Operational Control Procedures Bhel

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OPERATIONAL CONTROL PROCEDURES

BHARAT HEAVY ELECTRICALS LIMITEDPOWER SECTOR - EASTERN REGION

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

START REDUCING THE USE OF PLASTIC ENVIRONMENTAL CONSERVATION


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OPERATIONAL CONTROL PROCEDURES

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


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

OPERATIONAL CONTROL PROCEDURES Rev. No. : 02Eff. Date : 15.06.2005

TABLE OF CONTENTS Page 1 of 2

Sl.No

TitleNo. ofPages

OCPNo.

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 04 029. 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


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


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 0143. 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 andsystem.

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 0153. 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


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

OPERATIONAL CONTROL PROCEDURESRev. No. : 02

Eff. Date : 15.06.2005

AMENDMENT RECORDS SHEET Page 1 of 1

Old Document New DocumentSl.No. Date Page No. /

OCP No.Revision No.

Page No./OCP No.

Revision No.

Nature of Change EffectivDate

01. 25.11.02 - -OCP No. 01

to 26ll00 1

st issue 25.11.02

02. 25.06.03

TOC, AmmRecords,OCP No.01 to 26

00

TOC, AmmRecords,

OCP No. 01to 26

01

Revised after includingcomments from DNV andincluding new OCP Nos. 27to 52

25.06.03

03. 15.06.05

TOC, AmmRecords,OCP No.01 to 26

01

TOC, AmmRecords,

OCP No. 01to 26

02

Revised after unifyingamongst OCPs and includingnew OCP Nos. 00, 53 to 57 incommissioning area.

15.06.05

04. 15.06.05OCP No.27 to 52

00OCP No. 27

to 5201 - Do - 15.06.05


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Doc. No.: PSER:HSEOM:005:02OPERATIONAL CONTROL PROCEDURES 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 DepartmentHOS 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


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Doc. No.: PSER:HSEOM:005 : 02OPERATIONAL 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 safetyshoes, safety helmets, safety belts, safety goggles, faceshield, earplugs, hand gloves etc. as per job requirement.

ConcernedIndividual/Supervisor

2 Openings in the floors must be covered. Supervisor

3

Install handrails on platforms and stairs as soon as these areerected.Temporary handrails should be provided on temporaryplatforms.

Supervisor

4Ensure scaffolding materials are of proven quality andinspected by experienced supervisor.

Supervisor

5Check that there are no hindrances on walkways andsufficient 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 allwork 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 andaccess / exit routes.

Supervisor

11.Arrangement of emergency lighting is also called for toensure safety during power breakdown.

Head/SOX

12. Hazardous activity area should be cordoned off using tapeswith 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 alongwith First Aid Box.

Head/SOX

15Ensure adequate communication facilities between all workplaces and the office of Site- In charge / Emergency controlroom and fire station for handling emergency situation.

Head/SOX


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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 allhazard potentials and safety measures needed in the work;planned for the day.

Supervisor

18.Display appropriate posters in locally understood languagesregarding safety at site.

HSE Coordinator

7 Records :

Record Title Record No. Location Responsibility RetentionPeriod

8 Verification, Corrective and Preventive Action :

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


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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 hazardouschemicals

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 Responsibil ity1. Definition : Manufacture, Storage and import of Hazardous

Chemicals Rule 1989 under the Environment Protection(EP) Act 1986 define ~Hazardous Chemicals' based ontoxicity, flammability and explosivity.

--

2. Legal requirements : The Factories Act and the EnvironmentProtection Act & the the Rules made under these actsrequire :

Identification & Labeling, Obtaining Material Safety DataSheet & 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 infactory shall willfully :

Misuse any appliance

Do anything likely to endanger himself or others

Neglect to make use of any appliance provided forsecurity, 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 healthhazards & recommended PPEs

Know how to use the information provided on the labels

Do not handle any unlabelled container. Check with yoursupervisor

Supervisor


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OCP No. : 01 SAFE HANDLING OF CHEMICALS Page 3 of 3

Sr. No. Activity Responsibil ity9. General :

Use no sparking tools and flame proof electricalequipment in the area where flammable chemicals areused stored

Follow established work permit systems

Periodically vent all drums containing volatile liquids, ifprovision is available

Do not keep any food stuff or take meals in the areawhere hazardous chemicals are stored / handled. Washhands before eating.

Do not use any solvent for cleaning hands. Use soap.

Maintain good house keeping standards and avoidspillage.

Clean the floor immediately in case of any spillage.

Change contaminated clothes immediately.

Never take the chemicals away from the job for personaluse.

Identify hazardous chemicals at your workplace andknow their properties.

Supervisor

7. Records :


8. Verification, Corrective and Preventive Action :



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Eff. Date : 15.06.2005

OCP No. : 02 ELECTRICAL SAFETY Page 1 of 2

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



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

5. Cross reference : OHSAS : 18001

6. Procedure :

Sr. No. Activity Responsibil ity1. 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 equipmentat two locations on the body.

Supervisor

5. Certified electricians shall carry out all electricalconnections and wiring.

Supervisor

6. Ensure that all extension boards have earth wire

connected and only three pin metal clad industrial typesockets are mounted on the board.

Supervisor

7. Never draw power from a socket by inserting wires intothe socket.

Supervisor

8. Always use metal clad three pin plug tops for drawingpower for electrical hand tools.

Supervisor

9. Use only three core flexible wire for electrical handtools. Connect earth wire properly to the body of thehand 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 insulationdoes 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 preventdamage due to movement of materials and vehicles.

Supervisor

14. Install proper distribution boards at different locations toavoid haphazard laying of electrical wires.

HOD / Site Incharge


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OCP No. : 02 ELECTRICAL SAFETY Page 2 of 2

Sr. No. Activity Responsibil ity15. Frequent inspections should be carried out to identify

damaged insulation, loose connections, improperfuses; lack of earthing etc. and remedial action shouldbe initiated immediately.

Supervisor

16. Introduce permit system for electrical safety. While menare at work on electrical lines or equipment formaintenance/repair, main switch should be cut off and

fuses should be removed. Warning signs should bedisplayed on the main switch.

HOD / Site Incharge

7. Records :

Record Title Record No. Location Responsibility Retention Period




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

OPERATIONAL CONTROL PROCEDURES 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 responseplan 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 periodof time i.e. continuous improvement

5. Cross reference : ISO : 14001

6. Procedure :

Sr. No. Activity Responsibil ity

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 Supervisor6. 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 place1. 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 distributionpipelines

Supervisor

7. Use thermostatic controller for cooling tower fans Supervisor


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Sr. No. Activity Responsibil ity8. Optimize need of refrigeration and also the refrigeration

temperatureSupervisor

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 / Mess1. Keep the entire cooking material ready before lighting thestove

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 cookingutensils

Supervisor

6. Prefer small burner and light flame Supervisor

7. Ensure stable, bright and blue flame. Reduce flame whenboiling starts

Supervisor

8. Use only ISI mark stoves and kerosene wicks stove Supervisor

9. Use pressure cookers Supervisor10. Cook different types of food simultaneously by using

separatorsSupervisor

11. Avoid often re-heating of food, store food in insulatedcontainers.

Supervisor

D. On the road1. 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 changinggears

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


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7. Records :


Record for requiredillumination level invarious work area

1 HOD office HOD 1 year

MMD calibration record 2 Concernedarea

Supervisor 1 year

Waste record on fuel / oilleakage

3 Concernedarea

Supervisor 1 year

Preventive maintenancerecord for variousequipment

4 HOD office HOD 1 year

Vehicle service record 5 Concernedarea

Supervisor 1 year




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Eff. Date : 15.06.2005

OCP No. : 04 SAFE WELDING AND GAS CUTTINGOPERATION

Page 1 of 2

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

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

3. Responsibility : Concerned Head/ SOX

4. Performance criteria Number of such incidents/ accidents reported


6. Procedure :

Sr. No. Activity Responsibili ty1 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 uprightposition and ensure that they are not knocked over

Operator

3 Check that the valves of the gas cylinders are lightly shut whennot in use.

Operator

4 Do not release gas from the cylinder unless pressure regulatoris fitted to its valve. Operator

5 Use gas hoses specially designed for the purpose with standardcolour code.

Operator

6 Use proper clamps for hose connections, Check leakage fromhose connections before starting work. Never use steel wires forclamping.

Operator

7 Take care that there are no kinks in the hoses and the hosesare laid such that nobody steps on the hoses and these do notget damaged due to activities in progress in the vicinity.

Operator

8 Use flame flash back arrestors to avoid back firing in flammablegas cylinders.

Supervisor

9 Open the valve of oxygen gas first and then flammable gas forlighting the torch. Operator

10 Use friction gas lighters only for lighting the torch. Never usematches or smoldering manila ropes or rags for lighting thetorch.

Operator

11 Protect the gas cylinders and hoses from welding sparks or gascutting sparks falling on them.

Operator

12 Ensure that the valve key is easily accessible to close the valveimmediately in case of emergency.

Operator


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Eff. Date : 15.06.2005

OCP No. : 04 SAFE WELDING AND GAS CUTTING

OPERATION Page 2 of 2

Sr. No. Activity Responsibili ty13 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 thehoses in which gas had backfired.

Supervisor

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

Supervisor

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

7. Records :





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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 Responsibil ity1 Ensure safe access to and means of escape from all site

locationsSite Incharge

2 Construct temporary building like site offices and materialsstores with non combustible materials.

Site Incharge

3 Keep adequate safe distance between temporary buildings.Recommended safe distance of temporary sheds from mainbuildings is approx 15M and 9M from each other

Site Incharge

4 Provide free space between each section of the storedmaterials to allow access for fire fighting

Concerned HOS

5 Store inflammable materials separately Concerned HOS

6 Avoid using combustible materials for form work andscaffolding. Concerned HOS

7 Remove combustible packing material from the siteperiodically 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 inflammablematerials are stored.

Site HSE Coordinator

10 Dont light any fire in or around storage areas for cooking orany other purpose.

Concerned HOS

11 Inspect the work place thoroughly where welding and gascutting operations are to be carried out and remove anyinflammable materials around, before starting work

Concerned HOS

12 Ensure that welding and gas cutting sparks do not fall oncombustible materials. In case it cannot be avoided, coverthe materials with metal sheet

Supervisor

13 In case, welding or gas cutting has to be done on a vesse,lpipe or container, which contains or had earlier containedflammable liquids; ensure purging inerting and issue workpermit before starting work

Concerned HOS


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Sr. No. Activity Responsibil ity14 Ensure that there is no leakage of gases from hoses or hose

connections fitted with the gas cylinders before starting gascutting.

Supervisor

15 In case of electric welding, check that there are no looseconnections in welding cables and earth connection.

Supervisor

16 Do not leave electric circuits on or gas cutting torchesburning 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 aspossible to escape routes


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


21 Mark the type of extinguishers and the class of fire for whichthese are meant, conspicuously at each location


22 Maintain the fire extinguishers in fully charged and operablecondition


23 Inspect the extinguishers monthly to ensure that they havenot been actuated or tampered with and to detect anyphysical damage or corrosion


24 Recharge the extinguishers on expiry Site HSE Coordinator

25 Maintain effective communication system to site in chargeand fire safety officer from all fire hazard areas

Site Incharge

26Display telephone numbers and residential addresses of sitein charge, Fire safety officer, security officer, Fire brigade,doctor and police near each telephone


27 Post round the clock guards trained in fire fighting, atvulnerable locations

Site Incharge

28 Form fire-fighting teams with site supervisors, subcontractors, personnel and security guards. Impart adequatetraining 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 ofi) 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 fordifferent kinds of fire.

Prepare emergency plan indicating individualsresponsibility in the event of fire and keep theindividual properly informed.

Guideline for selection of type, size and quantity of fireextinguishers is annexed. However, exact requirement maybe determined in consultation with local fire authority and orthe underwriters



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7. Records :





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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)


4. Performance criteria decreasing number of such incidents/ accidents


6. Procedure :

Sr. No. Activity Responsibili ty1. 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


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Eff. Date : 15.06.2005

OCP No. : 06 SAFE USE OF HAND TOOLS Page 3 of 3

Sr. No. Activity Responsibili ty3.6 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 doesnot 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 :


8.0 Verification, Corrective and Preventive Action :



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Eff. Date : 15.06.2005

OCP No. : 07 FIRST AID Page 1 of 1

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



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


6. Procedure :

Sr. No. Activity Responsibil ity

1. Identification of location for putting up first aid boxes HR

2. Making of emergency medicines / first aid materials inconsultation with doctor

HR

3. Making / display of important telephone numbers ofhospitals / ambulance / fire brigade / local police

HR

4. Impart first aid training to various categories of staffduring breathing problem / electric shock / cuts and

wounds/ burns / suffocation / eye injury / poisoning /fracture

HR

7. Records :


First Aid training records FA-01 HR Three years

8. Verification, Corrective and Preventive Action:



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Eff. Date : 15.06.2005

OCP No. : 08 FOOD SAFETY AT CANTEEN Page 1 of 2

1. Purpose : To avoid food borne illness


3. Responsibility : HRM Department

4. Performance criteria : Exception points at management reviews.


6. Procedure :

Sr. Activity Responsibility

1 Legal Requirements :

Analysis of food samples by public analysts

Restriction on dose of irradiation for onions, potatoes,spices, mangoes, rice, dried fruits, and meat products.

Restriction on use of synthetic food colours in cakes/fruitdrinks

CanteenCommittee/CanteenContractor

2 Necessary steps at the time of procurement of raw materials

for canteen :To insist the contractor to buy Agmark/ISI certified productsviz. 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 orabove 60 degree C.3.Keep raw meat, poultry eggs, seafood and their juicesaway from ready to-eat foods

Contractor/CanteenCommittee.

5 Protection of food from insects. Contractor

6 To avoid contact between raw foodstuffs and cooked foodsthrough hands, flies, utensils or unclean surfaces.

Contractor

7 Food preparation- to keep the food preparation premises meticulously clean.

Canteen Contractor


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Eff. Date : 15.06.2005

OCP No. : 08 FOOD SAFETY AT CANTEEN Page 2 of 2


8 Avoid Biological Bacteria :-Wash hands thoroughly before start preparing or servingfood and after every interruption, esp. if you have used thetoilet.-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 waterafter cutting raw meat and poultry products and beforeslicing 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 canteenstaff/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. Incase of any deviation, shall take suitable corrective and preventive action.


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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


6. Procedure :

Sr. No. Activity Responsibil ity1 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 isrequired 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 thecrawler or tires to distribute load

Operator

4 Deploy only trained and experienced operators with validlicense 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 especiallyclutches, brakes and controls

Concerned HOD

7 Ensure that boom and hoist cut off limit switches areoperational

Supervisor

8 Before starting the crane, see that all the guards of movingparts are properly fitted

Operator

9 Shut off the engine when clearing, adjusting or lubricatingthe machine

Operator

10 Do not over lubricate the parts. Clean overflowing lubricants Supervisor

11 Keep the crane boom length as short as possible formaximum lifting capacity and greater safety

Operator

12 Do not work with the boom to close to the vertical, becausea sudden release of the load may throw the boom back overthe cab

Operator

13 Depute only trained and experienced riggers for slinging thematerials to be lifted

Supervisor

14 Ensure that only one person gives signals to the craneoperator

Supervisor


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Eff. Date : 15.06.2005


Sr. No. Activity Responsibil ity15 Before lifting load, be sure about the weight of the material.

When lifting near capacity load, calculate entire loadcarefully including hook block and slings; and check itagainst rated lifting capacity

Operator

16 Test the host brake by raising the load a few inches andholding it should hold easily

Operator

17 Dont pull sideways on the boom not even a little hit Liftstraight up on every load

Operator

18 Never move a crane away from the load while handling nearcapacity 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 surroundingpersonnel 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 Operator24 While loading or unloading a truck, never swing the load

over the truck cabinOperator

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 hasdone 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 boombeing thrown back over the cab

Operator

29 When the load is to be lifted to a higher elevation, tie theload with a manila rope to guide the load while in the air, sothat it does not strike any building or structure duringswinging

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. Donot allow any one on the ground to touch the crane. In caseit is absolutely necessary to leave the cabin, jump out; dontstep down

Operator

32 Do not leave the cabin with engine running or load in the air Operator


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Eff. Date : 15.06.2005


7. Records

Record Title Record No. Location Responsibility

Retention time

Crane fitnesscertificates

CR 01 RespectiveSite

SiteIncharge

Till deploymenyof crane

Maintenance records /TCs of wires. slings

CR 02 -do- SiteIncharge

Till deploymenyof wires/ slings




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Eff. Date : 15.06.2005

OCP No. : 10 STORAGE AND HANDLING OF GAS

CYLINDERSPage 1 of 2

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


3. Responsibility : Concerned Site Incharges

4. Performance cri teria : Exception points at management reviews.


6. Procedure :

S No. Activity Responsibil ity

1 While procuring gas cylinders, check that every cylinder is labeled withthe name of the gas and the name and address of the person by whomthe cylinder was filled

Indentors

2 Check that a warning is attached to every cylinder containingpermanent or liquefiable gas

Supervisor

3 Do not change colour of the cylinder Supervisor4 The cylinder should not be filled with any gas other than the one it now

containsSupervisor

5 No flammable material should be stored in the vicinity of the cylinder orin the same room in which it is kept Supervisor

6 No oil or similar lubricant should be used on the valves or other fitting ofthe cylinder

Supervisor

7 Please look for next date of test, which is marked on a metal ringinserted between the valve and the neck of the cylinder, and if this dateis over, do not accept the cylinder

Supervisor

8 Use trolleys and cradles of adequate strength, as far as possible, whilemoving the cylinders

Supervisor

9 Handle the cylinders carefully and dont allow the cylinders to fall uponone another or subjected to any shock

Handling staff

10 Dont slide or drop the cylinders Handling staff

11 Always keep LPG and other liquefiable gas cylinders in an uprightposition and see that they cannot be knocked over

Handling staff

12 Secure the cylinders used in horizontal position so that they cannotroll.

Handling staff

13 Store the cylinders in a cool, dry and well ventilated place under coverand 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


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Eff. Date : 15.06.2005

OCP No. : 10 STORAGE AND HANDLING OF GAS

CYLINDERSPage 2 of 2

S No. Activi ty Respons ibility16 Keep the cylinders containing flammable gases separated from

other gas cylinders by an adequate distanceSupervisor

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 leastdangerous to life and property and inform the supplier

Supervisor

21 Dont posses more than the following quantity of gas without a validlicense

Supervisor

Liquefied Petroleum Gas 100 Kg

(Flammable)

Disssolved Acetylene 15 Cylinders(Flammable)

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

(Total)

Chlorine 50 Cylinders(toxic gases)

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

7. Records :


Procurement /inspection records

GC - 01 Site Indenting dept. Till consumptionof cylinder


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

.


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Eff. Date : 15.06.2005

OCP No. : 11 MANUAL ARC WELDING Page 1 of 3

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


3. Responsibility : Concerned Head/SOX


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

6. Procedure :

ELECTRICAL HAZARDS

Sr. Activ ity Responsibil ity

1 All electrical equipment and the work-pieces should begrounded

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 atall times.

Supervisor

5 Dry gloves and rubber soled shoes should be worn Welder6 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 offimmediately and non-conducting materials should be used topull the victim from the live contact. A physician should becalled 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 beused to keep fume and gases from breathing zones and thegeneral work area.

Supervisor


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Eff. Date : 15.06.2005


NOISE


1 Ear muffs or earplugs may be used Supervisor

BURN PROTECTION

1 Worker should wear protective clothing made of fireresistance material

Supervisor

2 Pant cuffs or clothing with open pockets or other places on

clothing that can catch and retain molten metal or sparksshould not be worn.

Supervisor

3 High top shoes or leather leggings and fire resistance glovesshould 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 eyeprotection

Supervisor

9 Insulated gloves should be worn at all times when in contactwith hot items or handling electrical equipment.

Supervisor

FIRE PREVENTION

1 Welding should not be done in atmospheres containingdangerously reactive or flammable gases, vapours , liquid ordust.

Supervisor

2 All combustible materials should be removed from the welding

place.

Supervisor


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Eff. Date : 15.06.2005


RADIATION

1 Welding arcs should not be viewed except through weldingfilter plates

Welder

2 The casual passers by or welding operations should beprotected by the use of screens, curtains or adequatedistance from aisles, walkways, etc

Supervisor

3 Exposed skin should be protected with adequate gloves andclothing as specified.

Supervisor

SAFETY MEASURES IN RADIOGRAPHY

1 Permission from M/s BARC, Mumbai for use of radiographysource.

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 inradiographic 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 andarea of radiography to be cordoned off.

Supervisor

8 Only personnel certified by the site in-charge shall performNDE

Site Incharge

7. Records :





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Eff. Date : 15.06.2005

OCP No. : 12 SAFE USE OF HELMETS Page 1 of 2

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

2. Scope : PSER (HQs & Sites)

3. Responsibility Concerned HOD / Head/SOX



6. Procedure :

Sr. Activ ity Responsibili ty1 Ensure use of Safety Helmet by all the employees working at site

and the persons visiting the site for protection against headinjury

ConcernedSupervisors

2 Safety helmets shall conform to IS: 2925. Safety Coordinator

3 Safety helmet should be compatible with working requirementse.g.

Site Incharge

3.1 Helmet with chinstrap is useful for the person working in windycondition or repeated bending or looking upward.

Site HSEcoordinator

3.2 Helmet with head load ring is useful for the person carrying headload.

Check the helmet regularly for any signs of damage ofdeterioration. Replace the helmet immediately in case positivesigns of damage or deterioration are evident.

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

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

Adjust the headband and the chinstrap so that there are nochances of the helmet falling down.

Clean the helmet and its seat band regularly and change thesweatband 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 helmetbefore handing it over to a visitor.

Site HSEcoordinator


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Eff. Date : 15.06.2005

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

7. Records





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Eff. Date : 15.06.2005

OCP No. : 13 GOOD HOUSE KEEPING Page 1 of 2

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


3. Responsibility Concerned Site Incharges



6. Procedure :


1 Unload the materials where it is required. Materials normallytend to be dumped wherever space is open or where riggersfind 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 standardcode to avoid deterioration of materials and to ensure safetyof personnel handling the materials

Site Incharge

3 Keep the materials orderly and well stacked Supervisor

4 While stacking the materials, ensure that there is nohindrance in passages for movement of people

Supervisor

5 Dispose of bands, binders and other packing materials assoon as supplies are unwrapped

Supervisor

6 Place adequate number of suitable scrap bins, biodegradablewaste bins and non biodegradable waste bins in work area

Supervisor

7 Remove waste /scrap, generated during erection activitiesregularly from working area

Supervisor

8 Clean the work places and passages that are slippery dueto oil or water spillage. Sand or saw dust can be used forcleaning oil

Supervisor

9 Secure loose or light materials on open roofs and openfloors against wind

Supervisor

10 Always keep the elevated working platforms free fromunwanted tools, materials and scrap

Supervisor

11 Never throw materials or scrap from elevated locations tolower elevations. Take suitable measures to lower such itemssafely

Supervisor


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Eff. Date : 15.06.2005

OCP No. : 13 GOOD HOUSE KEEPING Page 2 of 2

7. RECORDS


8. VERIFICATION, CORRECTIVE AND PREVENTIVE ACTION ;



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Eff. Date : 15.06.2005

OCP No. : 14 SAFE EXCAVATION Page 1 of 2

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


3. Responsibility Concerned Head/SOX

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


6. Procedure :


1 Ensure proper barricading by ribbon/ rigid poles of theexcavated area

Head of Section

2 Proper side slopes of the excavation as per the type ofsoil should be maintained

Head of Section

3 If the side slopes cannot be provided due to spaceconstraints/ nearby structures

Head of Section

i)Before excavation sheet piling must be done to preventthe collapse of earth.

Head of Section

ii)Shoring and shuttering to be done Head of Sectioniii) As soon as the job is completed, immediate backfilling to be done

Head of Section

iv) Excavation below existing foundation must beavoided

Head of Section

4 Under water excavation to be done with propermechanical means.

Head of Section

5 A temporary coffer dam to be constructed whenexcavation is done by the side of water reservoir

Head of Section

6 No personnel be allowed within the swing area ofmechanical excavator when work is in progress.

Head of Section

7 In case of running plant permission must be obtainedfrom client for excavation.

Site Incharge

8 Before excavation in running plant, under ground pipesand cables to be de-energised

Site Incharge

9 Proper lighting to be arranged when the excavation iscarried out at night

Head of Section

10 Excavated earth to be dumped/ stored in a designatedplace only.

Head of Section


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Eff. Date : 15.06.2005

OCP No. : 14 SAFE EXCAVATION Page 2 of 2


11 Surplus earth to be transported and disposed in thearea provided by client. A written permission to beobtained.

Head of Section

12 Disposal and transportation of surplus earth to be donein a proper vehicle so that earth does not spill out.

Head of Section

13 Muck and slush generated from piling to be transported

in a closed container.

Head of Section

7. Records





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Eff. Date : 15.06.2005

OCP No. : 15 SAFE WORKING AT HEIGHT Page 1 of 2

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



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


6. Procedure :


1 SAFE USE OF SCAFFOLDS1.1 Provide scaffolds for all works that cannot be safety performed from

floor levelSupervisor

1.2 Ensure that the scaffold materials are of adequate strength for thepurpose it is to be used

Supervisor

1.3 Check scaffold components for damage and defect before use Supervisor1.4 Avoid using combustible materials for scaffolds Supervisor

1.5 For platforms, use planks of grade 1 quality at least 2 thick and 10wide; 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 Supervisor1.8 Planks used for platforms should overhang the supports by 150

300 mmSupervisor

1.9 Hold the planks together by splicing at the bottom Supervisor1.10 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 forplatforms higher than 2 M from floor level

Supervisor

1.13 Provide toe guards at the platform edges to eliminate hazard of toolsor other objects falling from the platform

Supervisor

1.14 Inspect the erected scaffolds regularly, if the scaffolds are to be usedfor a long period of time

Site HSEcoordinator

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 whileworking on a platform higher than 2 M from floor level

Supervisor

1.17 Do not allow persons to work from scaffold during storm or highwinds

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 allplatform levels

Supervisor


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OCP No. : 15 SAFE WORKING AT HEIGHT Page 2 of 2


2.0 SAFE USE OF LADDERS.

2.1 Use portable ladders for flights up to 4 M only Supervisor

2.2 Provide fixed ladders for flights above 4 M Supervisor

2.3 Place the ladder at an angle of 75 degrees (approx) from thehorizontal

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 anddistance between rungs is not more than 300 mm

Supervisor

2.7 Provide landings of minimum size 600 x 600 mm at intervals notmore than 6 M for fixed ladders. Check the ladders daily for anydefects

Site HSEcoordinator

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 amudsill 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 outany job standing on a ladder

Supervisor

2.11 Always face the ladder while climbing up or down Supervisor

2.12 Maintain three point contact while climbing up or down a ladder i.e.two hands and one foot or two feet and one hand on the ladder at all

the times.Avoid climbing up or down a ladder while carrying anything in hands.Lift tools, equipment and materials with a rope

Supervisor

7. Records





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Eff. Date : 15.06.2005

OCP No. : 16 SAFE FILLING OF HYDROGEN INGENERATOR

Page 1 of 2

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


3. Responsibility : Safety / Commissioning /Operation Department


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

6. Procedure :


1 To ensure that open flame ( welding, gas-cutting, smoking etc.)is never used in the vicinity of the generator and the Hydrogensystem ( consisting of Seal oil/Gas/ waste gas systems/Hydrogen cooler pipeline/ waste fluid system) as soon asGenerator is declared to be under commissioning/ it is inoperation.

CommissioningIN-charge/concerned SafetCoordinator

2 To ensure that Filling and emptying the Generator is done

preferably with the Generator at rest. Else Consumption ofCO2/H2 increases due to the whirling motion between themedium to be displaced and the medium admitted. This mayincrease the probability of an accident.

Commissioning

IN-charge/concerned SafetCoordinator

3 To ensure that ,If situation demands, Filling emptying should bedone at the most when Generator is at turning/barring gearspeed. At normal speed of 3000 rpm consumption of CO2/H2willbe enormous and hence should never be allowed.


4 To ensure that manufacturers recommendation/write-up/ O&Mmanual is available at site and the process is performed exactlyin line with manufacturer' recommendation. Ensure that , these

recommendations are properly understood by the persons whoare actually executing/supervising the subject activity.

CommissioningIN-charge/concerned Safet

Coordinator

5 To ensure that adequate cylinders of CO2/H2 is available (to bechecked before start of activity ). In case Gasses are providedwith pipelines then ensure that adequate quantity at appropriatepressure is available. Ensure that Air filling lines are in serviceand compressor is running. Air is available with proper dryness.

Concerned user


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Eff. Date : 15.06.2005

OCP No. : 16 SAFE FILLING OF HYDROGEN INGENERATOR

Page 2 of 2


6 To ensure that Seal oil system is put in auto ( never allow thisoperation while seal oil system is in manual mode) mode and allthe interlocks are checked.


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

Operation in-charge

8 To ensure that CO2 Flash evaporator is filled with heat transferliquid upto lower edge of the riser. Ensure that this equipment iscommissioned and its protection/interlocks are checked.

Operation in-charge

9 To ensure that the rubber flexible hose which connects air linewith compressed air filter ( at Generator gas unit) isdisconnected as soon as CO2/H2filling/ emptying activity starts

Operation in-charge

10 To ensure that all shutoff valve and three way valves in the gasvalve rack at the gas dryer and in the bottle rack are closedbefore start of Filling operation.

Operation in-charge

11 To ensure that only Flame proof lamps are used in theHydrogen filling area / Gas room for illumination purpose.


12 To ensure that Hydrogen Cylinders are handled properly at thetime of its unloading and fitting with manifold. Hydrogen cylindermanufacturers norms should be followed. While fitting thesecylinders 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)

CommissioningIN-charge/

13 To ensure that filled cylinders are always stored vertically up ,Empty cylinders are properly marked and stacked separately.

CommissioningIN-charge/

7. Records :





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Eff. Date : 15.06.2005

OCP No. : 17 ILLUMINATION Page 1 of 2

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

2. Scope : PSER HQs & Sites

3. Responsibility : Concerned HOD/ Head/SOX


5. Cross reference : OHSAS :18001

6. Procedure :


1 Provide adequate illumination at all work places and theirapproach passages/corridors. Refer recommended values ofillumination for different locations

HOD(HRM) / SiteIncharge

2 Ensure that artificial lighting do not cause excessive glare ordisturbing shadows


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


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

lamps


5 Provide emergency lighting to minimize danger in case ofpower failure



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Eff. Date : 15.06.2005

OCP No. : 17 ILLUMINATION Page 2 of 2


6 Recommended values of i llumination

S. No. Location Illumination(Lux)

A. Const ruct ion Area

1. Outdoor areas like store yards, entrance and exit roads 202. Platforms 503. Entrances, corridors and stairs 1004. General illumination of work area 1505. Rough work like fabrication, assembly of major items 1506. 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 2009. Electrical and instrument labs 450

B. Office

1. Outdoor area like entrance and exit roads 202. Entrance halls 1503. Corridors and lift cars 704. Lift landing 1505. Stairs 100

6. Office rooms, conference rooms, library reading tables 3007. Drawing table 4508. Manual telephone exchange 200

HOD(HRM) / Site Incharg

7. Records :

Record Title Record No. Location Responsibilit y Retention time




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Eff. Date : 15.06.2005

OCP No. : 18 HANDLING & ERECTION OF HEAVYMETALS

Page 1 of 2

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





6. Procedure :


1 Ensure proper maintenance of all the lifting machinery andtackles. Record of maintenance carried out should be available

Site Incharge

2 Inspect daily, before start of work, all such equipment and recordin a Daily Inspection Register

Concerned HOS

3 Test certificates of all the lifting machinery and tackles should bemaintained. Testing shall be done periodically s recommended bythe manufacturer

Site Incharge

4 Maximum safe working load shall be conspicuously marked on allthe lifting machinery and tackles

Concerned HOS

5 Ensure that the lifting machinery and tackles are not loadedbeyond maximum safe working load

Concerned HOS

6 Before lifting with a winch ensure proper anchoring of the winchand the pulleys. The pulleys must be checked thoroughly for anydefects

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 platformsor 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 Supervisor10 Never allow any person to ride on the loads being lifted Supervisor11 Deploy only trained and authorized operators for operating the

lifting machinerySupervisor

12 Ensure that only skilled riggers are engaged for slinging thematerial to be handled

Supervisor


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OCP No. : 18 HANDLING & ERECTION OF HEAVYMETALS

Page 2 of 2


13 Use of safety helmet, safety shoes and hand gloves by the riggersmust be ensured

Supervisor

14 Only one person should give signals to the operator to lifting themachinery

Supervisor

15 Ensure proper illumination of the area where material handling isin progress

Supervisor

16 Never carry out any welding in the boiler structure during drumlifting operation. This can damage wire ropes used for lifting ofdrum

Supervisor

7. Records :

Record Title Record No. Location Responsibili ty Retention time




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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 andsubcontractors by setting out the general requirements while conducting acicleaning activity and the specific requirements to avoid danger from specifichazards.


3. Responsibility : Concerned Head/SOX / Commissioning Head

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


6. Procedure :

Sr. Activi ty Responsibili ty

1 Identif ication 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 mainboiler 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 acidii) Rodineiii) Ammonium Bifluorideiv) Citric acidv) Hydrazine Hydratevi) Ammonium Hydroxidevii) Trisodium phosphateviii) Disodium phosphateix) Bleaching powderx) Hydrated lime or soda ashxi) Nitrogen gas

Supervisor


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Eff. Date : 15.06.2005



3 Identification of safety equipment:For Personnel -i) Gum boots 12 pairsii) Rubber gloves 12 pairsiii) Rubber or polythene aprons 12 nosiv) Helmets 12 nosv) Safety goggles (plain glass) 12 nosvi) Ear muffs 12 nosvii) Face masks(transparent, plastic) 12 nos

First aid box (containing dilute ammonium hydroxide, 50%

sodium bicarbonate solution, eye lotion, bandages, smellingsalts, Iodine, burnol, cotton and any other medicine prescribedby 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 pumpsii) Flushing water jetiii) Nitrogeniv) Tarpaulin and tin/asbestos sheetv) Fire extinguisher / tendervi) Ladder, temporary platform/scaffolding

Supervisor

5 For Environment i) Lime 20 Ton or Soda ash 10 Tii) Bleaching powder 5 Toniii) Neutralising pit at a safe location: 300 m3volume

Supervisor

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

ConcernedHOS

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 anypossible injury prior to start of activity.

Site Incharge

8 Work instructions explaining proper storage/ stacking, handling ofhazardous chemicals/gas to be pasted at identified hazardouslocations as identified in a)

ConcernedHOS

9 Notice board display and cordoning of identified hazardouslocations to prevent entry of personnel other than authorizedworking personnel

ConcernedHOS


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10 Prevention of any welding/ gas cutting at the time of acidcirculation. Possibility of localized explosion remains due topresence of hydrogen in acid fumes

ConcernedHOS

11 For working in electrical switchboard, related electrical safetyprocedure is to be followed

ConcernedHOS

12 For any repair/maintenance work in between the stages ofchemical cleaning, related site safety procedure is to be followedwith respect to handling, repair and maintenance equipment

ConcernedHOS

13 Working area should be cleared off all debris, scrap and non-related materials. Safe access to acid cleaning equipment is to beensured. Tin sheet roof is to erected over acid cleaning & transferpumping station, nitrogen blanketing station, electrical switchboardto prevent rain water falling over equipment

ConcernedHOS

14 To prevent surrounding plant equipment from any possibledamage, tarpaulin, tin sheet/asbestos sheet is to be used asguard

ConcernedHOS

15 Any area suspected to be contaminated by chemicals due toleakage or any other reason should be washed with copiousquantity water to dilute same and neutralized with lime before

leading to drain

ConcernedHOS

16 Makeshift covered store is to be utilized for storing the chemicalsnear to working area.Total area including workstations, passages, main boiler,staircases, neutralizing pit, road should be sufficiently illuminatedwith floodlight. In addition, hand lamps are to be made available

ConcernedHOS

17 All personnel handling the chemicals mentioned in step b) duringshifting, pouring in mixing tank & neutralizing pit and attending/guarding the leaking chemicals should wear protective clothing andgadgets mentioned in step c).

ConcernedHOS

18 Any person affected by acid or other chemicals should be treated

with flushed water first. If the affected area is considerable heshould be given a total shower bath. Cut or burn injury should betreated with proper medicine. For any inhalation of vapour, theaffected person should be taken to fresh air and administer artificialrespiration. For any eye injury due to chemicals first wash withwater and then apply eye lotion. For any injury of severe nature, heshould be transferred to hospital after applying necessary first aid.Trained medical attendants services should be utilized whileattending to the injured personnel.

Concerned

HOS


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19 All the effluent from boiler after chemical cleaning should beneutralized in neutralizing pit wherever necessary for maintainingpollution norm. Acidic water should be neutralized with lime orsoda ash. Effluent with Hydrazina and ammonia should be treatedwith bleaching powder

ConcernedHOS

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

Site HSEcoordinator

7. Records:

RECORD NO. TITLE AREA RETENTIONPERIOD

8. Verification, Corrective and Preventive Actions :



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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, BHELand sub contractors by setting out the general requirements while

conducting Oil Flushing activity and the specific requirements to avoiddanger from specific hazards.





6. Procedure :Sr. Activi ty Responsibili ty

1 Identification of hazardous locations:i) Oil storage area.ii) Turbo-generator floor, ground level , MOT level.

iii) Oil Pump stationiv) Oil Centrifuge area.v) Oil Piping from MOT to TG Bearings.

vi) Impure oil tank area.

Supervisor

2 Identif ication 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 Identif ication of hazardous gas:i) Oil Vapour

----

4 Identif ication of safety equipments:For Personnel i) Gum boots 12 pairsii) Rubber gloves 12 pairs

iii) Helmets 12 nos

iv) Safety goggles (plain glass) 12 nosv) Face masks(transparent, plastic) 12 nosvi) First aid box (containing dilute ammonium hydroxide,50% sodium bicarbonate solution, eye lotion, bandages,smelling salts, Iodine, burnol, cotton and any other medicineprescribed by plant medical unit doctor)For plant equipment i) Flushing water jetii) Fire extinguisher / tender.

Supervisor


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5 Pollution control acceptance criteria:Disposal of waste oil should be done cautiously without spilling iton the ground. The waste oil should be kept into either barrels orDirty oil tank.

Supervisor

6 Communication methodology i) Control room with telephone, PA system and walki talki.

Medical attendents full time presence is necessary.ii) Plant hospital to be sounded in advance for any possible

injury prior to start of activity.

Site Incharge

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

Site HSEcoordinator

8 Notice board display and cordoning of identified hazardouslocations to prevent entry of personnel other than authorizedworking personnel.

Site HSEcoordinator

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 safetyprocedure is to be followed.

Supervisor

11 For any repair/maintenance work during the process of OilFlushing,, related site safety procedure is to be followed with

respect to handling, repair and maintenance of equipment.

ConcernedHOS

12 Working area should be cleared off all debris, scrap and non-related materials. Safe access to Oil Flushing area is to beensured..

Supervisor

13 Any area contaminated with oil due to leakage or any otherreason should be covered with sand to avoid slippage as well asfire hazard.

Supervisor

14 Total area should be sufficiently illuminated with floodlight. Inaddition, hand lamps are to be made available.

ConcernedHOS

15 All personnel handling oil should wear protective clothing andgadgets mentioned in step c).

Supervisor

16 Any person affected by inhalation of oil vapour should be taken tofresh air and administer artificial respiration. For any eye injury dueto oil ingress first wash with water and then apply eye lotion. Forany injury of severe nature, he should be transferred to hospitalafter applying necessary first aid. Trained medical attendantsservices should be utilised while attending to the injured personnel.

Site HSEcoordinator

17 For any fire incident, applicable procedure is to be followed forextinguishing.

Site HSEcoordinator


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7. Records:


8. Verification, Corrective and Preventive Actions:



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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 customerBHEL and sub contractors by setting out the general requirements whileconducting Alkali Boil-out activity and the specific requirements to avoiddanger from specific hazards.





6. Procedure :


1 Identif ication 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 ofchemical solution, steam and water

Connected piping routing from Chemical cleaning station tomain boiler and neutralization pit

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

Supervisor

2 Identif ication of hazardous chemicals / gas:

Hydrazine Hydrate Ammonium Hydroxide Trisodium phosphate

Disodium phosphate

Supervisor


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Eff. Date : 15.06.2005

OCP No. : 21 SAFE ALKALI BOIL OUT Page 2 of 4


3 Identification of safety equipments:For Personnel -i) Gum boots 12 pairsii) Rubber gloves 12 pairsiii) Rubber or polythene aprons 12 nosiv) Helmets 12 nosv) Safety goggles (plain glass) 12 nosvi) Ear muffs 12 nosvii) Face ma

Operational Control Procedures Bhel

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