent discharge from boiler pH value should be 7.5 to 9.

Site engineer


talki. ii) Plant hospital to be sounded in advance for any

possible injury prior to start of activity.

Site engineer

8 Work instructions explaining proper storage/ stacking, handling of hazardous chemicals to be pasted at identified hazardous locations as identified

Site engineer


Site engineer

10 Prevention of any welding/ gas cutting at the time of boiler light up. Site engineer 11 For working in electrical switchboard, related electrical safety

procedure is to be followed Site engineer


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.

Site engineer


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

OCP No. : 55 SAFE BOILER LIGHT UP Page 3 of 3 Sr. Activity Responsibility 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 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 should be led to drain only after ensuring its proper pH.

Site engineer


Site engineer/HSE Coordinator


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. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of unsafe incident reported during rolling & synchronisation. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

Fuel oil storage area, unloading and pressuring pumping station Main boiler – ground level, firing floor, drum level Main turbine & generator--- turbine floor, MOT room, seal oil system Deaerator and BFP area Condenser , Ejector and CEP area Chemical dozing system ID/FD/AH/ESP area Boiler fill pumping station Compressor and compressed air piping network PRDS and auxiliary piping network Atomising steam piping network Fuel oil piping network HT, LT and DC switchgear, battery room Switchyard , generator bus duct, transformer, DG set CW pump house Cooling Tower Hydrogen/CO2 filling room and piping network Air conditioning system

Site engineer

2

Identification of hazardous chemicals / gas: i) Tri Sodium Phosphate ii) Di Sodium Phosphate iii) Hydrazine Hydrate iv) Ammonium Hydroxide v) Hydrogen vi) Carbon dioxide vii) Sulphuric acid

Site Supervisor



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 56 SAFE ROLLING & SYNCHRONISATION Page 2 of 3 Sr. Activity Responsibility 3. Identification of safety equipment: refer OCP no.12

For Personnel - i) Gum boots 6 pairs ii) Rubber gloves 6 pairs iii) Rubber or polythene aprons 6 nos iv) Helmets 12 nos v) Safety goggles (plain glass) 6 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


Site supervisor


Site supervisor


Site supervisor

6 Pollution control acceptance criteria: 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

7 Communication methodology - 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

8 Work instructions explaining proper storage/ stacking, handling of hazardous chemicals to be pasted at identified hazardous locations as identified in 1. Refer OCP no. 10.

Site engineer


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


Site engineer


Site engineer



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 56 SAFE ROLLING & SYNCHRONISATION Page 3 of 3 Sr. Activity Responsibility 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

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. 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 20 For any fire incident, applicable procedure is to be followed for

extinguishing. Site engineer/HSE Coordinator






Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 57 SAFE FULL LOADING OF UNIT Page 1 0f 3 1. Purpose : To promote safety of power station personnel including customer, own and subcontractors by setting out the general requirements while conducting unit full loading activity and the specific requirements to avoid danger from specific hazards. 2. Scope : PSER Sites 3. Responsibility : Concerned Head/SOX / Commissioning Head 4. Performance criteria : No. of unsafe incident during Full Loading. 5. Cross reference : ISO : 14001, OHSAS : 18001 6. Procedure : Sr. Activity Responsibility 1 Identification of hazardous locations:

Fuel oil storage area, unloading and pressuring pumping station Main boiler – ground level, firing floor, drum level Main turbine & generator--- turbine floor, MOT room, seal oil

system Coal bunker, feeder and milling system area Deaerator and BFP area Condenser , Ejector and CEP area Chemical dozing system ID/FD/AH/ESP area Boiler fill pumping station Compressor and compressed air piping network PRDS and auxiliary piping network Atomising steam piping network Fuel oil piping network HT, LT and DC switchgear, battery room Switchyard , generator bus duct, transformer, DG set CW pump house Cooling Tower Hydrogen/CO2 filling room and piping network Air conditioning system

Site engineer

2

Identification of hazardous chemicals / gas: i) Tri Sodium Phosphate ii) Di Sodium Phosphate iii) Hydrazine Hydrate iv) Ammonium Hydroxide v) Hydrogen vi) Carbon dioxide vii) Sulphuric acid

Site Supervisor



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 57 SAFE FULL LOADING OF UNIT Page 2 0f 3 Sr. Activity Responsibility 3 Identification of safety equipment: refer OCP no.12

For Personnel - i) Gum boots 6 pairs ii) Rubber gloves 6 pairs iii) Rubber or polythene aprons 6 nos iv) Helmets 12 nos v) Safety goggles (plain glass) 6 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


Site supervisor


Site supervisor


Site supervisor

6 Pollution control acceptance criteria: 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. ii) Plant hospital to be sounded in advance for any

possible injury prior to start of activity.

Site engineer

8 Work instructions explaining proper storage/ stacking, handling of hazardous chemicals/gas/ fuel oil/ coal to be pasted at identified hazardous locations as identified in 1. Refer OCP no. 10.

Site engineer


Site engineer

10 Prevention of any welding/ gas cutting at the time of full loading activity. Refer OP 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


Site engineer



Rev. No. : 00 Eff. Date : 15.06.2005

OCP No. : 57 SAFE FULL LOADING OF UNIT Page 3 0f 3 Sr. Activity Responsibility 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

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

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. 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

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 28 For any fire incident, applicable procedure is to be followed for

extinguishing. Refer OCP no. 05 Site engineer




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