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![ANNEXURE – R
HAZARD IDENTIFICATION RISK ASSESMENT (HIRA)
ix. List of Key Personnel with addresses, telephone number etc.
KEY ELEMENTS OF THE ON-SEMP
Emergencies can happen at any time in any types of industry, due to fire in a
process area, tank form area, toxic gas/liquid release into the area from storage
vessels or piping network, or a bomb threat. The approach of the plan is to eliminate
or reduce the risk of injury or harm that may occur during an evacuation by
undertaking following steps:-
a) Classification and identifying potentially hazardous situations;
b) Assessment of the risks;
c) Implementation and compliance of the regulatory provisions as per the
Manufacture, Storage Import of Hazardous Chemicals (MS and IHC) Rule
1989 and Chemical Accidents (Emergency Planning, Preparedness and
Response) [CA (EPPR)] Rules 1996 schedule;
d) Consequences of defaults or non-compliance of regulations;
e) Statutory requirements;
f) Pre-emergency planning;
g) Emergency mitigation measures;
h) Emergency preparedness measures;
i) Emergency response procedures and measures;
j) Emergency organization and responsibilities;
k) Infrastructure requirements;
l) Procedures for declaration of on-site and off-site emergency;
m) Resources for controlling emergency;
n) Demographic information;
o) Medical facilities;
p) Evacuation;
q) Public relations and information to public;
r) Reporting of the incident;
s) Emergency recovery procedures;
t) Emergency plans for tank trucks and pipelines carrying hazardous
products;
PRE- EMERGENCY PREPAREDNESS
This may have following components:
a) Information on the preliminary hazard analysis:
b) Type of accident
c) System elements or events that can lead to a major accident
d) Hazards
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![PROJECTS DEVELOPMENT
INDIA LIMITED
Date:
Project No.: PC-00187
SHEET 3 OF 20
• First all operating parameters are checked and then, Load Testing at Proof Load and
Over-Load is carried out.
‘Form-10’ Certificate as per govt. Format is issued on successful Inspection Testing of the
products.
Note: Form-10 Certificate is issued by Competent Person as per State Govt. Format in Gujarat
State. However, state wise this Form No. is different.
Interval for Inspection testing:
As directed in the Section-29 of Factories Act, these Tests are carried out annually and Register
should be maintained for every product to keep record regarding Health of the Products.
SECTION – 29 OF FACTORIES ACT - LIFTING TOOLS AND TACKLES
1. In any factory the following provisions shall be complied with in respect of every lifting
machine (other than a hoist and lift) and every chain, rope and lifting tackle for the purpose
of raising or lowering persons, goods or materials :-
• All parts, including the working gear, whether fixed or movable, of every lifting
machine and every chain, rope or lifting tackle shall be –
• Of good construction, sound material and adequate strength and free from
defects;
• Properly maintained; and
• Thoroughly examined by a competent person at least once in every period of
twelve months, or at such intervals as the Chief Inspector may specify in
writing, and a register shall be kept containing the prescribed particulars of
every such examination;
• No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of
test, be loaded beyond the safe working load which shall be plainly marked thereon
together with an identification mark and duly entered in the prescribed register; and
where this is not practicable, a table showing the safe working loads of every kind
and size of lifting machine or chain, rope or lifting tackle in use shall be displayed in
prominent position on the premises;
• While any person is employed or working on or near the wheel track of a traveling
crane in any place where he would be liable to be struck by the crane, effective
measures shall be taken to ensure that the crane does not approach within 63[six
meters] of that place.
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- 8. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 8 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. roof structure material is allowed for trailer driving. • Proper equipment should be used to lift and shift the material. Lifting work by using Hydra/Cran e toppling • Hit by objects. • Vehicle accident. • Failure of lifting tools & Tackle. • Trip / fall hazard 4 5 20 A • T.P.I certified hydra / crane should be used to pull the loads. • All cranes / hydras used in the lifting / shifting the material should be fit for the laying activity. • Ground conditions should be assessed prior to setting up the crane / hydra for lifting the material. • No tandem lifts should be carried out and no hydras should be used to transport the material. • No lifting activity should be carried out if wind speed is more than 9.8m/min. 3 3 9 B • Basic PPEs S S P • Fall of plates during lifting 4 5 20 A • Plates should be unlashed only after inspection and confirmed that it will not slip from the trailer. • Enough support should be provided to all Sides of trailers. • Plate clamps should be used to 3 3 9 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 9. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 9 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. lift plates. • One plate should be lifted at a time. • No plates should be lifted with forklifts. • Plates should not be pushed or pulled from the trailer. • Area of lifting radius / material movement should be barricaded • Failure of lifting tools. 5 4 20 A • Proper lifting tools shouldbe selected and used. • Lifting tools should not be subjected to tensions and should not be used to pull the loads. • Damaged lifting tools should not be used. • All lifting tools should be inspected prior to use. • All lifting tools should be protected from sharp edges. • All lifting tools should have TPIs & should be colour coded according to the project colour code. 3 3 9 B • Basic PPEs S S P • Hit by object 5 3 15 A • No lifting should be carried out during high wind conditions. • Load should be controlled by guide ropes & should not be 3 3 9 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 10. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 10 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. handled directly. • Area of plate handling shouldbe kept barricaded to restrict the entry of unwanted personnel. • Proper sign boards should be displayed. • No one should be allowed to work under the suspendedload. 5 Loading and Unloading of steel plates using Hydra/ Crane • Hit to men or materials 5 5 25 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Plate clamps should be used to lift plates. One plate should lift at a time. • No plates should be lifted with forklifts. • Ensure trained and competent personnel operating tower crane to lift the Bucket • Tool Box Talks to be conducted before start of the activity. • Ensure the LG and machines have legal documents Like TPI. • Ensure before starting the work physical inspection should be done for the crane and Sand Bucket using the check list 3 1 3 C • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 11. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 11 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. 9.Provide proper tag line to avoid oscillation. • Deploy trained signal man for proper lifting • Ensure Sign boards should be provided. • Ensure hooks in the Sand Bucket should be properly inspected before lifting • Ensure No man movement in the lifting area • Ensure Proper supervisionuntil the task complete. • Ensure no person should work underneath the Suspended load. • Barricade the Lifting area before starting the work. Offloading & movement of steel plates, Structure material • Fall of Materials • Fall of steel plates. 5 5 25 A • Deploy trained riggers for loading and unloading of Steel plates materials • Ensure web slings are free from damage. • Ensure while slinging rigger must worn with safety Harness. • Use Proper communication device for safe signalpropose. • Provide proper tag line to avoid oscillation. 3 1 3 C • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 12. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 12 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • 5.While loading the teeth of the VR hook should be inserted fully in the • Avoid overloading. • Ensure Center of gravity should be stable while loading and unloading. • Ensure proper supervision until the task complete. • 8. Provide proper PPEs for the work men who work in the activity. Lifting work by using Hydra/Cran e toppling. • Hit by objects. • Vehicle accident. • Failure of lifting tools & Tackle. • Trip / fall hazard 5 5 25 A • Inspected hydra / crane should be used to pull the loads. • Ground conditions should be assessed prior to setting up the crane / hydra for lifting the material. • No lifting activity should be carried out if wind speed is more than 9.8m/min. • Flagman should be assigned to guide the traffic. • Drivers should follow the traffic rules while driving inside the project areas. • No lifting activity should be carried out during night shiftif 2 1 2 C • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 13. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 13 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. sufficient illumination is not provided. • All lifting tools should be inspected before taking in to use for damages. • All lifting tools should have TPI certificates. • Lifting tools should not subject to tensions and should not be used to pull any material. • Employees should use crow bars while handling the material. • Leather hand gloves shouldbe used while handling the material. • Proper coordination is to be maintained between the crew while handling the material. • Outriggers to be fully extended on stable/solid & even ground, using wood sole plates (if applicable). • Stop crane lifting in rainy, foggy weather or during dust storm. Monitor wind factor, If wind velocity exceeds established maximum speed limit, stop all lifting operations. Download HSE Docs hseprof.com
- 14. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 14 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Signal to the crane operator should be given by rigger only and not by any unauthorized person. • Required number of riggers should be provided. Using Chain block, Come along, slings, shackles • Defective or damaged chain block, Come along, slings, shackles, wire rope 4 3 12 A • All lifting equipments (chain blocks, come along sling, and shackles) must be inspected & certified • Determine load & always stay within the SWL of the lifting/pulling equipment. • Never use live pipelines and fragile structures to hang chain pulley for lifting a load. AVOID sharp contact, Avoid shock loads. • Avoid pinch point. NEVER leave a suspended load unattended 2 2 4 C • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Forklift Operations • Failure of load • Unauthorized use of forklift. • Unauthorized movement of forklift. • Speeding with forklift. 3 3 9 B • Only use Forklift trucks that are inspected, certified and roadworthy. • Only allow certified and experienced forklift operators to operate forklifts. • Forklifts should be accompanied during travel and operations. 2 2 4 C • Hard Hat, • Leather gloves, • Safety glasses • Safety shoes • Coverall S S P Download HSE Docs hseprof.com
- 15. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 15 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Unsafe loading of forklift. • Inexperienced and un-licensed operator. • No flagman during operations and travel. • Roll over • Personnel hit by Forklift • Forklifts should never be operated at speeds in excess of the required maximum speed (should be at walking pace). • Operator must wear a seat-belt. • Only materials and equipment to be loaded and moved. • Forklifts are NOT ALLOWED TO TRANSPORT OR LIFT PASSENGERS. • Ensure fitness of equipment. • Secure the load and maintain load integrity. • All hydraulic systems shouldbe tested before use. • Forklift Operations must conform to all relevant GNFC safety procedures. • Reflective vests to be worn by the flagman Fabrication of Exposure to heat and hot material • Hot work • Careless handling of lighted cutting torch, hot particles may cause burns. • Using cutting torch too close to combustible • Plasma cutting should be carried out in an isolated area. • Enough drinking water shouldbe made available in the fabrication yard. • Proper breaks should give to the employees engaged in the plasma cutting. • Flask back arrestor at both sides shall be used for gas cutting set. • Hard Hat, • Rubber gloves, • Safety glasses, • Safety shoes, • Coverall • protective clothing, plate and structure material. 6 5 3 15 A 2 2 4 C S S P Welding, cutting & grinding (Hot Work) if Download HSE Docs hseprof.com
- 16. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 16 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. required materials / personnel. • Gas leaking from hoses / valves or flash back arrester • Gas cutting set shall be up right position and secured by chain. • Wear protective clothing, gauntlets, face shield and welding glass along with other regular PPEs. • Ensure to have proper fire blanket and barrication. • Keep suitable fire extinguisher nearby with a fire watch. • Keep hoses clear of sharp edges & abrasives. • Do not allow hot metal or spatter to fall on hoses. • Clamp the work piece, don’t hold it by hand. • Work in safe location and maintain safe distance of at least 5 feet distance between two personnel. • Ensure cutting torch is fitted with spring loaded non return valve to prevent backflow. • Ensure to have flash back arresters to protect cylinders from flashbacks. • On return valves to prevent oxygen reverse flow in tofuel • gauntlets, • face shield • welding glass/ shield Download HSE Docs hseprof.com
- 17. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 17 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. line & vice versa. • Turn off cylinder valves when not in use. • Handle cylinders carefully and always keep them in an upright position and fasten them to prevent them from falling. • Drainage manhole near the location must be cover by fire blanket. • Fire watcher must be at site while work is in progress. • Electrocution 5 4 20 A • All connections of the plasma cutting machine should be done through proper rated ELCBs and ELCBs should be inspected and recorded on periodic basis as per project requirements. • Proper earth should be provided to all required parts of the plasma cutting machine. • No employee other than electrician should carry out the maintenance of the electrical systems of the machine. • No substandard joints of cables are accepted. • Operator & electrician should 1 3 3 C • Hard Hat, • Rubber gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 18. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 18 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. inspect the machine every day before starting the job. • Burn & cut injuries, personal injuries 5 4 20 A • Employees should be provided with proper hand gloves and clothing. • After cutting plates, scrap should be disposed properly. • Proper handling of scrap material. 2 2 4 C • Basic PPEs • Proper hand gloves and clothing S S P • Fire 5 3 15 A • Obtain hot work permit. • All combustible material should be removed under the cutting area. • Metal plates should be placed under the bed & area under the bed of machine should be closed with metal sheets to avoid. • Proper fire extinguisher shall be provided for all hot work. 1 3 3 C • Hard Hat, • Rubber gloves, • Safety glasses, • Safety shoes, • Coverall. 7 Rolling and bending of plates and angles Lifting work by using Hydra/Cran e toppling • Hit by objects. • Vehicle accident. • Failure of lifting tools & Tackle. • Trip / fall hazard 5 5 20 A • Inspected hydra / cranes should be engaged in plate rolling. • Alternative arrangement using power operated chain blocks should be made. • Hydra / cranes used in rolling of plates, proper coordination should be maintained. • Proper coordination should be 2 3 6 B • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 19. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 19 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. maintained between hydra/ crane operators & rolling machine operator. • Hydras /crane should not be left unattended while it is being used to control the load whichis placed in bending machine. • Crush injuries 5 4 20 A • Only trained operators should be engaged in the bending / rolling operation. • All rotating parts of the bending machine should be guarded. • Proper fencing should be maintained around the machine. • After rolling, rolled platesshould be stored properly and should be locked against rolling from stored place. 2 2 4 C S S P • Injuries due to sharp edges 5 4 20 A • Leather hand gloves shouldbe used to handle plate. • Employees should be provided with full body protective clothing. • Guide lines should be usedto control the load. • Area of lifting / shiftingshould be barricaded. • Proper coordination between 1 3 3 C • Basic PPEs (Safety helmet, Safety Glass, Leather gloves, Safety Shoe) • Full body S S P Download HSE Docs hseprof.com
- 20. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 20 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. crew to avoid communication gap. protective clothing • Electrocution 5 4 20 A • Rolling machine should be placed at proper location. • No one other than electrician should be allowed to do the electrical maintenance work for the machine. • Machine should be inspected on daily basis and thoroughly on periodic basis for identifyingany damages. 1 1 1 C • Basic PPEs • Full body harness • Respirator • Dust coverall S S P 8 Hot work (welding, cutting ,grinding) • Electrocution 5 5 25 A • Welding machine should be placed at proper location. • Electrical cables of machines should be protected from the damages. • No one other than electrician should be allowed to do the electrical maintenance work for the machine. • Proper earth should be provided to the machine. • Power supply of the machine should be provided through proper rated ELCBs or GFCIs. • Machine should be protected from rain and other bad weather 3 3 9 B • Basic PPEs • Rubber Gloves S S P Download HSE Docs hseprof.com
- 21. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 21 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. conditions. • Machine should be inspected on daily basis and thoroughly on periodic basis for identifying any damages. • Cables should be protected from the damages due to its exposure to sharp edges. • Cables should be protected from hot surfaces. • Plugs of welding machine should not be inserted / removed from the sockets while socket is live. • Naked electrical cable should not be allowed. • Fire 5 4 20 A • All combustible material should be removed from the area. • Buds of the welding rods should be collected and disposed at proper location. • All electrical connections should be made with proper plugs, sockets, connectors. • No loose connections are allowed. • Cables with damage insulation should be taken out of use. • Welder should inspect the 2 4 8 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 22. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 22 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. cables every day for identifying damages. • Electrical supply of welding machine should be switchedoff • Fire extinguishers should be made available at site and employees should be trained to use the same. • Burn injuries 5 4 20 A • Employees engaged in the hot works should be provided with proper PPEs & its use should be ensured. • Welding flux should be disposed in proper manner. • Welding rod buds shouldbe disposed at a designated location only. • Welder / employees engagedin over head hot works should be provided with leather apron & leather sleeves. 3 3 9 B • Basic PPEs • Leather apron • Leather Coveralls S S P • Damage to gas cylinder & hoses 5 5 25 A • Hoses should be laid in proper manner. • Hoses should be protected from sharp edges. • Hoses should be checked for damages on daily basis and if it is cracked, cut it should be 2 4 8 B • Basic PPEs • Repertory mask S S P Download HSE Docs hseprof.com
- 23. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 23 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. replaced. • Cylinder should be stored away from the work area in the proper trolley. • Soap solution should be kept available to identify gas leaks from hoses and connections of gas cylinders. • Cylinder should not be rolled & should be kept upright even ifit is empty. • Fall of person from height 5 5 25 A • Only trained employees should be engaged in working at height. • Employees should be medically fit for working at height. • Working at Height” permit should be taken prior to starting the work. • Proper scaffolding platform should be provided to the employees working at height. • Fall arrestors, full bodyharness should be provided & its use should be ensured. • 100% tie off should be explained and practiced. • Scaffolding should bedesigned & erected properly; no 3 3 9 B • Basic PPEs • Fall arrestors • Full body harness S S P Download HSE Docs hseprof.com
- 24. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 24 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. alteration should be done by authorized personnel while working on it. • Platforms should be constructed in such a manner that there should not be any gaps in the platform, proper toe guard should be provided to the platforms of the scaffolding. 9 Cutting of steel using bar cutting machine • Crush Injury • Hit the men due to temper. 5 4 20 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Deploy trained worker for to cut the steels • Tool Box Talks to be conducted before start of the activity. • Ensure the machine is inspected by EHS dept before entering to site and color coded. • Ensure safety guard provided for the rotating parts of machine. • Pedal guard/Hand lever protection against accidental activation. • Ensure cover guard protection for cutting part of machine. • Place re bar in position and 3 1 3 C • Hard Hat, • Leather gloves, • Safety glasses, • Safety shoes, • Coverall. S S P Download HSE Docs hseprof.com
- 25. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 25 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. cover before activating the foot pedal/Hand lever. • Rods should be hold tightly while cutting. • Provide proper PPEs for the work men who work in the activity. • Adequate supervision until the task completed. 10 Roof plate and compressor ring dismantling & erection • Crane / hydra toppling 5 5 25 A • Obtain work permit. • Lifting shall be carried out as per procedure. • All cranes / hydras used in the lifting / shifting the material should be fit for the laying activity. • Ground conditions should be assessed prior to setting up the crane / hydra for lifting the material. • No tandem lifts should be carried out and no hydras should be used to transport the material. • No lifting activity should be carried out if wind speed is more than 9.8m/min. 3 3 9 B • Basic PPEs • Fall arrestors • Full body harness S S P • Fall of person 4 5 20 A • Only trained employees should 3 3 9 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 26. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 26 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. from height be engaged in working at height. • Employees should be medically fit for working at height. • Working at Height” permit should be taken prior to starting the work. • Proper scaffolding platform should be provided to the employees working at height. • Full body harness shall beused for height work • Proper life line or anchoring point shall be provided • Barricaded the effecting radius. • Fall arrestors • Full body harness • Fall of plates during lifting, demounting & after installation 4 5 20 A • Barricaded the effecting radius. • All the plate shall be properly weld to avoided any fall • Remove all unwanted materials from height • After erection the job engineer shall be check and ensure there is no any lapse. 2 4 8 B • Basic PPEs • Fall arrestors • Full body harness S S P 11 Installation of hydraulic jacks and lifting of tank • Fall of lifted material due to failure of jacks 5 5 20 A • All jacks should be inspected for damages before taking it into use. • All hydraulic hoses shouldbe laid properly & should be prevented from damages. 4 3 12 A • Basic PPEs • Fall arrestors • Full body harness S S P Download HSE Docs hseprof.com
- 27. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 27 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Hydraulic jacks and its accessories selected should be more the 1.5 times of the load which is being lifted. • Approximately 20 hydraulic jacks each capacity of 12 ton shall be use to lift the tank step by step. • Before start lifting of tank, it must be ensured that all shell plates are welded properly and are safe for lifting. • Tank shell to be lift Maximum 2.6 meter height • After reaching the required height of lifting of each level, lifted shell should be properly supported to prevent its fall from height. • Jacks should be placed at appropriate locations of the tank to avoid fall of shell due to bending of shell plates. • Pinch point injuries & crush injuries 4 5 20 A • Proper coordination should be maintained between the crew engaged in the lifting of shell. • No employees should allow passing under the shell while it is being lifted. 3 2 6 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 28. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 28 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • All area around the tank should be kept barricaded while shell is being lifted & proper warning signs should be provided. • Hydraulic oil spillage 4 5 20 A • Hoses used for jacks should have proper fittings & should sustain the required pressure. • Spill kit should be made available & employees should be trained to use the same. • Drip trays should be used while refilling the oil. • Spilled oil must be cleaned off immediately. 2 2 4 C • Basic PPEs • Spill kit • PVC Suit S S P • Fall of person on same level due to slip & trip hazards 5 4 20 A • Proper housekeeping needs to be maintained all the time. • Hoses, cables should be laid properly. • Proper access should be maintained to enter the tank after installation of shell plates. 3 1 3 C • Basic PPEs S S P 12 Lifting of roof structure by hydraulic jack • Fall of lifted material due to failure of jacks 5 5 25 A • All jacks should be inspected for damages before taking it into use. • All hydraulic hoses shouldbe laid properly & should be prevented from damages. • Hydraulic jacks and its 4 3 12 A • Basic PPEs • Fall arrestors • Full body harness S S P Download HSE Docs hseprof.com
- 29. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 29 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. accessories selected should be more the 1.5 times of the load which is being lifted. • Approximately 20 hydraulic jacks each capacity of 12 ton shall be use to lift the roof structure step by step. • Maintain minimum 30 mm distance from shell to truss during lifting. • Packing plates used between ram of the jack and structure being lifted should be welded to prevent fall of structure due to its slipping. • Maximum 2.3 meter shall be lift by the help of jack. • Lifting should be carried out gradually & no lifting should be done more than 2.3meter height of the jack to avoid the toppling of jacks. • Hydraulic oil spillage 4 5 20 A • Hoses used for jacks should have proper fittings & should sustain the required pressure. • Spill kit should be made available & employees should be trained to use the same. 2 1 2 C • Basic PPEs • Spill kit • PVC Suit S S P Download HSE Docs hseprof.com
- 30. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 30 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Spilled oil must be cleaned off immediately. 13 ND Testing – DP Test, Radiography, Vacuum Test • Exposure to chemicals • Exposure to the radiation 5 5 25 A • Proper masks should be provided to crew engaged inthe DP test. • MSDS of chemicals used in the DP test should be available and it should be explained to the employees engaged in the DP test. • Eye protection should be usedto prevent eye injuries. • Ensure radiography permit is obtained • Proper communication to be done to all personnel working inside • Barricade and clear off all personnel in the affected area. • Ensure the standby man people at all the entry point to be effected area. • Confirm sign board is place at all entry point. • Locate the flash light at prominent place. • Preferable time for the 2 3 6 B • Basic PPEs • Eye protection • Proper Mask S S P Download HSE Docs hseprof.com
- 31. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 31 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. radiography is break times and shift change/over time. • Fire, burn injuries 5 3 15 A • No dye, chemicals should be sprayed on the hot surfaces / open flames. • Cans of dye, chemicals used for DP testing should be disposed at designated locations & should not be exposed to heat. 1 3 3 C • Basic PPEs S S P • Hazards associated with radiography 5 4 20 A • Follow the safety requirements for the radiography & radiography permits to carry out the radiography. • Radiography should be pre planned and informationabout the same should be passed to other contractors working adjacent to the work area. • Competent radiography technician shall be engaged for radiography work. • All safety material like safety sign board, dosimeter, survey meter, and warning light shall be provided. • BARC Authorized radiography agency shall be engaged for radiography work. 3 3 9 B • Basic PPEs • Eye protection • Proper Mask S S P Download HSE Docs hseprof.com
- 32. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 32 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Separate PIT room shall be provided for handling andstore the source. • Fall of person due to bad lighting and housekeeping 5 3 15 A • Proper lighting arrangements should be made to work inside the tank. • Hoses, cables should be laid properly and maintained the same • Daily housekeeping should be practiced at the end of the day. • Proper working platform if RT works at height. 2 2 4 C • Basic PPEs S S P 14 Nozzle installation • Fall of person from height 5 5 25 A • Only trained employees should be engaged in working at height. • Employees should be medically fit for working at height. 3 2 6 B • Basic PPEs • Fall arrestors • Full body harness S S P • Fall of material from height 5 4 20 A • Material should not be stacked on the scaffolding or any other place at height. • Platforms should be constructed in such a manner that there should not be any gaps in the platform, proper toe guard should be provided to the platforms of the scaffolding. • Structure components should 3 3 9 B • Basic PPEs • Fall arrestors • Full body harness S S P Download HSE Docs hseprof.com
- 33. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 33 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. not be left suspended with the lifting tools. It should be tack welded to its position. • Only qualified tack welders should be allowed to do the tack welds. • Material should not be stacked on high Elevations. 15 Painting work at tank outer shell (work at height) • Fall of person from height 5 5 25 A • Only trained employees should be engaged in working at height. • Employees should be medically fit for working at height. • Working at Height” permit should be taken prior to starting the work. • FBH shall be provided for height work. • If ladders are used, it should be secured prior to start working on it. • Proper life lines should be installed and used while working at height 3 3 9 B • Basic PPEs • Fall arrestors • Full body harness S S P • Injuries due to slip, trip & fall 4 5 20 A • Hoses cables should be laid in proper manner. • Paint box should be removed from the scaffolding platform on daily basis. 2 3 6 B • Basic PPEs • Fall arrestors • Full body harness S S P Download HSE Docs hseprof.com
- 34. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 34 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Platform should be maintained uniform & steps should be avoided. • Proper lighting arrangements should be made at each platform level of the scaffolding. • Exposure to paint fumes 5 5 25 A • Sufficient ventilation should be maintained at the place of paining. • Canister masks should be provided & its use shouldbe ensured. • No hot work should be carried out in the nearby confined spaces without gas testing. 3 3 9 B • Basic PPEs • Canister masks S S P • Fire, explosion 4 5 20 A • Paint should be stored away from the heat or sparks. • Paint should be stored away from the heat or sparks. • All electrical connections should be provided with proper earth connections and no lose connections are allowed as it may lead to fire. • Empty paint drums should be disposed properly & it shouldbe disposed at specified location. • Fire extinguishers should be 3 3 9 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 35. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 35 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. made available at site and employees should be trained to use the same. 16 Blasting and painting work • Injuries due to high pressure grits 5 5 25 A • Area of blasting should be isolated and proper warning signs should be placed aroundit. • All pressure hoses should be inspected on daily basis before stating the job. • Whiplash arrestors should be used to control the accidental movement of hoses if unlocked from couplings. • To control the grits area around the blasting should be isolated with GI sheets / Tarpaulin. • Blaster should wear the required protective clothing. • Full body protective clothing is must for blaster. • Moisture separator should be installed on the air linesupplying air to hood of the blaster as moisture can restrict the vision of blaster. • Only approved blaster should be engaged in the job. 3 2 6 B • Basic PPEs • Full body protective clothing S S P • Injuries due to 5 4 20 A • All hoses should be laidproperly 2 2 4 C • Basic PPEs S S P Download HSE Docs hseprof.com
- 36. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 36 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. uncontrolled high pressure hoses and should be prevented from damages. • All hoses should be connected to compressors with proper connectors / coupling and hose clamps. • Whiplash arrestors should be provided to all extension joints of the hoses. • No vehicles should be moved on hoses. • Hoses should not be subjected to excessive pressure than its design pressure. • Proper rated hoses should be used. • All hoses should be inspected regularly to identify the damages. • Only skilled and trained personnel body armor, shin guards, arm protection allowed for work. • Use special type of PPE (i.e. body armor, shin guards, arm protection) for ultra pressure. • Use only inspected hoses and accessories. • Full body protective clothing • Body armor • Shin guards • Arm protection Download HSE Docs hseprof.com
- 37. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 37 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Noise exposure 5 4 20 A • Automatic grit blasting machine should be used to minimize the hazards of open air gritblasting. • All employees engaged in the blasting should be provided with ear plugs & its use should be ensured. • Blasting activity should be carried out by scheduling it during particular intervals. • Compressors should beprovided with covers to reduce the noise and should be checked on regular basis. 2 2 4 C • Basic PPEs • Ear Plug/Ear Muff S S P • Exposure to paint fumes 5 4 20 A • Sufficient ventilation should be maintained at the place of paining. • Canister masks should be provided & its use shouldbe ensured. • Cartridges of the canister masks should be replaced after 12 days. 2 3 6 B • Basic PPEs • Canister masks S S P • Fire, explosion 5 4 20 A • Painting area should be declared as no smoking zone. • Hot work should be carried out at least 5 meter away from the painting area. 2 3 6 B • Basic PPEs S S P Download HSE Docs hseprof.com
- 38. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 38 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Paint should be stored away from the heat or sparks. • Empty pain drums should be disposed properly & it shouldbe disposed at specified location. • Fire extinguishers should be made available at site and employees should be trained to use the same. • Environmental pollution due to paint drums disposal & • grit disposal 5 4 20 A • As grits & empty paint drums are considered as hazardous waste, it should be disposed at designated location. • Ensure proper shield for blasting shed to avoid dust flying to environment. 2 3 6 B • Basic PPEs • Shield for blasting shed S S P 17 Torque /tensioning • Pressurized system • Bursting of hoses. • Personal injury 4 3 12 A • Use calibrated gauge in the pump. Ensure proper supervision at all times • Use calculated value of pump pressure in case of bolt tensioning. • Release pressure in hose before disconnection. • Barricade area at ground level to prevent unauthorized entry. • Tommy bar should be tied with rope to prevent falling. 2 2 4 C • Basic PPEs S S P Download HSE Docs hseprof.com
- 39. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 39 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Secure the hoses with whiplash arrestor, and remove the defective hoses from location. 18 Hydro Testing/ pneumatic test if required. General requireme nts • Slip/trip/fall • Pinch hazards • Over pressurization • Personnel injury due to hose rupture. • Unauthorized entry 4 5 20 A • Valid work permit shall be obtained from GNFC before start of work. • All employees/ workers should wear necessary PPES. • Ensure proper housekeeping around the area • Ensure TBT meeting before start of work. • Inspect to all equipments before use at site. • Barricade the work area. • Display related safety sign / caution boards. • Use leather gloves • Use calibrated and certified pressure gauges only. • Use certified and pressure tested hoses for hydro test. • Ensure the hose connected properly with whip check and safety pin fixed. • Inform all adjacent groups prior to starting pressure testing. • Ensure all hoses are arranged in 2 3 6 B • Basic PPEs S/ P S P Download HSE Docs hseprof.com
- 40. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 40 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. such a way that it does not pose any unnecessary tripping hazards. • Area must be barricadedwith red & white striped Filling of water into Tank • Area may be slippery and chance to fall /slip 4 5 20 A • Fill the water in safe manner. • Water filling should be done by using water hose or mechanized pump. • Ensure controlling of spillage / flooding. • Ensure the area is free from obstructions. 2 2 4 C • Basic PPEs S S P Use of pressure pump • Pump hose may burst and cause injury 4 2 8 B • Inspection the pressure lifting pump before use. • Ensure hoses used are free from crack/ damage. • Use pressure hose as per design / calculation. • Ensure trained andexperienced person operates the pressure pump. • Calibration certificate of pressure gauge to be verified. • Pressurizing to be stopped if fluctuation in gauge is not observed, maybe due to defect or choke. 2 1 2 C • Basic PPEs S S P Download HSE Docs hseprof.com
- 41. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 41 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. Increasing of pressure level inside Tank • Pressure buildup may cause failure of flange / plate blind joints and rupture of hose. • Welding joints may crack/ burst and water may release with high pressure. • Chance of Physical injury 5 4 20 A • The flanges / joints shall be visually checked before starting of Hydro testing. • Suspend all works nearby the testing area. • Area shall be cordoned off to restrict entry of other persons. • Blind should be welded perfectly at the end of pipe spool. Avoid use of rusted / corroded plates as blind. • Ensure welding of blind is inspected by competent person before pressure test. • Ensure pressure is increased gradually. • Ensure pressure inside pipe does not exceed the designpressure. • Ensure skilled experienced workers are involved for hydro testing activities. 3 2 6 B • Basic PPEs S S P Pressure holding in loop • Pipe may burst or blind joint may crack 3 2 6 B • Ensure area is barricaded until releasing of water pressure. • Ensure only hydro testing crew should enter the barricaded zone. • Pressurized lines / piping spools to be inspected / monitored 2 1 2 C • Basic PPEs S S P Download HSE Docs hseprof.com
- 42. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 42 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. during testing period. • Display safety signage / caution boards. • Restrict others to not to enter into pressure testing zone. • Ensure TBT for the crew. Releasing of pressure / Dewatering of pipe • Slip /trip/ fall hazards 4 5 20 A • Don’t vent the water openly or in pressure mode at workplace. • Dewatering should be done safely. • Workers should maintain a safe distance from the vent point while releasing pressure. • Water should be drained slowly by water hose to nearby drains or water collection tanks avoiding flooding of the area. 2 2 6 B • Basic PPEs S S P 19 Pressure testing & Box up • Blast of tank • Hand injury • Failure in identifying blind(s) may leads to process hindrance 5 4 20 A • Proper arrangements should be done prior to do pressure testing of the tank. • If required, permits should be taken before starting the pressure test the same should be communicated to the other contractors working in the vicinity of the tank being pressure tested well in advance. • All equipments used for 1 2 2 C • Basic PPEs S/ P S P Download HSE Docs hseprof.com
- 43. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 43 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. pressure testing should be calibrated & should be inspected prior to use at site at the time of testing. • Continues monitoring is essential & test area should not be left unattended. • The manifold should be fitted with proper drains, vents, calibrated pressure gauge & calibrated PSV to avoid the blasting of tanks. • Obtain appropriate permit to work. • Use right and correct size of tools & equipments for the job. • Wear hand gloves and other required PPEs. • Supervise the de-blinding crew closely. • Injuries due to busting of pressure lines 4 5 20 A • Proper rated hoses, pipes, fitting should be used for supply lines for the tanks during testing. • All hoses, pipes, fittings should be visually inspected for defects before installation & prior to start the testing. 3 3 9 B • Basic PPEs S S P 5 3 15 A • Identified drains & vents should 2 2 4 C • Basic PPEs S S P Download HSE Docs hseprof.com
- 44. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 44 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Sudden release of pressure be provided to release the pressure of tank in case of emergency. • Arrangements for safe release of medium used for testing should be made & proper barication with required signs should be provided to the same. • Area barricading shall be ensured . • Entrapment of person 3 5 15 A • Before box up all unwanted materials shall be removed. • Before box up, it should be ensured that the tank is completely vacant. • Company safety officer shall give final box up clearance after sign in procedure. 2 4 8 B • Basic PPEs S S P 20 Confined Space Entry for cleaning and repair activities (if required) • Sharpsurfaces • Possible hydro- carbon vapors present. • Insufficient Oxygen Levels. • Insufficient light. • Slippery surfaces. 5 4 20 A • Obtain a valid Permit to Work as well as a Confined Space Permit Issued at the site • Ensure PTW is in place and ensure check for Gases and shall ensure that Oxygen 20.8% & LEL - 0% which need to be monitored continuously. • All crew members working in confined space shall betrained 3 2 6 B • Hard hat, • safety glasses, • Dust mask, • coverall, • Rubber gum boots, • Leather S S P Download HSE Docs hseprof.com
- 45. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 45 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. because of the viscous material inside • High temperatures inside the confined space and competent to work in confined space • Ensure standby man remains at entrance with constant communication with the crew. • Post signage and barricades CONFINED SPACE ENTRY – DO NOT ENTER. • Erect sufficient lighting. • Ensure adequate ventilation and airflow. • Ensure constant airmonitoring. • Do gas testing for explosive or flammable atmospheres due to hidden hydro-carbon vapors. • Ensure that an ENTRY LOGSHEET is completed by all ENTRANTS and controlled by the STANDBY MAN. • Constant supervision is vital. gloves, • Safety shoes • Full body harness with double lanyard and shock absorber (when working at heights 21 Vacuum out sludge using vacuum truck and disposed designated area. • Hand injuries while setting- up and making connections • Possible injuries as result of tripping over 4 2 8 B • Ensure that hand protection and all other PPE, as required are worn. • Ensure all hoses are arranged in such a way that it does not pose any unnecessary tripping hazards. • Qualified Gas Tester 2 1 2 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S/ P P Download HSE Docs hseprof.com
- 46. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 46 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. hoses. • Flammable, Radioactive and health • Failure to follow procedure • Hose failure • Static electricity generation may be a source of ignition • Inhalation of Toxic Fumes • Inhalation of Hazardous Substance • Possibility of fire • Ensure no one is standing close to the Equipment man way. • To follow GNFC procedure • Ensure to assess the vacuum truck approach roads & its set up area in coordination with GNFC 's competent representative and ensure that, it is clear from all obstacles before obtaining PTW • Depute only qualified and trained vacuum truck drivers and ensure to wear appropriate PPE. • Ensure all hoses are inspected, tested and certified prior to its use. • Barricade the area and post “DO NOT ENTER” sign board. • The vacuum truck and hose must be grounded properly. • Ensure earth continuity test from hose suction point to vehicle earthing clamp is carried out prior to work commencing. • If the material to be suck is in liquid form it may release fumes that are hazardous to health Download HSE Docs hseprof.com
- 47. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 47 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. depending on the type of material. • If the material to be suck is in solid form it may generate dust like particles that will be absorb by the body throughinhalation. • Provide and used the appropriate PPE as recommended by MSDS. • Ensure portable fire extinguishers fully charged, sealed with inspection tags are suitably placed, • Ensure that vacuum truck is not left unattended whilst engine is running. 22 Working at night • Poor visibility 4 4 16 A • Ensure night work permit • Ensure adequate illumination • Hoses cables should be laid in proper manner. • Paint box should be removed from the scaffolding platform on daily basis. • Platform should be maintained uniform & steps should be avoided. • Proper lighting arrangements should be made at each 3 1 3 C • Safety helmet, • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P • Slipping and Tripping hazard 4 3 12 A 3 1 3 C S S P • Lack of supervision 4 3 12 A 3 1 3 C S S P • Unavailability of first aid facilities. 4 4 16 A 3 1 3 C S S P Download HSE Docs hseprof.com
- 48. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 48 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Drowsiness (feeling sleepy) 4 3 12 A platform level of the scaffolding. • Ensure use of personal protective equipments-Shoe- Helmet-Gloves. • Break needs to be taken at regular intervals. • Full or alternative supervision throughout the work. • Emergency vehicles with driver should be there through the work time. • Effective supervision will be made by nominating designated decision making person as in charge for night shift. • Drinking water, snacks and other amenities will be available. 2 1 2 C S S P • Fatigue 4 3 12 A 3 1 3 C S S P • Lack of amenities. 4 3 12 A 2 1 2 C S S P 23 Housekeeping • Possible slipping and falling of personnel 4 3 12 A • Ensure frequent cleaning of work station from obstructing, unwanted material / objects and slippery floor. • Any spillage should be cleaned up immediately and stored into approved container. • Make sure that hoses used are arrange in such a way that it will not pose a tripping hazard during the housekeeping job. 2 1 2 C • Safety helmet, • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S/ P P Download HSE Docs hseprof.com
- 49. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 49 of 66 ANNEXURE – R N L R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. CIVIL WORK Sr. No. STEPS/ METHODS (MAIN ACTIVITIES) SUB ACTIVITIES POTENTIAL HAZARD (What can cause harm?) RISK RATING WITH EXISTING RISK CONTROL RISK CONTROL MEASURES/ MITIGATIONS (What can be done to prevent it from going wrong?) RISK RATING WITH ADDITIO CONTRO MEASURES RISK PPEs TO BE USED RESPONSIBILI TY G N F C P D I L L S T K C L R C L 1 Layout of pilling area and line marking with chalk powder • Fall on the same level due to tripping because of uneven ground. • Dust entering eyes and nose due to loose soil & gusty winds • Skin irritation and trip hazards. 5 4 20 A • Be cautious while walking on uneven ground surface. • Wear safety shoes for protection. • Removal of thorny plants, debris and other material if any before marking. • Plan marking when the wind is low and wear safety glasses and dust mask 3 1 3 C • Safety helmet, • Safety Goggles, • Respirator • Dust coverall, • gloves, S S P 2 Loading & unloading of materials from truck for pilling work • Inadvertent movement / roll of materials from the stack while loading / 4 4 16 A • Check the stack condition for any disturbance that may cause movement. • Do not step over the load that may cause imbalance;instead 2 1 2 C • Safety helmet, • Safety Goggles, • Respirator S S P Download HSE Docs hseprof.com
- 50. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 50 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. unloading • Overloading vehicle / axle load exceeding rated capacity use tailor made platforms, where required • Always load / unload from top layers in the stack; Remove / place layer by layer progressively. • Move to a safe distance before signaling the operator to lift the load. • Use guide ropes to control the load from swinging while lifting mechanically; do not be close to the lifted load. • Restrict movement of personnel in the vicinity; do not allow unauthorized personnel in the work area. • Never over load than the rated capacity of the vehicle. • Axle load shall be within those prescribed by the manufacturers and in conformance to road specifications. • Dust coverall, • gloves, 3 Erection /Assembly of Rig Leveling of ground • Damage could result to the existing materials on 3 3 9 B • Before leveling clear the area. 2 1 2 C • Safety helmet, • Safety Goggles, • Respirator S S P Download HSE Docs hseprof.com
- 51. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 51 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. ground, if any. • Dust coverall, • gloves, Assembly of A- Frame including placing of roller tubes, main sill, positioning of winch up to First stage of A- Frame. • Crane used for erection could be toppled during assembly. • Fall might result during height works. • Hit may result due to breaking of wire ropes / slings. • Traffic problem • Poor access 4 5 20 A • Ensure SWL, Lifting radius etc. of the erection crane. • Provide experienced rigger for signaling. • Provide licensed operator. • Area shall be barricaded. • Double lanyard Full body harness with shock absorber with fall arrester, where necessary, shall be usedwhile work at height. • Tag Line shall be used to control movement of lifted loads. • Ensure TPI for all lifting tools and tackles including Rig assembly. • Ensure life line for Tie offthe harness, if required. • Traffic control by signalman with flag. • Access ways and unloading zone identified 2 2 4 C • Safety helmet, • Safety Goggles, • Respirator • Dust coverall, • gloves, S S P Lifting of Derrick Post and • May hit the assembled part of A- Frame. 5 4 20 A • Ensure SWL, Lifting radius etc. of the erection crane. • Provide experienced foreman 3 3 9 B • Safety helmet, • Safety S S P Download HSE Docs hseprof.com
- 52. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 52 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. assembly of second , third , fourth and fifth stage of A- Frame • May hit the persons involved. • Fall of persons might result during height works. • 3. Hit may result due to breaking of wire ropes / slings. for signaling. • Provide licensed operator. • Area shall be barricaded. • Double lanyard Full body harness with shock absorber with fall arrester, where necessary, shall be usedwhile work at height. • Tag Line shall be used to control movement of lifted loads. • Ensure TPI for all lifting tools and tackles including Rig assembly. Goggles, • Dust coverall, • gloves, • Double lanyard Full body harness with shock absorber with fall arrester 4 Driving of piles Area clearance and identificati on of buried cables, utilities and chemicals etc. • Damage to underground utilities 4 5 20 A • Valid permit should be obtained on daily basis, which can provide information about the existence of underground utilities, if any. • If required, cable detectors would be used to detect underground cables. • A signal man shall be assigned to monitor the excavation. • TBT shall be conducted on daily basis. 2 2 4 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P Placement of piling shoe on the pile location • Hand injury might happen. • Pile shoe could slip and fall. 4 3 12 A • All workers should use hand gloves/ safety shoes. • 2.TBT shall be held with crew 2 2 4 C • Basic PPEs • coverall, • Leather gloves, S S P Download HSE Docs hseprof.com
- 53. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 53 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. 5 Placing the concrete mixer near to the rig • Collision with piling rig • Hit to person 4 3 12 A • Reverse horn of miller shall be in working condition • Signal man shall be provided • Ensure area is clear from obstacles for movements. • Provide valid licensed driver 2 2 4 C • Basic PPEs • Safety Goggles, • Dust coverall, • Leather gloves, S S P 6 Vertical, Lateral and Pull out test Shifting of rebar, farm and scaffolding materials for pile head preparation • Struck by rebar, slip, trip, fall to same level 4 4 16 B • Keep clear access and hand gloves shall be in use. • Provide steps for excavation or provide ladder for assess. 2 2 4 C • Basic PPEs • Safety Goggles, • Dust coverall, • Leather gloves, S S P 7 Lifting, shifting and Placing of load (concrete block and beams) with the help of hydra • Load or hydra may collapse due to overloading • Load collapsed due to failure of lifting tools • Load or hydra may be collapsed due to uneven floor 5 5 25 A • Load shall be lifted as per the load chart • Licensed and experienced operator shall be allowed to operate the hydra • Proper training shall be provided to the hydra operator and helper • Certified and inspected lifting tools shall be allowed to lift the load Ground area shall be 3 3 9 B • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P Download HSE Docs hseprof.com
- 54. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 54 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. surface Strike with moving or stationary object properly leveled. • Tagline shall be provided to control the load • Bank man shall be provided with hydra • Horns and lights shall be in proper working condition. • Workplace shall be cordon off prior to start of pile testing operating • Maintain a safe distance while placing the bearing supports and jacks. • Ensure falling of objects is not in line with your body posture. • Only certified hydraulic jack (SCP112) 300MT Capacity shall be used for testing purpose • Place the concrete cube safely to protect from falling. 8 Cutting of steel using bar cutting machine • Crush Injury • Hit the men due to temper. 5 4 20 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Deploy trained worker for to cut the steels • Tool Box Talks to be conducted before start of the activity. 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P Download HSE Docs hseprof.com
- 55. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 55 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Ensure the machine is inspected by EHS dept before entering to site and color coded. • Ensure safety guard provided for the rotating parts of machine. • Pedal guard/Hand lever protection against accidental activation. • Ensure cover guard protection for cutting part of machine. • Place re bar in position and cover before activating the foot pedal/Hand lever. • Rods should be hold tightly while cutting. • Provide proper PPEs for the work men who work in the activity. • Adequate supervision until the task completed. 9 Bending of steel using bar bending machine • Crush Injury • Hit the men due to temper. 5 4 20 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Deploy trained worker for to cut the steels • Tool Box Talks to be conducted before start of the activity. 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P Download HSE Docs hseprof.com
- 56. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 56 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Ensure the machine is inspected by EHS dept before entering to site and color coded. • Ensure safety guard provided for the rotating parts of machine. • Ensure the second stopper for protection against struck by swing arm in case of failure of first stopper. • Ensure pinching will happen by using multiple rods. • While operating the machine stand front to the machine to hold the rod to avoid hit. • Ensure emergency switch is in working condition. • Provide proper PPEs for the work men who work in the activity. • Adequate supervision until the task completed. Binding of steels using binding wire • Pinching hazard 4 4 16 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Deploy trained worker for to cut the steels • Tool Box Talks to be conducted 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather S S P Download HSE Docs hseprof.com
- 57. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 57 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. before start of the activity. • Use proper gloves to avoid pinching of wires. • Ensure workers are free from heat stress. • Adequate supervision until the task completed. gloves, Shifting Of fixed rods to working area manually • Fall of materials on men/hit the men 4 4 16 A • Ensure all personnel have undergone Site Safety Induction. • Ensure PTW Issued by the PMC before starting the work. • Deploy trained worker for to cut the steels • Tool Box Talks to be conducted before start of the activity. • Ensure access free from obstruction. • Ensure no unwanted men movement in the shifting area. • Ensure proper positioning of fixed rods 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, S S P 10 Electrical Operation • Electrocution 5 4 20 A • Ensure Competent Person Must work with electrical machine Like motors • Ensure cables free from damaged. • Ensure Safety devices Like ELCB/RCCB Connected withthe 3 2 6 B • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather / S S P Download HSE Docs hseprof.com
- 58. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 58 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. circuit. • Ensure isolation of power source while maintenance works. • Ensure proper body earthen should be provided to the electrical machines. • Ensure cables are over headed. • Ensure there is no damage in electrical panel Boards. • Ensure working area should be barricaded. • Ensure LOTO is following while electrical maintenance. • Ensure Proper PPEs provided for the Electrical Technician and operator • Ensure adequate supervision until the task complete. rubber gloves, 11. Reinforcement Work • Fall of materials and men 5 5 25 A • Ensure trained workmen working in height. • Ensure workmenundergone with height work training. • Ensure Scaffold is inspected daily before starting the work. • Ensure proper working platform provided for the workmen. • Ensure all tools and tackles Tied with rope avoid falling. 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Leather gloves, • Safety harness S S P Download HSE Docs hseprof.com
- 59. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 59 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Ensure Reinforced materials erected and proper support should be given. • Ensure workers worn proper PPEs like Safety harness. • Ensure Proper supervision until the task complete. 12 Concreting. • Mechanical failure. • Lack of supervision. • Striking against objects. • Improper barrication. • Unguarded rotating parts. • Spillage of concrete. • Skin rashes. 4 4 16 A • Prior checks to be done for vehicle/concrete pump. • Ensure the equipmentshould have proper documents. • Continuous supervision to be provided. • Proper barrication has to be done for the entire area. • No Unauthorized entry during the activity. • Guards to be provided for rotating parts • Concrete to be removed and after completion of the work. • Proper access/platform to be provided. • PPE like rubber hand gloves goggles should be wearied. 3 1 3 C • Basic PPEs • Safety Goggles, • Respirator • Dust coverall, • Gumboots • Rubber gloves S S P 13 Vibrator • Electrocution • Health hazard • Skin diseases 5 5 25 A • Ensure Competent Person Must work with electrical machine Like vibrator 3 2 6 B • Basic PPEs • Safety Goggles, S S P Download HSE Docs hseprof.com
- 60. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 60 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Collapse of wheel barrow with person over speeding • Over turning of rider. • Inhalation of cement Dust, Eye and skin irritation by direct contact with cement. • Electric Shock due to water spillage. • Air pollution • Entanglement • Ensure cables free from damage • Ensure Safety devices Like ELCB/RCCB Connected with the circuit. • Ensure isolation of power source while maintenance works. • Ensure proper body earthen should be provided to the electrical machines. • Ensure cables are over headed. • Ensure there is no damage in electrical panel Boards. • Ensure Proper PPEs provided for the Electrical Technician and operator • Ensure Adequate supervision until the task complete • Ensure person who working with vibrator machine must need time interval (Rest). • Ensure person is medically fit to operate the vibrator. • Ensure worker provided with required PPEs • Ensure Adequate supervision until the task complete • Ensure LEL level zero by using Multi Gas Detector • Respirator • Dust coverall, • Leather gloves, Download HSE Docs hseprof.com
- 61. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 61 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Ensure Edge protection/proper support/working platform • Use proper PPEs, follow updaily tool box talk & work permit system. • Availability of Machine guard • Arrangement of portable fire fighting facilities nearby workplace • Ensure uses of PPEs like safety goggles, gumboots, rubber gloves and helmets. • Ensure availability of Trained / experienced vibrator operator. • Ensure proper maintenance of vibrators. • Ensure adequate support to make for vibrator machine when in use. • Ensure the connection should be drawn through 30mA rated capacity of ELCB/RCCB • Valid license holder electrician should check the electrical system becomes healthy before start of work. 14 Curing. • Slips and trips 4 3 12 A • Use proper access and good housekeeping. 3 1 3 C • Basic PPEs • Safety S S P Download HSE Docs hseprof.com
- 62. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 62 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Proper PPE’s like gumboot and rubber gloves to be used while curing. • No Electrical wires to be in place while curing. Goggles, • Respirator • Dust coverall, • Gumboots • Rubber gloves 15 Bitumen Heating • Burn injury. • Breathing problem due to inhalation of smoke. • Chance of fire. • Explosion. • Personal injury. • May cause severe • Injuries or prove fatal. • Property Damage. 5 5 25 A • Heating activity shall be always carried out by trained and experienced person. • Workmen shall be work with necessary PPEs at site. • Provide nose mask to the workmen. • For eyes protection goggle to be provided. • Flash back arrestor shall be ensured. • Before starting of job burner & hose to be checked. • Gas leakage to be checked with soap solution. • Keep LPG/metal cutting cylinder free from spark/ heat. • Use fire blanket for covering of cylinder. • Fire extinguisher/fire hose shall be placed nearby hotworkplace. 3 4 12 B • Basic PPEs • Safety Goggles, • Respirator • Face shield • Leather gloves • Protective cloth S S P Download HSE Docs hseprof.com
- 63. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 63 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. • Stacking of LPG shall be placed separately in up rightdirection. 16 Fire prevention and protection. • Small fires can become big ones and may spread to the Surrounding areas. • Cause burn injuries and may prove fatal 5 4 20 A • In case a fire breaks out, press fire alarm system and shout "Fire, Fire" • Keep buckets full of sand / fire extinguishing equipment near hazardous locations • Train people for using specific type of fire fighting equipment’s under different classes of fire • Keep fire doors/shutters, passages and exit doors unobstructed. • Maintain good housekeeping and first-aid boxes • Don't obstruct assess to Fire extinguishers. • Do not use elevators for evacuation during fire. • Maintain lightening arrestors for elevated structures • Stop all electrical motors with internal combustion. 3 3 9 B • Basic PPEs • Safety Goggles, • Respirator • Face shield • Leather gloves • FRC Cloths S S P • Fire 4 5 20 A • Ensure usage of correct fire extinguisher meant for the specified fire. • Do not attempt to extinguish Oil 3 4 12 B • Basic PPEs • Face shield • Leather S S P Download HSE Docs hseprof.com
- 64. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 64 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. and electric fires with water. • Use sand bucket/CO2/DCO/sand or earth. gloves • FRC Cloths 17 Applying bitumen to surface. • Bitumen liquid may chance to fall hand/feet /lower body part. • Burn injury. 5 5 25 A • Ensure proper PPEs to work (helmet, shoes, goggles, leather hand gloves, protective cloth etc.) • Activity shall be always carried out by trained and experienced person. • Working under supervision. • Awareness/ training program to be conducted. 3 3 9 B • Basic PPEs • Safety Goggles, • Respirator • Face shield • Leather gloves • Protective cloth S S P 18 Restriction of unauthorized entry near work area. • Men/ material may fall down through cut out opening. • Slip, trip & fall • Physical injury • Person may get injure. • May prove fatal. 5 5 25 A • Work area shall be barricaded to restrict entry. • Openings shall be covered if work is preceded in the higher elevation. • Access shall be kept clean. • No loose materials shall be stacked near the edge of the openings. • When people are working close to the cut out openings wearing of full body harness. 4 3 12 B • Basic PPEs • Safety Goggles, • Respirator • Face shield • Leather gloves • Protective cloth S S P Download HSE Docs hseprof.com
- 65. HAZARD IDENTIFICATION &RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 65 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects & Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. RISK MATRIX C = CONSEQUENCES Rating 5 = Almost certain 5 10 15 20 25 Rating 4 = Very likely 4 8 12 16 20 Rating 3 = Possible 3 6 9 12 15 Rating 2 = Unlikely 2 4 6 8 10 Rating 1 = Very unlikely 1 2 3 4 5 * Rating 1 = Negligible Rating 2 = Slight Rating 3 = Moderate Rating 4 = High Rating 5 = Very High First aid injury or illness Minor injury or illness '3 day' injury or illness Major injury or illness Fatality, disabling injury, etc. L = LIKELIHOOD / SEVERITY Risk Risk Level Action A = 1 to 5 Low Risk May be acceptable but review task to see if risk can be reduced further. B = 6 to 10 Medium Risk Task should only be undertaken with appropriate management authorization after consultation with specialist personnel. C = 12 to 25 High Risk Task must not proceed. It should be redefined or further control measure put in place to reduce risk. Download HSE Docs hseprof.com
- 66. HAZARD IDENTIFICATION RISK ASSESMENT (HIRA) NOTE: All the activities may have impact on the running plants in surroundings of the tank location hence, extra care should be taken while execution of work. Page 66 of 66 ANNEXURE – R Nature of the Job: Dismantling and erection of ammonia tank Date: 02/12/2020 Project No: PC-00187 Name of the Contractor: Projects Development India limited Job Location: GNFC -1003A Project Bharuch Site Name of the Safety Engineer: Mr. Tarik Vahora Contract Project manager: Mr. Prepared By: SAFETY ENGINEER/PDIL Checked By: RCM/PM/PDIL Approved By: GNFC Other Download HSE Docs hseprof.com
- 67. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) INTRODUCTION ON SITE EMERGENCY PLAN Emergency planning is an integral part of the overall loss control programme and is essential for our organization. The same is important for effective management of an accident to minimize the losses to the people and property, both in and around the facility. The important aspect in emergency management is to prevent by technical and organizational measures, the unintentional escape of hazardous materials out of the facility and minimize accidents and losses. Emergency planning demonstrates the organizational commitment to the safety of employees and increases our organization’s safety awareness. An emergency in the factory has potential to cause serious injuries or loss of live or extensive damage to the property and / or environment and serious disruption both inside and / or outside the works. In such cases sometimes outside agencies are required to call for help in handling the situation. The causative factors like plant / equipment failure, human error, earthquake, sabotage etc. will normally manifest in various forms viz. Fire, Explosion, Toxic and Structure collapse etc. In spite of best design and layout of plant, safe operating procedures and various preventive measures the possibility of a disaster cannot be totally ruled out. During this event timely and organized action must be taken to control the situation and to minimize the damage or loss to the factory, human beings and environment hence, the need of a proper “On–Site Emergency Plan (EPRP)”. Such plan gives the guidelines for employees, contractors, transporters and Visitors etc. The EPRP not only defines the responsibilities but also inform about prompt rescue / evacuation /co-ordination operations and some more. WHY INTRODUCTION OF EMERGENCY PLANNING IS REQUIRED? After the incident of Bhopal gas disaster, the Factories Act has been amended and a new chapter i.e. Chapter IVA – provision relating to hazardous processes has been added to the Factories Act with addition of new provisions sec 41A, 41B, 41C, 41D, 41E, 41G 41H covering all hazardous process industries. Under the provision of Sec 41B (4) every occupier shall with the approval of the Chief Inspector of Factories draw up an On-site Emergency Plan and detailed disaster control measures for his factory and make known to the workers employed therein and to the general public living in the vicinity of the factory the safety measures required to be taken in the event of an accident taking place. This is the statutory provision laid down in the act for preparation of On-site Emergency Plan to control disaster in the factories. Major accidents may cause emergency and it may lead to disaster, which Download HSE Docs hseprof.com
- 68. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) may cause heavy damage to plant, property and harm to person and create adverse affects on production. Many disasters like Bhopal gas tragedy, Chernobyl nuclear disaster etc. have occurred at many places in the world causing heavy loss of life and property. Emergency situation arises all on a sudden and creates havoc and damage to person, property, production and environment. Therefore such situations and risks should be thought in advance and it should be planned before hand to tackle them immediately and control them within the shortest time. OBJECTIVE The main objective of On-site emergency management plan (On-SEMP) is in emergency management planning is to ensure that everyone knows: • What are the hazards and risk in the plant • What and how to do in the event of an emergency; and • Preparations for potential and unexpected incidents at the workplace. The types of emergencies to plan for include fire, explosion, toxic releases, injuries and rescues in the hazardous events. Plan improves local, district, state and national capacity to respond to disasters and public health emergencies, scaling up the actions with vulnerable communities in health promotion, disease prevention and disaster risk reduction. As per our Indian regulations we have regulatory provisions that On-site Emergency Management Plan (On-SEMP) will be prepared by industrial units and Off-site Emergency Management Plan (Off SEMP) by District Collector. An occupier will prepare and keep an up-to date on-site emergency plan containing details of Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules 1989 and detailing how major accidents will be dealt with on the site on which the industrial activity is carried on and that plan will include the name of the person who is responsible for safety on the site and the names of those who are authorized to take action in accordance with the plan in case of an emergency. The occupier will ensure that the emergency plan prepared takes into account any modification made in the industrial activity and that every person on the site who is affected by the plan is informed of its relevant provisions. The occupier will prepare the emergency plan required – • In the case of a new industrial activity, before that activity is commenced; • (In the case of an existing industrial activity within 90 days of commencing into operation of these rules. Download HSE Docs hseprof.com
- 69. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) On-site emergency can be due to the following causes Man-made Cause Natural Cause Extraneous Fire Flood Riots / Civil disorder Explosion/ Leakage Earthquake Terrorisms Failure of critical control system Cyclone Sabotage Design deficiency Outbreak of Disease Bomb Threat Unsafe Acts Extensive Rains War/Hit by missiles In-adequate maintenance Tsunami Abduction Food poisoning / Water Poisoning WHAT IS EMERGENCY? An emergency is a situation, which may lead to or cause a large-scale damage or destruction to life or property or environment within or outside the factory. Sometimes emergency results into uncontrollable situations which leads towards the disaster. Such an unexpected severe situation may be too great for the normal workforce in the area within the plant. In any industry emergency can arise at any moment and this depends on the type of Structure, Raw Materials, Machines / Plant, Nearby Industries etc. A major emergency can be defined as an accident/ incident that have potential to cause serious injuries or loss of life. It may cause extensive damage of property, serious disruption both in production and working of factory and may adversely affect the environment. The following factors may cause major emergency. (i) Plant failure. (ii) Human error. (iii) Vehicle crash. (iv) Sabotage. (v) Earthquake. (vi) Natural Calamities. ON-SITE EMERGENCY: If an accident/ incident takes place in a factory, its effects is confined to the factory premises, involving only the persons working in the factory and the property inside the factory it is called as On-site Emergency. OFF-SITE EMERGENCY: If the accident is such that it affects inside the factory are Download HSE Docs hseprof.com
- 70. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) uncontrollable and it may spread outside the factory premises, it is called as Off-site Emergency. NATURE OF EMERGENCY The emergency has been identified and can be specified in one or more of the followings with source and effect: Sr. No Emergency Source Effect 1 Fire / Explosion Electrical Panels, Flammable oil storage tanks, Compressors, coolants, paints, etc. Small fires complete equipment loss, complete Area burn out, Air pollution, Soil pollution, Dangers to Human beings. 2 Spillage of flammable / Hazardous Oils coolant etc Hydraulic oil, Furnace Oil, Coolant etc. Fire, Burns, Soil pollution, Injury by slippage 3 Electric Shock Electrical panels, Power Distribution Board, DG Set, Overhead Crane, Voltage stabilizer, Electric Transformer Machine Operated by electricity, etc. Burns, suffocation, Death. Toxic chemical ingestion into blood stream 4 Accidents – Factory (Major) Fall from height Falling of Heavy Materials, Dies, Bins or other Heavy object. Fracture 5 Accidents-Transport Accident due to transportation of man material Death or Injury to Body 6 Personal confinement Toilets, offices, Basement Suffocation 7 Natural calamities such as storm, earthquakes, etc. Nature Structural collapse, Death 8 Structure collapse Office building, Any Wall or part Of Factory building. Serious injury, Major Fracture, Death 9 Riots, Arson, Sabotaging Anti Social elements. Serious injury, major Fracture, Death. Download HSE Docs hseprof.com
- 71. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) 10 Toxic gas leakage Fire Hazard, Suffocation Serious injury, Death 11 TANK DYKE Fire Fire Hazard Serious injury, Death 12 Electric fire Fire Hazard Serious injury, Death 13 Office fire Fire Hazard Serious injury, Death 14 Person on flames Fire Hazard Serious injury, Death 15 Food/Water Poisoning Health Hazard Poisoning, Death 16 Bomb hoax Bomb threat Explosion, Death, fear 17 Burn-Minor Health Hazard Burn injury 18 Electric shock casualties Health Hazard Injury, Death 19 Non Functioning of STP and ETP Spillage of untreated water on ground Land Contamination EMERGENCY ACTION PLAN: The Action Plan should consist Designated Emergency Control Centre/Room. Key Personnel. EMERGENCY CONTROL CENTRE: This is the main center from where the operations to handle the emergency are directed and co-ordinate. Maximum facilities to be made available in the emergency control are – i. Internal and external communication. ii. Computer and other essential records. iii. Daily attendance of workmen employed in factory. iv. Storage of hazardous material records and manufacturing records. v. Pollution records. vi. Walky-talky. vii. Plan of the plant showing- a. Storage area of hazardous materials. b. Storage of safety equipments. c. Fire fighting system and additional source of water. d. Site entrance, roadway and emergency exist. e. Assembly points. f. Truck parking area. g. Surrounding location. viii. Note Book, Pad and Pencil. Download HSE Docs hseprof.com
- 72. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) ix. List of Key Personnel with addresses, telephone number etc. KEY ELEMENTS OF THE ON-SEMP Emergencies can happen at any time in any types of industry, due to fire in a process area, tank form area, toxic gas/liquid release into the area from storage vessels or piping network, or a bomb threat. The approach of the plan is to eliminate or reduce the risk of injury or harm that may occur during an evacuation by undertaking following steps:- a) Classification and identifying potentially hazardous situations; b) Assessment of the risks; c) Implementation and compliance of the regulatory provisions as per the Manufacture, Storage Import of Hazardous Chemicals (MS and IHC) Rule 1989 and Chemical Accidents (Emergency Planning, Preparedness and Response) [CA (EPPR)] Rules 1996 schedule; d) Consequences of defaults or non-compliance of regulations; e) Statutory requirements; f) Pre-emergency planning; g) Emergency mitigation measures; h) Emergency preparedness measures; i) Emergency response procedures and measures; j) Emergency organization and responsibilities; k) Infrastructure requirements; l) Procedures for declaration of on-site and off-site emergency; m) Resources for controlling emergency; n) Demographic information; o) Medical facilities; p) Evacuation; q) Public relations and information to public; r) Reporting of the incident; s) Emergency recovery procedures; t) Emergency plans for tank trucks and pipelines carrying hazardous products; PRE- EMERGENCY PREPAREDNESS This may have following components: a) Information on the preliminary hazard analysis: b) Type of accident c) System elements or events that can lead to a major accident d) Hazards Download HSE Docs hseprof.com
- 73. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) e) Safety relevant components f) Details about the site g) Location of dangerous substances. h) Seat of key personnel i) Emergency control room j) Description of hazardous chemicals at plant site: k) Chemicals (Quantities and toxicological data) l) Transformation if any, which could occur. m) Purity of hazardous chemicals. n) Likely dangers to the plant. o) Enumerate effects of Accident p) Stress and strain caused during normal operation q) Fire and explosion inside the plant and effect if any, of fire and explosion outside. THE KEY PERSONNEL THEIR ROLE FOR ONSITE EMERGENCY 1. Works main site controller. 2. Works incident controller. a. Communication Officer. b. Security and Fire Officer. c. Telephone Operators. d. Medical Officer. e. Personnel/Administrative Officer. f. Essential work team leaders. SITE CONTROLLER is the person who assumes absolute control of the Factory and determines the action necessary to control the Emergency. He / She will wear a Red White Helmet to confirm his identity. The General Manager will be the site controller. Site controller will ensure that all members of his/her team have been informed to collect at Emergency Control centre. He / She will then proceed to Emergency Control Centre to take charge. After firsthand assessment of situation he/she will give necessary instructions to Emergency Control Team. He / She will maintain a Log book of all the activities. He/she will keep in touch with the external communication Team. He/she will ensure that information is sent to outside emergency services (Police and Fire Brigade). He/she will depute people to, • Attend to telephone • Keep in touch with incident controller • Communicate with Assembly Points • Meet outside emergency services Download HSE Docs hseprof.com
- 74. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) • Ensure proper flow of traffic and security • Meet media/ other people coming at site from outside. • Arrange for Medical Aid INCIDENT CONTROLLER is the person who goes to the scene of emergency and supervises the actions taken at the incident to overcome the Emergency. Shift Manager will act as Incident Controller. His responsibilities will be • Direct all efforts to contain and control the incident. • Keep non-essential persons away from the site. • Guide outside emergency services at the site. • Arrange to remove any casualties at the site. • Keep in touch with Emergency Controller. SECURITY IN-CHARGE WILL • Actuate the Emergency Siren, if not done already. • Send one guard to start the fire pump. • Attend to incoming telephone. • Await instructions from the Emergency Controller COMMUNICATION OFFICER Public Relations Officer will act as Communication Officer. On hearing alarm He will proceed to Emergency Control Centre. • Maintains communication with Incident Controller and Deputy Incident Controller • Recruits suitable staff to act as messengers if telephone and other communications fail • Organizes all requirement of Emergency Control Centre • Arranges Food, Transport, Nursing Home etc PERSONNEL MANAGER • He/she will work as Liaison officer. He should be positioned in the office near gate. • Will deal with police, media and outside enquiries in consultation with Site Controller. • Will keep in touch with Union • Will arrange for refreshments if required • Will control traffic movement inside the factory and arrange for alternative transport if required • Will keep a record of attendance of workers, staff, contractor’s personnel, and visitors at the Gate which will act as Assembly Point. SAFETY OFFICER • Will assist the Incident Controller with his special knowledge on the safety Download HSE Docs hseprof.com
- 75. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) aspects in the factory. He will help to identify the hazardous chemicals, hazard zones and zone of probable impact in different accident scenarios • Will select people with special training in safety matters to assist in the control activities FIRE SECURITY OFFICER • His/her main task is fire fighting andcontrol • Announce through PAS about the incident zone and any other immediate information needed for the people nearby • Maintains liaison with the Fire Brigade team fromoutside MEDICAL OFFICER • Will immediately open a First Aid Centre at Control Centre or at Assembly Point • Will take up the full responsibility of providing medical assistance during emergency • Will arrange for outside medical help if required. TELEPHONE OPERATOR • On hearing the emergency alarm, he/she will immediately contact Site Controller • On the advice of Site controller/Incident Controller/Security Officer will ring Fire brigade, Police etc • Keep telephone board free for urgent communications. GENERAL EMPLOYEES Who have not been specified a duty in case of emergency should proceed to/contact the Emergency Assembly Point in their area. Designated persons will carry out the actions detailed in the Individual Plant Emergency Procedure. The Roll Call leader will hold a Roll call. Personnel not at their normal work place must go to the emergency assembly point. Personnel will remain at these points and await instructions from the Site Controller. Essential Works and Team Leaders: During emergency the plants immediately affected or likely to be affected, as determined by the Works Main Controller, need to be shut down for safety. In the area immediately affected, it may be possible to isolate equipment from which flammable or toxic material is leaking. This work must be immediately carried out by plant supervisors and essential operators. Workers/ staffs need to be nominated to carry out the following essential works at the time of emergency- • Extra first aid personnel to deal with casualties. • Emergency engineering works, provision of extra or replacement of light, isolation of equipment, temporary by pass electrical lines etc. Download HSE Docs hseprof.com
- 76. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) • Moving tankers or other vehicles from area of risk. • To carry out tests on ambient air quality. • To act as runner in case of communication system fails. • The Works Main Controller will require a task force of suitable trained people for the following works- i. Manning of assembly points to record the arrival of evacuated people. ii. Assistance of casualty arrival areas to record details of casualties. iii. Manning the factory entrance in liaison with security to direct emergency vehicle containing the gate e.g. ambulance, fire tenders etc. For these essential jobs designated teams should be made available. The responsibilities of the team and the leader should be given. The essential work teams are- 1. Task Force and repair team. 2. Fire fighting team. 3. Communication team. 4. Security Team. 5. Transport Team. 6. First aid and medical team. 7. Safety team. CONTRACTOR’S EMPLOYEES Contractor's employees will be instructed in the Emergency Procedures before commencing work on this site. They will report to the emergency assembly point on this site. Personnel Manager will guide them in case a major decision like evacuation from the factory is taken. VISITORS Infrequent visitors are registered on each visit. They will be given a Visitors pass which includes an emergency action statement. The responsibility for visitors in emergency situation rests with the person being visited. RESPONSIBILITIES OUTSIDE GENERAL SHIFT HOURS SHIFT SUPERVISOR He/she will act as Site controller for the time being. As soon as becomes aware of the emergency and its location, he will proceed to the scene. He will assess the scale of the incident and direct operations within the affected areas. He/she will contact and inform the Site Controller and Incident Controller immediately. Till their arrival he will continue to perform their duties. He/she will contact the departmental head to act as incident controller and guide Download HSE Docs hseprof.com
- 77. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) Safety Officer and Security Officers for containing the damage. He/she will call the Medical Officer to the plant if necessary. Other staff with designated responsibilities will act as instructed. INFRASTRUCTURE: FIRE FIGHTING FACILITIES: The plant will have adequate fire fighting aids including fire hydrants close to the required locations. There will be Portable Fire Extinguishers of different types and sizes are installed in specific places. The factory siren will be used for raising the alarm and also for ALL CLEAR signal. FIRST AID BOXES are provided in specific locations including at the Assembly point for administering preliminary treatment. A number of employees are trained for first aid use. EMERGENCY CONTROL CENTRE is the point from which the Site Controller directs the movements of Personnel and Equipment during an Emergency. Contents of Emergency Control Centre: • External telephone line and a list of relevant telephone numbers. Below Table 1 provides a list of relevant telephone numbers • Internal telephone and telephone list of Emergency Assembly Points. • List of Emergency Control Team, who must be called showing addresses and telephone numbers. • Emergency Controller's Red White Helmet. • A list of all persons (by title) responsible for groups of employees. • Logs and Emergency Controller's checklist. • Emergency lighting. • Copy of the emergency plan. • List of persons trained in First Aid Fire Fighting. • List of safety cabinets and their contents locations. • Battery operated torches. • Detailed site plan. • First aid equipment including stretchers (in surgery). ASSEMBLY POINT is a place containing an internal telephone and paging system, where people can wait in a group during emergency to receive instructions from the Emergency Controller. A safe place far away from the plant should be pre determined as assembly point Download HSE Docs hseprof.com
- 78. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) where in case of emergency personnel evacuated from the affected areas are to be assembled. The plant workers, contract workers and visitors should assemble in assembly point in case of emergency and the time office clerk should take their attendance so as to assess the missing person during emergency. ALARM SYSTEM: Alarm system varies and will depend on the size of the works area. Simple fire bell, hand operated siren – break open type, fire alarm etc. Automatic alarm may be needed for highly hazardous nature of plant. COMMUNICATION SYSTEM: Communication is a key component to control an emergency. The following communication system may be provided in the plant- • Walky Talky. • Telephone (internal external). • Cell phone. • Intercom/paging. • Runners (verbal or written messages). SIREN FOR EMERGENCY: Siren for emergency should be different from the normal siren. The emergency siren should be audible to a distance of 5 KM radius. The emergency siren should be used only in case of emergency. ESCAPE ROUTE: The escape route from each and every plant should be clearly marked. The escape route is the shortest route to reach out of the plant area to open area, which leads to assembly point. This route should be indicated on the layout plan attached to the On-site Emergency Plan. EVACUATION: All non-essential staff should be evacuated from the emergency site. As soon as the emergency siren rings the workers have to shut down the plant and move to the assembly point. The plant shut down procedure in case of emergency should be prepared and kept ready and responsible person should be nominated for the purpose. PERSONNEL COUNTING: All personnel working in the plant should be counted. Time office person should collect the details of personnel arriving at the assembly point. These should be checked with the attendances of regular workers, contract workers present in the site on the day of emergency. The accident control should be informed and arrangement should be made for searching missing person in the emergency affected area. The employees’ address, contact number of next to kin should be maintained in the time office so that during emergency relatives of those affected due to emergency may be informed accordingly. Download HSE Docs hseprof.com
- 79. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) Information in respect of emergency should be given to the media and other agency. ALL CLEAR SIGNAL: After control of emergency the Work Incident Controller will communicate to the works main controller about the cessation of emergency. The main controller can declare all clear by instructing the time office to sound “All Clear Sirens”. MUTUAL AID SYSTEM: Mutual aid scheme should be introduced among industries so that in case of emergency necessary help from mutual aid partner may be extended. Essential elements of this scheme are – • Mutual aid must be a written document signed by the Chief Executive of the industries concerned. • Specify key personnel who are authorized to give requisition of materials from other industries. • Specify the available quantity of material/equipment that can be spared. • Mode of requisition during emergency. • Mode of payment/ replacement of material given during an emergency. • May be updated from time to time based on experience gained. MOCK DRILLS on emergency planning should be conducted once in 6 months and sequence of events should be recorded for improvement of the exercise. Exercises on On-site Emergency Planning should be monitored by Factory Inspectorate and the high officials of the organization and the plan is reviewed every year. EMERGENCY FACILITIES: The following facilities should be provided in any factory to tackle any emergency at any time. The onsite emergency plan so prepared shall be documented in a printed form in sufficient copies to give all concerned for knowledge, study and easy follow up. The emergency plan shall be rehearsed and practiced at regular intervals to test efficiency of personnel, equipments co-ordinate efforts and to increase confidence and experience to operate such plan • On-site emergency plan should contain - 1. Site plan and topographic plan. 2. Plan showing the fire fighting facilities. 3. Plan showing hazardous material storage area. 4. Material safety data sheets for hazardous chemicals. 5. Facilities available in main control center. 6. List of emergency equipment. 7. List of Safety Equipment. Download HSE Docs hseprof.com
- 80. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) 8. Names and address contact telephone number of Key Personnel 9. List of important telephone numbers and addresses. i. Nearest hospitals and ambulance service center. ii. Nearest fire station. iii. Govt. Officials. iv. Transport provider. • Fire protection and fire fighting facilities. • Emergency lighting and standby power. • Emergency equipment and rescue equipment – i. Breathing apparatus with compressed air cylinder. ii. Fire proximity suit. iii. Resuscitator. iv. Water gel Blanket. v. Low temperature suit. vi. First aid kit. vii. Stretchers. viii. Torches. ix. Ladders. • Safety Equipment – i. Respirators. ii. Gum boots. iii. Safety helmets. iv. Asbestos Rubber hand gloves. v. Goggles and face shield. vi. Toxic gas measuring instruments. vii. Explosive meter. viii. Oxygen measuring instruments. ix. Toxic gas measuring instrument. x. Wind direction indicator. EXTERNAL COMMUNICATION will be done by Site Controller. The following persons and offices may be given updated information as necessary and ask for necessary help. • SDO • Police • Fire Brigade • District Hospital • GPCB • Factory Inspector • Local Media • District Magistrate Download HSE Docs hseprof.com
- 81. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) Table: Important Telephone Numbers NAME DESIGNATION CONTACT NO EXT.NO (INT) Security Officer Fire Officer Safety Officer Plant Manager Operation Manager ERT Manager Police Officer Medical Officer OFF-SITE EMERGENCY PLAN Type of emergency facilities/ actions required from outside bodies: • Fire fighting facilities required: Factory will have its own fire fighting facilities but during emergency, fire brigade may be called. • Police help required during emergency for evacuation of the people, traffic control security arrangements etc. will be available. • Medical help required: seriously injured personnel may be referred to the local Hospital / Nursing Home / ESI Hospital depending upon the gravity and type of injuries. CONCLUSION: To carry out mock exercises and rehearsal of the off site plan to ensure its efficiency, test and response, interaction and co-ordination of operators various service organizations evaluate the effectiveness and adequacy of the equipments and to gain experience and confidence to implement the plan. The finalized disaster plan shall be given to all concerned for implementation and rehearsal forpreparedness. Download HSE Docs hseprof.com
- 82. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) Deals withpolice, media andoutside enquiries Works as Liaison officer Decides the level of the emergencydiscussing with Incident Controller Undertake a continuous review of the possible developments and take decision accordingly Deputy Incident controller will act as assistant to Incident controller Guides with knowledge of safety aspects in the factory Fire Fighting Plant officers take up duties Involving their own units Informs Medical Officer EMERGENCY RESPONSE DIAGRAM Incident Controller will rush to the incident site and takes all site related Personnel Manager Communication Officer Safety Officer Security Officer Organizes all requirements of Emergency Emergency Proceeds to the Emergency Control Centre and takes Message to Site Controller Download HSE Docs hseprof.com
- 83. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) PURPOSE AMMONIA (NH3) The major use of ammonia is as a fertilizer. It can be applied directly to the soil or in the form of ammonium salts. Ammonia is also used in the manufacture of commercial explosives (e.g., TNT, nitroglycerin, and nitrocellulose). In the textile industry, ammonia is used in the manufacture of synthetic fibers (e.g., nylon and rayon). It also neutralizes acidic by-products of petroleum refining, and in the rubber industry it prevents the coagulation of raw latex during transportation from plantation to factory. Ammonia is used in various metallurgical processes, including the nitriding of alloy sheets to harden their surfaces. Because ammonia can be decomposed easily to yield hydrogen, it is a convenient portable source of atomic hydrogen for welding. In addition, ammonia can absorb substantial amounts of heat from its surroundings (i.e., one gram of ammonia absorbs 327 calories of heat), which makes it useful as a coolant in refrigeration and air-conditioning equipment. Ammonia used commercially is often called anhydrous ammonia. Household ammonia is a solution of anhydrous ammonia (NH3) and water. PHYSICAL CHEMICAL PROPERTIES / DEFINITION OF CHEMICAL GROUP CAS: 7664-41-7 Class: Toxic, Compressed gas, Corrosive Molecular Formula: NH3 Form (physical state): gas Color: Colorless Boiling Point: -33 ° C POTENTIAL HAZARDS / TOXICITY Potential Health Effects Target Organs: Lungs, Central nervous system, Liver, Kidney Inhalation: May be harmful if inhaled. Material is extremely destructive to the tissue of the mucous membranes and upper respiratory tract. Skin: May be harmful if absorbed through skin. Causes skin burns. Eyes: Causes eye burns. Ingestion: May be harmful if swallowed. PERSONAL PROTECTIVE EQUIPMENT (PPE) RESPIRATORY PROTECTION: Use a full-face particle respirator with type N100 (US) respirator cartridges. Download HSE Docs hseprof.com
- 84. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) Respirators should be used only under any of the following circumstances: • As a last line of defense (i.e., after engineering and administrative controls have been exhausted). • When Permissible Exposure Limit (PEL) has exceeded or when there is a possibility that PEL will be exceeded. • Regulations require the use of a respirator. • An employer requires the use of a respirator. • There is potential for harmful exposure due to an atmospheric contaminant (in the absence of PEL) • As PPE in the event of a chemical spill clean-up process HAND PROTECTION: Gloves must be worn. Use proper glove removal technique to avoid any skin contact. Nitride or Neoprene gloves are recommended. • NOTE: Consult with your preferred glove manufacturer to ensure that the gloves you plan on using are compatible with Ammonia. EYE PROTECTION: Wear chemical splash goggles or a face shield to protect from splash hazards and chemical vapors. SKIN BODY PROTECTION: • Flame resistant lab coat • Full-length pants • Closed-toe rubber or leather shoes HYGIENE MEASURES: Avoid contact with skin, eyes, and clothing. Wash hands before breaks and immediately after handling the product. ENGINEERING CONTROLS: Handle using a chemical fume hood with good ventilation and electrically grounded lines and equipment. FIRST AID PROCEDURES If inhaled…Move to fresh air and give oxygen. If the person is not breathing, give artificial respiration. Avoid mouth to mouth contact. In case of skin contact…Remove all contaminated clothing. Immediately (within seconds) flush affected area for FIFTEEN (15) minutes. In case of eye contact…Remove any contact lenses. Use nearest emergency eyewash immediately for at least 15 minutes. Continue eye rinse during transport to the hospital. Download HSE Docs hseprof.com
- 85. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) If swallowed…DO NOT INDUCE VOMITING. Never give anything by mouth to an unconscious person. SPECIAL STORAGE HANDLING REQUIREMENTS STORAGE • Ensure the container is tightly closed at all times. • Keep in a dry, cool, and well-ventilated area. • Keep away from incompatible materials and conditions. • Keep cool and protect from sunlight. HANDLING • The lab where the material is being handled has an approved / certified emergency eyewash and safety shower. • Ensure you are wearing the following minimum PPE: tightly fitting safety goggles and face shield, flame resistant lab coat, full length pants, close-toe rubber or leather shoes, gloves constructed with nitrile or neoprene. • Lab emergency contact information must be readily posted. Easy access to a cellular phone or land line is readily available. • Avoid inhalation and contact with skin and eyes. • Avoid inhalation of vapor or mist. • Avoid formation of dust. SPILL AND ACCIDENT PROCEDURE PERSONAL PRECAUTIONS: Avoid breathing vapors, mist or gas. Ensure adequate ventilation. Evacuate personnel to safe areas. Do not attempt clean-up without minimum PPE. Beware of vapors accumulating to form explosive concentrations. Vapors can accumulate in low areas. ENVIRONMENTAL PRECAUTIONS: Prevent further leakage or spillage – if safe to do so. Do not allow product to enter drains. Discharge into environment must be avoided. METHODS AND MATERIALS FOR CONTAINMENT AND CLEAN-UP: Consider material compatibility prior to clean-up. Verify spill kit is available. Contain spillage and the collect with an electrically protected vacuum cleaner or by wet-brushing and place in container for disposal according to regulations. • Immediately assess amount spilled, follow posted Emergency Response Guide procedures for hazardous materials incidents. • If a chemical exposure has occurred, a fellow worker shall call Emergency number and EHS department. Download HSE Docs hseprof.com
- 86. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) • Don compatible gloves and other protective PPE if not already being worn. • Secure / restrict access to the area of the spill to prevent spread of the chemical. • Use the available spill kit to stop and contain the spill. Bag the collected material. • Label and tag as hazardous waste and submit a pick-up request to EHS using EHS Assistant. DECONTAMINATION / WASTE DISPOSAL PROCEDURE LABEL WASTE: Attach a completed Hazardous Waste tag to all waste containers as soon as the first drop of waste is added to the container. STORE WASTE • Store hazardous waste in closed containers, in secondary containment and in a designated storage location. • Double-bag dry waste using sealable transparent bags. • Waste must be under the control of the person generating and disposing of it. DISPOSE OF WASTE • Dispose of regularly generated chemical waste within 90 days. • Use EHS Assistant online hazardous waste pick-up request system. • Contact EHS Department with questions. DOCUMENTATION OF TRAINING • Prior to conducting any work with this material, Principal Investigator or designee must provide to his/her laboratory personnel specific to the hazards involved in working with this substance, work area decontamination, and emergency procedures. • The Principal Investigator must provide his/her laboratory personnel with a copy of SOP and a copy of the MSDS provided by the manufacturer. EDUCATION OF PUBLIC / WORKER People working within the influence zone will be educated on the emergency in a suitable manner. This can be achieved only through the Local and District Authorities. However, necessary information can be extended to the Authority. ******* Download HSE Docs hseprof.com
- 87. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) STANDARD OPERATING PROCEDURE (EHS) PROJECT PROJECT MANAGEMENT CONSULTANCY SERVICES FOR REPLACEMENT OF SINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK AT GNFC AMMONIA PLANT, BHARUCH OWNER GUJARAT NARMADA VALLEY FERTILIZERS CHEMICALS BHARUCH - GUJARAT, INDIA ENGINEERING CONSULTANT PROJECTS DEVELOPMENT INDIA LIMITED (A Govt. of India Undertaking) SAMTA, SUBHANPURA, VADODARA 0 17.12.2020 17.12.2020 FOR IMPLEMENTATION TAV KMS SNY REV REV DATE EFF.DATE PURPOSE PREPD REVWD APPD All rights reserved Download HSE Docs hseprof.com
- 88. ANNEXURE – R HAZARDIDENTIFICATION RISK ASSESMENT (HIRA) CONTENT CLAUSE TITLE PAGE NO. 1 .0 Scope 6 2 .0 References 6 3 .0 Requirement of Health, Safety and Environment (HSE) Management System to be complied by Bidders 7 3.1 Management Responsibility 7 3.1 .1 HSE Policy Objective 7 3.1 .2 Management System 7 3.1 .3 Indemnification 7 3.1 .4 Deployment Qualification of Safety Personnel 7 3.1 .5 Implementation, Inspection Monitoring 10 3.1 .6 Behavior Based Safety 12 3.1 .7 Awareness Motivation 14 3.1 .8 Fire prevention First-Aid 14 3.1 .9 Documentation 15 3.1 .10 Audit 15 3.1 .11 Meetings 16 3.1 .12 Intoxicating drinks drugs and smoking 17 3.1 .13 Penalty 18 3.1 .14 Accident/Incident investigation 21 3.2 House Keeping 22 3.3 HSE Measures 23 3 .3 .1 Construction Hazards 23 3 .3 .2 Accessibility 25 3 .3 .3 Personal Protective Equipments (PPEs) 26 3 .3 .4 Working at height 27 3 .3 .5 Scaffoldings Barricading 29 3 .3 .6 Electrical installations 30 3 .3 .7 Welding/Gas cutting 34 3. 3 .8 Ergonomics and tools tackles 35 3.3 .9 Occupational Health 36 3.3.10 Hazardous substances 37 3.3.11 Slips, trips falls 38 3.3.12 Radiation exposure 38 3.3.13 Explosives/Blasting operations 39 3.3.14 Demolition/Dismantling 39 3.3.15 Road Safety 40 3.3.16 Welfare measures 41 3.3.17 Environment Protection 42 3.3.18 Rules Regulations 42 3.3.19 Weather Protection 43 Download HSE Docs hseprof.com
- 89. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 3 OF 63 3.3.20 Communication 43 3.3.21 Confined Space Entry 44 3.3.22 Heavy Lifts 44 3.3.23 Key performance indicators 45 3.3.24 Unsuitable Land Conditions 46 3.3.25 Under Water Inspection 47 3.3.26 Excavation 47 3 .4 Tool Box talks 48 3 .5 Training Induction Program 49 3 .6 Additional safety requirements for working Inside a running plant. 51 3 .7 Self Assessment and Enhancement 53 3 .8 HSE Promotion 53 3 .9 LOTO for isolation of energy source 53 4 .0 Details of HSE Management System by Contractor 54 4 .1 On Award of Contract 54 4 .2 During Job Execution 55 4 .3 During short listing of the sub-contractors 57 APPENDICES 1. Standards/Codes on HSE Appendix-A 2. Details of First AID Box Appendix-B 3. Types of Fire Extinguishers their Appln. Appendix-C 4. Indicative List of statutory Acts Rules Appendix-D 5. Training subjects / topics Appendix-E 6. List of HSE procedures Appendix-F Download HSE Docs hseprof.com
- 90. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 4 OF 63 ABREVATIONS AERB : Atomic Energy Regulatory Board ANSI : American National Standards Institute BARC : Bhabha Atomic Research Centre BS : British Standard PDIL : Projects development India Limited ELCB : Earth Leakage Circuit Breaker EPC : Engineering, Procurement and Construction EPCC : Engineering, Procurement, Construction and Commissioning ESI : Employee State Insurance GCC : General Conditions of Contract GM : General Manager GTAW : Gas Tungsten Arc Welding HOD : Head of Department HSE : Health, Safety Environment HV : High Voltage IS : Indian Standard IE : Indian Electricity JSA : Job Safety Analysis LOTO : Lock Out Tag Out LPG : Liquefied Petroleum Gas LSTK : Lump Sum Turn Key MV : Medium Voltage PPE : Personal Protective Equipment RCM : Resident Construction Manager or Site-in-Charge, as applicable ROW : Right of Way SCC : Special Conditions of Contract SLI : Safe Load Indicator TBM : Tool Box Talks/Meeting Download HSE Docs hseprof.com
- 91. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 5 OF 63 1.0 SCOPE This specification establishes the Health, Safety and Environment (HSE) management requirement to be complied by Contractors/Vendors including their sub-contractors/sub vendors during work. This specification is not intended to replace the necessary professional judgment needed to design implement an effective HSE system for construction activities and the contractor is expected to fulfill HSE requirements in this specification as a minimum. It is expected that contractor shall implement best HSE practices beyond whatever are mentioned in this specification. Requirements stipulated in this specification shall supplement the requirements of HSE Management given in relevant Act(s)/legislations, General Conditions of Contract (GCC), Special Conditions of Contract (SCC) and Job (Technical) Specifications. Where different documents stipulate different requirements, the most stringent shall apply. REFERENCES The document should be read in conjunction with following: - General Conditions of Contract (GCC) - Special Conditions of Contract (SCC) - Building and other construction workers Act, - Indian Factories Act - Job (Technical) specifications - Relevant International / National Codes - Relevant State National Statutory requirements. - Operating Manuals Recommendation of Manufacturer of various construction Machineries Download HSE Docs hseprof.com
- 92. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 6 OF 63 3.0 Requirements of HSE Management system to be complied by Bidders 3. 1 Management Responsibility 3 .1.1 HSE Policy Objectives The Contractor should have a documented HSE policy duly objectives to demonstrate commitment of their organization to ensure health, safety and environment aspects in their line of operations. HSE Policy of the contractor shall be made available to Owner / PDIL at the place of execution of specific contract works, as a valid document. 3 .1.2 Management System The HSE management system of the Contractor shall cover the HSE requirements and commitments to fulfill them, including but not limited to what are specified under clause 1.0 and 2.0 above. The Contractor shall obtain the approval of its site specific HSE Plan from PDIL /Owner prior to commencement of any site works. Corporate as well as Site management of the Contractor shall ensure compliance of their HSE Plan at work sites in its entirety in true spirit. 3 .1.3 Indemnification Contractor shall indemnify hold harmless, Owner /PDIL their representatives, free from any and all liabilities arising out of non-fulfillment of HSE requirements or its consequences. 3 .1.4 Deployment qualifications of Safety personnel The Contractor shall designate/deploy various categories of HSE personnel at site as indicated below in sufficient number. In no case, deployment of safety Download HSE Docs hseprof.com
- 93. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 7 OF 63 Supervisor / Safety Steward shall substitute deployment of Safety Officer / Safety Engineer what is indicated in relevant statute of BOCW Act i.e. deployment of safety officer /Safety Engineer is compulsory at project site. The Safety supervisors, Safety stewards etc. would facilitate the HSE tasks at grass root level for construction sites and shall assist Safety Officer / Engineers. A) Safety Steward For every 250 workmen, one safety steward shall be deployed. As a minimum, he shall preferably possess School leaving Certificate (of Class XII with Physics Chemistry etc.) and trained in fire-fighting as well as in safety/occupational health related subjects, with minimum two year of practical experience in construction work environment and preferably have adequate knowledge of the language spoken by majority of the workers at the construction site. B) Safety Supervisor For every 500 workmen, one safety Supervisor shall be deployed. As a minimum, he shall possess a recognized Degree in Science (with Physics Chemistry) or a diploma in Engineering or Technology with minimum Two years of practical experience in construction work environment and should possess requisite skills to deal with construction safety fire related day-to-day issues. C) Safety Officer / Safety Engineer One for every 1000 workers or part thereof shall be deployed. Safety officer/ Engineer Should Possess following Qualification Experience: • Recognized degree in any branch of Engineering or Technology or Architecture with practical experience of working in a building or other Download HSE Docs hseprof.com
- 94. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 8 OF 63 construction work in supervisory capacity for a period of not less than two years, or possessing recognized diploma in any branch of Engineering or Technology with practical experience of building or other construction work in supervisory capacity for a period of not less than five years. • Recognized degree or diploma in Industrial safety with one paper in Construction Safety. • Preferably have adequate knowledge of the language spoken by majority of the workers at the construction site. • Person possessing Graduation Degree in Science with Physics Chemistry and degree or diploma in Industrial Safety (from any Indian institutes recognized by AICTE or State Council of Tech. Education of any Indian State) with practical experience of working in a building, plant or other construction works (as Safety Officer, in line with Indian Factories Act, 1958) for a period of not less than five years, may be considered as Safety Officer, in case Owner/Client of the project agrees for /approves the same. D) HSE In-Charge In case there is more than one Safety Officer at any project construction site, one of them, who is senior most by experience (in HSE discipline), may be designated as HSE In-Charge. Duties responsibilities of such person shall be commensurate with that of relevant statute and primarily to coordinate with top management of Client and contractors. In case the statutory requirements i.e. State or Central Acts and / or Rules as applicable like the Building and Other Construction Workers’ Regulation of Employment and Conditions of Service- Act,1996 or State Rules (wherever notified), the Factories Act, 1948 or Rules (wherever notified), etc. are more stringent than above clarifications, the same shall be followed. Contractors shall ensure physical availability of safety personnel at the place of specific work location, where Hot Work Permit is required / granted. No work Download HSE Docs hseprof.com
- 95. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 9 OF 63 shall be started at any of the project sites until above safety personnel concerned Site Engineer of Contractor are physically deployed at site. The Contractor shall submit a HSE organogram clearly indicating the lines of responsibility and reporting system and elaborate the responsibilities of safety personnel in their HSE Plan. The Contractor shall verify authenticate credentials of such safety personnel and furnish Bio-Data/ Resume/ Curriculum Vitae of the safety personnel as above for PDIL/Owner’s approval, at least 1 month before the mobilization. The Contractor, whenever required, shall arrange submission of original testimonials/certificates of their Safety personnel, to PDIL /Owner (for verification /scrutiny, etc.) Imposition / Realization of penalty shall not absolve the Contractor from his/her responsibility of deploying competent safety officer at site. Adequate planning and deployment of safety personnel shall be ensured by the Contractor so that field activities do not get affected because of non-deployment of competent qualified safety people in appropriate numbers. 3 .1.5 Implementation, Inspection / Monitoring • The Contractor shall be fully responsible for planning, reporting, implementing and monitoring all HSE requirements and compliance of all laws statutory requirements. The Contractor shall also ensure that the HSE requirements are clearly understood implemented conscientiously by their site personnel at all levels at site. • The Contractor shall ensure physical presence of their field engineers/supervisors, during the continuation of their contract works /site activities including all material transportation activities. Physical absence of experienced field engineers / supervisors of Contractor at critical work spot during the course of work may invite severe penalization as per the discretion of EIC, including halting / stoppage of work. Download HSE Docs hseprof.com
- 96. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 10 OF 63 • Contractor shall furnish their annual Inspection Plan, with regard to project issues /subjects, frequency and performers to PDIL /Owner. • The Contractor shall regularly review inspection report internally and implement all practical steps / actions for improving the status continuously. • The Contractor shall ensure important safety checks right from beginning of works at every work site locations and to this effect “Daily Safety Check List” shall be prepared by field engineer duly checked by safety personnel for conformance. • The Contractor shall carry out inspection to identify various unsafe conditions of work sites/machinery/equipments as well as unsafe acts on the part of workmen/supervisor /engineer while carrying out different project related works. • Adequate records for all inspections shall be maintained by the Contractor and the same shall be furnished to PDIL /Owner, whenever sought. • The Contractor shall not carry-out work by engaging single worker anywhere without any supervisor anytime during day or night. • To demonstrate involvement/commitment of site management of Contractor, at least one Safety Walk through in a month shall be carried out by Contractor’s head of site (along with his area manager/field engineers) and a report shall be furnished to PDIL/Owner “Safety walk through report” followed by compliance for unsatisfactory remarks. • As a general practice lifting tools/tackles, machinery, accessories etc. shall be inspected, tested and examined by competent people (approved by concerned State authorities) before being used at site and also at periodical interval (e.g. during replacement, extension, modification, elongation / reduction of machine / parts, etc.) as per relevant statutes. Hydra, cranes, lifting machinery, mobile equipments / machinery / vehicles, etc. shall be inspected regularly by only competent / experienced personnel at site and requisite records for such inspections shall be maintained by every contractor. Contractor shall also maintain records of maintenance of all other site Download HSE Docs hseprof.com
- 97. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 11 OF 63 machinery (e.g. generators, rectifiers, compressors, cutters, etc.) portable tools /equipments being used at project related works (e.g. drills, abrasive wheels, punches, chisels, spanners, etc.). The Contractor shall not make use of arbitrarily fabricated ‘derricks’ at project site for lifting / lowering of construction materials. • Site facilities /temporary installations, e.g. batching plant, cement go down, DG-room, temporary electrical panels/distribution boards, shot-blasting booth, fabrication yards, etc. and site welfare facilities, like labour colonies, canteen/pantry, rest-shelters, motorcycle/bicycle-shed, site washing facilities, First-aid centers, urinals/toilets, etc. should be periodically inspected by Contractor (preferably utilizing HR /Admin personnel to inspect site welfare facilities) and records to be maintained. 3 .1.6 Behavior Based Safety • The contractor shall develop a system to implement Behavior-Based Safety (BBS) through which work groups can identify, measure and change the behaviors’ of employees and workers. • The BBS process shall include the following: • Identify the behaviors’ critical to obtaining required safety performance. • Communicate the behaviors’ and how they are performed correctly to all observe the work force and record safe/at risk behaviors Intervene with workers to give positive reinforcement when safe behaviors’ are observed. • Provide coaching/ corrections when at risk behaviors’ are observed. • Collect and record observation data. • Summarize and analyze observation data • Communicate observation data and analysis results to all employees. • Provide recognition or celebrate when safe behavior improvements occur. Download HSE Docs hseprof.com
- 98. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 12 OF 63 • Change behaviors to be observed or change activators or change consequences as appropriate. • Communicate any changes to workforce. • Contractor through its own HSE committee shall implement the above process. The necessary procedures and reporting formats shall be developed by the contractor for approval by PDIL /Owner. • The HSE committee of contractor shall observe individual’s behavior for safe practices adapted for utilization /execution of work for following as a minimum:- - PPE - Tools equipment - Hazard Identification control - House keeping - Confined space entry - Hot works - Excavation - Loading unloading - Work at height - Stacking storage - Ergonomics - Procedures 3 .1.7 Awareness and Motivation • The Contractor shall promote and develop awareness on Health, Safety and Environment protection among all personnel working for the Contractor. Download HSE Docs hseprof.com
- 99. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 13 OF 63 • Regular awareness programs and fabrication shop / work site meetings at least on monthly basis shall be arranged on HSE activities to cover hazards/risks involved in various operations during construction. • Contractor to motivate encourage the workmen supervisory staff by issuing / awarding them with tokens/ gifts/ mementos/ monetary incentives / certificates, etc. • Contractor shall assess recognize the behavioral change of its site engineers / supervisors periodically and constantly motivate / encourage them to implement HSE practices at project works. 3 .1.8 Fire prevention First-Aid • The Contractor shall arrange suitable First-aid measures such as First Aid Box (Refer Appendix-B for details), trained personnel/nurse (male) to administer First Aid, stand-by Ambulance vehicle. • The Contractor shall arrange installation of fire protection measures such as adequate number of steel buckets with sand water and adequate number of appropriate portable fire extinguishers (Refer Appendix-C for details) to the satisfaction of PDIL /Owner. • The Contractor shall deploy trained supervisory personnel / field engineers to cater to any emergency situation. • In case the number of workers exceeds 500, the Contractor shall position an Ambulance / vehicle and nurse on round the clock basis very close to the worksite. • The Contractor shall arrange FIRE DRILL at each site at least once in three months, involving site workmen and site supervisory personnel engineers. The Contractor shall maintain adequate record of such fire drills at project site. 3 .1.9 Documentation Download HSE Docs hseprof.com
- 100. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 14 OF 63 The Contractor shall evolve a comprehensive, planned and documented system covering the following as a minimum for implementation and monitoring of the HSE requirements and the same shall be submitted for approval by Owner/PDIL. - HSE Organogram - Site specific HSE Plan - Safety Procedures, forms and Checklist. - Inspections and Test Plan - Risk Assessment Job Safety Analysis for critical works. The monitoring for implementation shall be done by regular inspections and compliance of the observations thereof. The Contractor shall get similar HSE requirements implemented at his sub-contractors work site /office. However, compliance of HSE requirements shall be the responsibility of the Contractor. Any review/approval by PDIL /Owner shall not absolve contractor of his responsibility /liability in relation to fulfilling all HSE requirements. 3 .1.10 Audit The Contractor shall submit an Audit Plan to PDIL/Owner indicating the type of audits and covering following as minimum: • Internal HSE audits regularly at least on quarterly basis by engaging internal qualified auditors (viz safety officers /Construction personnel having 5 years experience in construction safety and Lead Auditor Course :OSHA 18001 certification). • External HSE audits regularly at least on every six months by engaging qualified external auditors (viz safety officers/Construction personnel having 10 years experience in construction safety and Lead Auditor Course :OSHA 18001 certification). All HSE shortfalls/non-conformances on HSE matters brought out during review /audit shall be resolved forthwith (generally within a Download HSE Docs hseprof.com
- 101. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 15 OF 63 week) by Contractor compliance report shall be submitted to PDIL /Owner. In addition to above audits by contractor, the contractor’s work shall be subjected to HSE audit by PDIL /Owner at any point of time during the pendency of contract. The Contractor shall take all actions required to comply with the findings of the Audit Report and issue regular Compliance Reports for the same to Owner /PDIL till all the findings of the Audit Report are fully complied. Failure to carry-out HSE Audits its compliance (internal external) by Contractor, shall invite penalization. 3 .1.11 Meetings • The Contractor shall ensure participation of his top most executive at site (viz. Resident Construction Manager / Resident Engineer / Project Manager / Site- in-Charge) in Safety Committee/ HSE Committee meetings arranged by PDIL/Owner usually on monthly basis or as and when called for. In case Contractor’s top most executive at site is not in a position to attend such meeting, he shall inform PDIL/Owner in writing before the commencement of such meeting indicating reasons of his absence and nominate his representative – failure to do so may invite very stringent penalization against the specific Contractor, as deemed fit in Contract. The obligation of compliance of any observations during the meeting shall be always time bound. The Contractor shall always assist PDIL/Owner to achieve the targets set by them on HSE management during the project implementation. • In addition, the Contractor shall also arrange internal HSE meetings chaired by his top most executive at site on weekly basis and maintain records. Such internal HSE meetings shall essentially be attended by field engineers / supervisors ( not by safety personnel only) of the Contractor and its associates. Records of such internal HSE meetings shall be maintained by the Contractor for review by PDIL/Owner or for any HSE Audits. Download HSE Docs hseprof.com
- 102. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 16 OF 63 • Agenda of internal HSE meeting should broadly cover: - a. Confirmation of record notes / minutes of previous meeting b. Discussion on outstanding subjects of previous points / subjects, if any c. Incidents / Accidents (of all types) at project site, if any d. Current topics related to site activities / subjects of discussion e. House keeping f. Behavioral Safety g. Information / views / deliberations of members / site sub Contractors h. Report from Owner / Client i. Status of Safety awareness, Induction programs Training programs j. The time frame for such HSE meeting shall be religiously maintained by one and all. 3 .1.12 Intoxicating drinks drugs and Smoking • The Contractor shall ensure that his staff members workers (permanent as well casual) shall not be in a state of intoxication during working hours and shall abide by any law relating to consumption possession of intoxicating drinks or drugs in force. • The Contractor shall not allow any workman to commence any work at any locations of project activity who is/are influenced / effected with the intake of alcohol, drugs or any other intoxicating items being consumed prior to start of work or working day. • Awareness about local laws on this issue shall form part of the Induction Training and compulsory work-site discipline. • The Contractor shall ensure that all personnel working for him comply with “No-Smoking” requirements of the Owner as notified from time to time. Cigarettes, lighters, auto ignition tools or appliances as well as intoxicating drugs, dry tobacco powder, etc. shall not be allowed inside the project / plant complex. Download HSE Docs hseprof.com
- 103. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 17 OF 63 • Smoking shall be permitted only inside smoking booths exclusively designated authorized by the Owner /PDIL. 3 .1.13 Penalty The Contractor shall adhere consistently to all provisions of HSE requirements. In case of non compliances and also for repeated failure in implementation of any of the HSE provisions, PDIL /Owner may impose stoppage of work without any cost time implication to the Owner and/or impose a suitable penalty. The amount of penalty to be levied against defaulted Contractor shall be up to a cumulative limit of 2 .0 % (Two percent) of the contract value for Item Rate, 0 .5 % (Zero decimal five percent) of the contract value for LSTK, EPC, EPCC This penalty shall be in addition to all other penalties specified elsewhere in the contract. The decision of imposing stop-work-instruction and imposition of penalty shall rest with PDIL /Owner. The same shall be binding on the Contractor. Imposition of penalty does not make the Contractor eligible to continue the work in unsafe manner. The amount of penalty applicable for the Contractor on different types of HSE violations is specified below: Sr. No. Violation of HSE norms Penalty Amount 1 For not using personal protective equipment (Helmet, Shoes, Goggles, Gloves, Full body harness, Face shield, Boiler suit, etc.) Rs 500/- per day/ Item / Person. 2 Working without Work Permit / Clearance Rs 20,000/- per occasion. 3 Execution of work without deployment of requisite field engineer / supervisor at work spot. Rs. 5,000/- per violation per day 4 Unsafe electrical practices (not installing ELCB, using poor joints of cables, using naked wire without top plug into socket, laying wire / cables on the roads, electrical jobs by incompetent person, etc.) Rs 5,000/- per item per day. 5 Working at height without full body harness, using Rs. 5,000/- per case per day. Download HSE Docs hseprof.com
- 104. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 18 OF 63 non-standard/ rejected scaffolding and not arranging fall protection arrangement as required, like handrails, life-lines, safety nets etc. 6 Unsafe handling of compressed gas cylinders (No trolley, jubilee clips double gauge regulator, and not keeping cylinders vertical during storage/handling). Rs 500/- per item per day. 7 Use of domestic LPG for cutting purpose / not using flash back arresters on both the hoses/tubes on both ends. Rs. 3,000/- per occasion. 8 No fencing /barricading of excavated areas/trenches. Rs. 3,000/- per occasion 9 Not providing shoring /strutting /proper slope and not keeping the excavated earth at least 1.5 M away from excavated area. Rs.5,000/- per occasion 10 Non display of scaffold tags, caution boards, list of hospitals, emergency services available at work locations. Rs.1,000/- per occasion per day 11 Traffic rules violations like over speeding of vehicles, rash driving, talking on mobile phones during vehicle driving, wrong parking, not using seatbelts, vehicles not fitted with reverse horn / warning alarms / flicker lamps during foggy weather. Rs. 2,000/- per occasion per day 12 Absence of Contractor’s RCM/SIC or his nominated representative (prior approval must be taken for each meeting for nomination) from site HSE meetings whenever called by PDIL / Owner failure to nominate his immediate deputy (in the site organogram) for such HSE meetings. Rs5,000/- per meeting 13 Failure to maintain HSE records by Contractor Safety personnel, in line with approved HSE Plan/Procedures/Contract specifications. Rs 5,000/- per month 14 Failure to conduct daily site safety inspection (by Contractor’s safety engineers/safety officers), internal HSE meeting, internal HSE Awareness / Motivation Program, Site HSE Training and HSE audit at predefined frequencies (as approved in HSE Plan). Rs.10,000/- per occasion. 15 Failure to submit the monthly HSE report by 5th of subsequent month to Project’s Engineer-in-Charge / Owner Rs. 10,000/- per occasion and Rs. 1,000/- per day of further delay. 16 Liquor/alcohol/ drugs/ Intoxicating drinks etc. carrying or consumption inside port premises. Rs 1,000 warning letter on 1st offence, Rs 2,500 termination of worker on 2nd offence. 17 Failure to report follow up accident (including Rs. 25,000/- per occasion Download HSE Docs hseprof.com
- 105. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 19 OF 63 Near Miss) reporting system within specific timeframe. 18 Degradation of environment (not confining toxic spills, spilling oil /lubricants onto ground) Rs10,000/- per occasion 19 Not medically examining the workers before allowing them to work at height / to work in confined space / to work in shot-blasting / to work for painting / to work in bitumen or asphalt works, not providing ear muffs while allowing them to work in noise polluted areas, made them to work in air polluted areas without respiratory protective devices, etc. Rs 5,000/- per occasion per worker 20 Violation of any other safety condition as per job HSE plan / work permit and HSE conditions of contract (e.g. using crowbar on cable trenches, improper welding booth, not keeping fire extinguisher ready at hot work site, unsafe rigging practices, non-availability of First-Aid box at site, not using hood with respiratory devices by blaster for shot//grit blasting, etc.) Rs. 5,000/- per occasion 21 Failure to carry-out Safety audit in time (internal external), close-out of identified shortfalls of Observations of Safety Aspects(OSA),etc Rs. 20,000/- per occasion 22 Carrying out sand blasting instead of grit / shot blasting Rs. 50,000/- per day 23 Failure to deploy adequately qualified and competent Safety Officer Rs. 10,000/- per day per Officer 24 Utilization of hydra/ back-hoe loader for material shifting or any other unauthorized /unsafe lifting works Rs 25,000/- per occasion 25 Any incident / accident at project site has been caused because of willful negligence or gross violation of safety measures / provisions on the part of the Contractor or any of its sub-agencies (Fatal ,Major Accidents) Rs 10,00,000/- per occasion (1st Instant) Rs 15,00,000/- per occasion (2nd Instant) Termination of present Contract (3rd instant) 26 Poor Housekeeping Rs. 5,000/- per occasion per day 27 Any violation not covered above To be decided by PDIL/Owner. The Contractor shall make his field engineers/supervisors fully aware of the fact that they keep track with the site workmen for their behavior and compliance of Download HSE Docs hseprof.com
- 106. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 20 OF 63 various HSE requirements. Safety lapses /defects of project construction site shall be attributable to the concerned job supervisor /engineer of the Contractor, (who remains directly responsible for safely executing field works). For repeated HSE violations, concerned job supervisor /engineer shall be reprimanded or appropriate action, as deemed fit, shall be initiated (with information to PDIL Owner) by the concerned Contractor. Contractor shall initiate levy of mentioned cash fine and verbal warning shall be given to the worker/employee during his first HSE violation. A written warning shall be issued on second violation Fine will be double and specific training shall be arranged / provided by the Contractor to enhance HSE awareness/skill including feedback on the mistakes/ flaws. Any further violation of HSE stipulations by the erring individuals shall call for his forthright debar from the specific construction site and fine will be 10 times higher. A record of warnings for each worker / employee shall be maintained by the Contractor, like by punching their cards / Gate passes or by displaying their names at the Project entry gate. Warnings, penalizations, appreciations etc. shall be discussed in HSE Committee meetings by site Head of the Contractor. 3 .1.14 Accident / Incident investigation All accidents / incidents shall be informed to PDIL / Owner at least telephonically by Contractor immediately and in writing within 24 hours as applicable, by Contractor. Thereafter, a Supplementary Accident / Incident investigation Report shall be submitted to PDIL / Owner within 72 hours. Near Miss incidents, Dangerous accidents / incident shall also be reported within 24 hours. The accident/ incident shall be investigated by a team of Contractor’s senior Site personnel (involving Site-in- Charge or at least by his deputy) for establishing root-cause and recommending corrective preventive actions. Findings shall be documented and suitable actions taken to avoid recurrences shall be communicated to PDIL / Owner. Owner/ PDIL shall have the liberty to Download HSE Docs hseprof.com
- 107. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 21 OF 63 independently investigate such occurrences and the Contractor shall extend all necessary help and cooperation in this regard. PDIL/Owner shall have the right to share the content of this report with the outside world. 3. 2 House Keeping The Contractor shall ensure that a high degree of housekeeping is maintained and shall ensure the followings: • All surplus earth and debris are removed /disposed off from the working areas to designated locations. • Unused /surplus cables, steel items and steel scrap lying scattered at different places within the working areas are removed to identifylocations. • All wooden scrap, empty wooden cable drums and other combustible packing materials, shall be removed from work place to identified locations. • Roads shall be kept clear and materials like pipes, steel, sand, boulders, concrete, chips and bricks etc shall not be allowed on the roads to obstruct free movement of men machineries. • Fabricated steel structural, pipes piping materials shall be stacked properly for erection. • Water logging on roads shall not be allowed. • No parking of trucks /trolleys, cranes and trailers etc shall be allowed on roads, which may obstruct the traffic movement. • Utmost care shall be taken to ensure over all cleanliness and proper upkeep of the working areas. • Trucks carrying sand, earth and pulverized materials etc. shall be covered while moving within the plant area /these materials shall be transported with top surface wet. • The contractor shall ensure that the atmosphere in plant area and on roads is free from particulate matter like dust, sand, etc. by keeping the top surface wet for ease in breathing. Download HSE Docs hseprof.com
- 108. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 22 OF 63 • At least two exits for any unit area shall be assured at all times – same arrangement is preferable for digging pits /trench excavation /elevated work platforms /confined spaces etc. • Welding cables and the power cable must be segregated and properly stored and used .The same shall be laid away from the area of movement and shall be free from obstruction. • Schedule for upkeep /cleaning of site to be firmed up and implemented on regular basis for maintaining high standard of housekeeping and maintain records for the same. 3. 3 HSE Measures 3 .3.1 Construction Hazards The Contractor shall ensure identification of all Occupational Health, Safety Environmental hazards in the type of work he is going to undertake and enlist mitigation measures. Contractor shall carry out Job Safety Analysis (JSA) /Risk Analysis specifically for high risk jobs /critical jobs like. • Working at height (+2.0 Mts height) for cold (incl. colour washing, painting, insulation etc.) hot works. • Work in confined space, • Deep excavations trench cutting (depth 2.0 mts.) • Operation Maintenance of Batching Plant. • Shuttering / concreting (in single or multiple pour) for columns, parapets roofs. • Erection maintenance of Tower Crane. • Erection of structural steel members /roof-trusses /pipes at height more than 2.0 Mts. with or without crane. Download HSE Docs hseprof.com
- 109. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 23 OF 63 • Erection of pipes (full length or fabricated) at height more than 2.0 Mts. height with Crane of 100T capacity. • All lifts using 100T Crane plus mechanical pulling. • All lifts using two cranes in unison (Tandem Lifting). • Any lift exceeding 80% capacity of the lifting equipments (hydra, crane etc.). • Lying of pipes (isolated or fabricated) in deep narrow trenches– manually or mechanically. • Maintenance of crane /extension or reduction of crane-boom on roads or in yards. • Erection of any item at 2.0 Mts. height using 100T crane or of higher capacity • Hydrostatic test of pipes, vessels columns and water-flushing. • Radiography jobs (in-plant open field) • Work in Live Electrical installations / circuits • Handling of explosives Blasting operations • Demolishing / dismantling activities • Welding / gas cutting jobs at height (+2.0 Mts.) • Lifting / placing roof-girders at height (+2.0 Mts.) • Lifting laying of metallic / non-metallic sheet over roof /structures. • Lifting of pipes, gratings, equipments/vessels at heights (+2.0 Mts) with without using cranes. • Calibration of equipment, instruments and functional tests at yards / work- sites. • Operability test of Pump, Motors (after coupling) Compressors. • Cold or Hot works inside Confined Space. • Transportation shifting of ODC consignments into project areas. • Working in “charged /live” elect. Panels • Stress Relieving works (Electrically or by Gas-burners). Download HSE Docs hseprof.com
- 110. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 24 OF 63 • Pneumatic Tests • Card board blasting • Chemical cleaning and take feedback from PDIL /Owner. The necessary HSE measures devised shall be put in to place, prior to start of an activity also shall be maintained during the course of works, by the Contractor. Copies of such JSAs shall be kept available at work sites by the Contractor to enable all concerned carrying out checks /verification. Accessibility • The Contractor shall provide safe means of access(in sufficient numbers) efficient exit to any working place including provisions of suitable and sufficient scaffolding at various stages during all operations of the work for the safety of his workmen and PDIL /Owner. • The Contractor shall implement use of all measures including use of “life line”, “fall arresters”, “retractable fall arresters” , “safety nets” etc. during the course of using all safe accesses exits, so that in no case any individual remains at risk of slip fall during their travel. • The access to operating plant /project complex shall be strictly regulated. Any person or vehicle entering such complex shall undergo identification check, as per the procedures in force /requirement of PDIL /Owner. Accessibility to ‘confined space’ shall be governed by specific system /regulation, as established at project site. Personal Protective Equipments (PPEs) • The Contractor shall ensure that all their staff, workers and visitors including their subcontractors have been issued (records to be kept) wear appropriate PPEs like nape strap type safety helmets preferably with head Download HSE Docs hseprof.com
- 111. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 25 OF 63 sweat band with ¾” cotton chin strap (made of industrial HDPE), safety shoes with steel toe cap and antiskid sole, full body harness (CE marked and conforming to EN361), protective goggles, gloves, ear muffs, respiratory protective devices, etc. All these gadgets shall conform to applicable IS Specifications /CE or other applicable international standards. The Contractor shall implement a regular regime of inspecting physical conditions of the PPEs being issued /used by the workmen of their own also its sub-agencies and the damaged / unserviceable PPEs shall be replaced forthwith. • Owner /PDIL may issue a comprehensive color scheme for helmets to be used by various agencies. The Contractor shall follow the scheme issued by the Owner /PDIL and shall choose any colour other than white (for Owner) or blue (for PDIL) All HSE personnel shall preferably wear dark green band on their helmet so that workmen can approach them for guidance during emergencies. HSE personnel shall preferably wear such dresses with fluorescent stripes, which are noticeable during night, when light falls on them. • For shot blasting, the usage of protective face shield and helmets, gauntlet and protective clothing is mandatory. Such protective clothing should conform relevant IS Specification. • For off-shore jobs/contracts, contractor shall provide PPEs (new) of all types to PDIL Owner's personnel, at his (contractor's) cost. All personnel shall wear life jacket at all time. • An indicative list of HSE standards/codes is given under Appendix-A. • Contractor shall ensure procurement usage of following safety equipments/ accessories (conforming to applicable IS mark /CE standard) by their staff, workmen visitors including their subcontractors all through the span of project construction /pre-commissioning /Commissioning:- a. PPEs (Helmet, Ear-muff, Face shield, Hand gloves, Safety Shoes, etc) b. Barricading tape / warning signs c. Rechargeable Safety torch (flame-proof) Download HSE Docs hseprof.com
- 112. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 26 OF 63 d. Safety nets (with tie-chords) e. Fall arresters f. Portable ladders (varying lengths) g. Life-lines (steel wire-rope, dia not less than 8.0 mm) h. Full body harness (double lanyard) i. Lanyard j. Karabiner k. Retractable fall arresters (various lengths) l. Portable fire extinguishers (DCP type) – 6 kg capacity m. Portable Multi Gas detector n. Sound level meter o. Digital Lux meter p. Fire hoses flow nozzles q. Fire blankets / Fire retardant cloth (with eyelets) Working at height • The Contractor shall issue permit for working (PFW) at height after verifying and certifying the checkpoints. He shall also undertake to ensure compliance to the conditions of the permit during the currency of the permit including adherence of personal protective equipments. Contractor’s Safety Officer shall verify compliance status of the items of permit document after implementation of action is completed by Contractor’s execution / field engineers at work site. Job Safety Analysis (JSA) for specific works at height duly commented by PDIL /Owner, shall be kept attached with particular Permit for Work (PFW) at site for ready reference follow-up. Such PFW shall be initially issued for one single shift or expected duration of normal work and extended further for balance duration, if required. PDIL /Owner can devise block-permit system at any specific area, in consultation with project specific HSE Committee to specify the time-period of validity of such PFW or Download HSE Docs hseprof.com
- 113. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 27 OF 63 its renewal. This permit shall be applicable in areas where specific clearance from Owner’s operation Dept. / Safety Dept. is not required. PDIL /Owner’s field Engineers /Safety Officers / Area Coordinators may verify and counter sign this permit (as an evidence of verification) during the execution of the job. • All personnel shall be medically examined certified by registered doctor, confirming their ‘medical fitness for working at height. The fitness examination shall be done once in six months. • In case work is undertaken without taking sufficient precautions as given in the permit, PDIL /Owner Engineers may exercise their authority to cancel such permit and stop the work till satisfactory compliance /rectification is arranged made. Contractors are expected to maintain a register for issuance of permit and extensions thereof including preserving the used permits for verification during audits etc. • The Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems by his workers. Fall arresters are to be used while climbing /descending tall structures or vessels /columns etc. These arresters should lock automatically against the anchorage line, restricting free fall of the user. The device is to be provided with a double security opening system to ensure safe attachment or release of the user at any point of rope. In order to avoid shock, the system should be capable of keeping the person in vertical position in case of a fall. • The Contractor shall ensure that Full body harnesses conforming EN361 and having authorized CE marking is used by all personnel while working at height. The lanyards and life lines should have enough tensile strength to take the load of the worker in case of a fall. One end of the lanyard shall be firmly tied with the harnesses and the other end with life line. The harness should be capable of keeping the workman vertical in case of a fall, enabling him to rescue himself. Download HSE Docs hseprof.com
- 114. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 28 OF 63 • The Contractor shall provide Roof Top Walk Ladders for carrying out activities on sloping roofs in order to reduce the chances of slippages and falls. • The Contractor shall ensure that a proper Safety Net System is used wherever the hazard of fall from height is present. The safety net, preferably a knotted one with mesh ropes conforming to IS 5175 /ISO 1140 shall have a border rope tie cord of minimum 12mm dia. The Safety Net shall be located not more than 6.0 meters below the working surface extending on either side up to sufficient margin to arrest fall of persons working at differentheights. • In case of accidental fall of person on such Safety Net, the bottom most portion of Safety Net should not touch any structure, object or ground. • The Contractor shall ensure positive isolation while working at different levels like in the pipe rack areas. The working platforms with toe boards hand rails shall be sufficiently strong shall have sufficient space to hold the workmen and tools tackles including the equipments required for executing the job. Such working platforms shall have mid-rails and top-rails, to enable people work safely in sitting posture. Scaffoldings Barricading • Suitable scaffoldings shall be provided to workmen for all works that cannot be safely done from the ground or from solid construction except such short period work that can be safely done using ladders or certified (by 3rd party competent person) man-basket. When a ladder is used, an extra workman shall always be engaged for holding the ladder. • The Contractor shall ensure that the scaffolds used during construction activities shall be strong enough to take the designed load. Main Contractor shall always furnish duly approved construction-design details of scaffold SWL (from competent designers) free of charge, before they are being installed /constructed at site. Owner /PDIL reserves the right to ask the Contractor to submit certification and or design calculations from his Head Download HSE Docs hseprof.com
- 115. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 29 OF 63 office /Design /Engineering expert regarding load carrying capacity of the scaffoldings. • All scaffolds shall be inspected by a competent Scaffolding Inspector of the Contractor. He shall paste a GREEN tag (duly signed by competent Scaffolding Inspector) on each scaffold found safe and a RED tag (duly signed by competent Scaffolding Inspector) on each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted to be used and Scaffolds with RED ones shall immediately be made inaccessible. Work being found continuing on scaffolds with RED tag shall be considered unauthorized work by Contractor and may invite penalization from PDIL/Owner. For every 120- 125 m/m area / volume or 2/3 its parts there of minimum one TAG shall be provided. • The Contractor shall ensure positive barricading (indicative as well as protective) of the excavated, radiography, heavy lift, high pressure hydrostatic pneumatic testing and other such areas. Sufficient warning signs shall be displayed along the barricading areas. Scaffolding shall be constructed using foot seals or base plates only. 3 .3.6 Electrical installations • All electrical installations/connections shall be carried out as per the provisions of latest revision of following codes/standards, in addition to the requirements of Statutory Authorities and IE/applicable international rules regulations: - OISD STD 173: Fire prevention protection system for electrical installations - SP 30 (BIS) : National Electric Code Download HSE Docs hseprof.com
- 116. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 30 OF 63 • All electrical installations shall be approved by the concerned statutory authorities. • All temporary electrical installations/facilities shall be regularly checked by the licensed/competent electricians of the Contractor and appropriate records shall be maintained. Inspection of temporary electrical booth/installation at project construction site”. Such inspection records are to be made available to PDIL /Owner, whenever asked for. 3 .3 .6 .1 The Contractor shall meet the following requirements: • Shall make Single Line Diagram (SLD) for providing connection to each equipments machinery and the same (duly approved by PDIL/Owner) shall be pasted on the front face of DBs (distribution boards) /JBs (Junction boxes) at every site. • Ensure that electrical systems and equipment including tools tackles used during construction phase are properly selected, installed, used and maintained as per provisions of the latest revision of the Indian Electrical / applicable international regulations. • Shall deploy qualified licensed electricians for proper safe installation and for regular inspection of construction power distribution system /points including their earthing. A copy of the license shall be submitted to PDIL /Owner for records. Availability of at least one competent (ITI qualified) / licensed electrician (by State Elec. authorities) shall be ensured at site round the clock to attend to the normal /emergency jobs. • All switchboards /welding machines shall be kept in well-ventilated covered shed /with rain shed protection. The shed shall be elevated from the existing ground level to avoid water logging inside the shed. Installation of electrical switch board must be done taking care of the prevention of shock and safety of machine. • No flammable materials shall be used for constructing the shed. Also flammable materials shall not be stored in and around electrical Download HSE Docs hseprof.com
- 117. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 31 OF 63 equipment/switchboard. Adequate clearances and operational space shall be provided around the equipment. Fire extinguishers and insulating mats shall be provided in all power distribution centers. • Temporary electrical equipment shall not be employed in hazardous area without obtaining safety permit. • Proper housekeeping shall be done around the electrical installations. • All temporary installations shall be tested before energizing, to ensure proper earthing, bonding, suitability of protection system, adequacy of feeders /cables etc. 3.3.6.2 The following features shall also be ensured for all electrical installations during construction phase by the contractor: • Each installation shall have a main switch with a protective device, installed in an enclosure adjacent to the metering point. The operating height of the main switch shall not exceed 1.5 M. The main switch shall be connected to the point of supply by means of armored cable. • The outgoing feeders shall be double or triple pole switches with fuses/ MCBs. Loads in a three phase circuit shall be balanced as far as possible and load on neutral should not exceed 20% of load in the phase. • The installation shall be adequately protected against overload, short circuit and earth leakage by the use of suitable protective devices. Fuses wherever used shall be HRC type. Use of re-wired fuses shall be strictly prohibited. The earth leakage device shall have an operating current not exceeding 30 mA. • All connections to the hand tools / welding receptacles shall be taken through proper switches, sockets and plugs. • All single phase sockets shall be minimum 3 pin type only. All unused sockets shall be provided with socket caps. • Only 3 core (P+N+E) overall sheathed flexible cables with minimum conductor size of 1.5 mm copper shall be used for all single phase hand tools. Download HSE Docs hseprof.com
- 118. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 32 OF 63 • Only metallic distribution boxes with double earthing shall be used at site. No wooden boxes shall be used. • All power cables shall be terminated with compression type cable glands. Tinned copper lugs shall be used for multi-strand wires / cables. • Cables shall be free from any insulation damage. • Minimum depth of cable trench shall be 750 mm for MV control cables and 900 mm for HV cables. These cables shall be laid over a sand layer and covered with sand, brick soil for ensuring mechanical protection. Cables shall not be laid in waterlogged area as far as practicable. Cable route markers shall be provided at every 25 M of buried trench route. When laid above ground, cables shall be properly cleared or supported on rigid poles of at least 2.1 M high. Minimum head clearance of 6 meters shall be provided at road crossings. Underground road crossings for cables shall be avoided to the extent feasible. In any case no underground power cable shall be allowed to cross the roads without pipe sleeve. • An independent earthing facility should preferably be established within the temporary installation premises. All appliances and equipment shall be adequately earthed. In case of armored cables, the armor shall be bonded to the earthing system. • All cable joints shall be done with proper jointing kit. No taped /temporary joints shall be used. • All cables and wire rope used for earth connections shall be terminated through tinned copper lugs. • In case of local earthing, earth electrodes shall be buried near the supply point and earth continuity wire shall be connected to local earth plate for further distribution to various appliances. All insulated wires for earth connection shall have insulation of green colour. • Separate core shall be provided for neutral. Earth /Structures shall not be used as a neutral in any case. Download HSE Docs hseprof.com
- 119. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 33 OF 63 • ON / OFF position of all switches shall be clearly designated /painted for easy isolation in emergency. 3 .3.7 Welding / Gas cutting • Contractor shall ensure that flash back arrestors conforming to BS: 6158 or equivalent are installed on all gas cylinders as well as at the torch end of the gas hose, while in use. All cylinders shall be mounted on trolleys and provided with a closing key. Empty filled-up gas cylinders shall be stored separately with TAG, protecting them from direct sun or rain. Minimum 2 nos. of Portable DCP type fire extinguishers (10 kg) shall be maintained at the gas cylinder stores. Stacking storing of compressed gas cylinders shall be arranged away from DG set, hot works, Elect. Panels /Elec. boards, etc • The burner and the hose placed downstream of pressure reducer shall be equipped with Flash Back Arrester /Non Return Valve device. • The hoses for acetylene and oxygen cylinders must be of different colours. Their connections to cylinders and burners shall be made with a safety collar. • At end of work, the cylinders in use shall be closed and hoses depressurized. • Cutting of metals using gases, other than oxygen acetylene, shall require written concurrence from Owner. • All welding machines shall have effective earthing at least at distinctly isolated two points. In order to help maintain good housekeeping, and to reduce fire hazard, live electrode bits shall be contained safely and shall not be thrown directly on the ground. • The hoses of Acetylene and Oxygen shall be kept free from entanglement away from common pathways /walkways and preferably be hanged overhead in such a manner which can avoid contact with cranes, hydra or other mobile construction machinery. Download HSE Docs hseprof.com
- 120. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 34 OF 63 • Hot spatters shall be contained /restricted appropriately (by making use of effective fire retardant cloth/fabric) and their flying-off as well as chance of contact with near-by flammable materials shall be stopped. • The Contractor shall arrange adequate systems practices for accumulation /collection of metal other scraps and remnant electrodes and their safe disposal at regular interval so as to maintain the fabrication and other areas satisfactorily clean tidy. • All gas cylinders must have a cylinder cap on at all times when not in use. 3 .3.8 Ergonomics and tools tackles • The Contractor shall assign to his workmen, tasks commensurate with their qualification, experience and state of health. • All lifting tools, tackles, equipment, accessories including cranes shall be tested periodically by statutory /competent authority for their condition and load carrying capacity. Valid test fitness certificates from the applicable authority shall be submitted to Owner /PDIL for their review /acceptance before the lifting tools, tackles, equipment, accessories and cranes areused. • The contractor shall not be allowed to use defective equipment or tools not adhering to safety norms. • Contractor shall arrange non-sparking tools for project construction works in operating plant areas /hydrocarbon prone areas. • Wherever required the Contractor shall make use of Elevated Work Platforms (EWP) or Aerial Work Platforms (mobile or stationary) to avoid ergonomically risks and workmen shall be debarred to board such elevated platform during the course of their shifting /transportation. • Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes (while in use) to minimize overloading risk. SLI shall have capability to continuously monitor and display the load on the hook, and automatically compare it with the rated crane capacity at the operating condition of the Download HSE Docs hseprof.com
- 121. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 35 OF 63 crane. The system shall also provide visual and audible warnings at set capacity levels to alert the operator in case of violations. • The contractor shall be responsible for safe operations of different equipments mobilized and used by him at the workplace like transport vehicles, engines, cranes, mobile ladders, scaffoldings, work tools, etc. • The Contractor shall arrange periodical training for the operators of hydra, crane, excavator, mobile machinery, etc. at site by utilizing services from renowned manufacturers. 3 .3.9 Occupational Health • The contractor shall identify all operations that can adversely affect the health of its workers and issue implement mitigation measures. • For surface cleaning operations, sand blasting shall not be permitted even if not explicitly stated elsewhere in the contract. • To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc Welding shall not contain Thorium. • Appropriate respiratory protective devices (hood with respiratory devices) shall be used to protect workmen from inhalation of air borne contaminants like silica, asbestos, gases, fumes, etc. • Workmen shall be made aware of correct methods for lifting, carrying, pushing pulling of heavy loads. Wherever possible, manual handling shall be replaced by mechanical lifting equipments. • For jobs like drilling /demolishing /dismantling where noise pollution exceeds the specified limit of 85 decibels, ear muffs shall be provided to theworkers. • To avoid work related upper limb disorders (WRULD) and backaches, Display Screen Equipments' workplace stations shall be carefully designed used with proper sitting postures. Power driven hand-held tools shall be maintained in good working condition to minimize their vibrating effects and personnel Download HSE Docs hseprof.com
- 122. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 36 OF 63 using these tools shall be taught how to operate them safely how to maintain good blood circulation in hands. • The Contractor shall arrange health check up (by registered medical practitioner) for all the workers at the time of induction. Health check may have to be repeated if the nature of duty assigned to him is changed necessitating health check or doubt arises about his wellness. PDIL/Owner reserves the right to ask the contractor to submit medical test reports. Regular health check-ups are mandatory for the workers assigned with Welding, Radiography, Blasting, Painting, Heavy Lift and Height (2m) jobs. All the health check-ups shall be conducted by registered Medical practitioner and records are to be maintained by the Contractor. • The Contractor shall ensure vaccination of all the workers including their families, during the course of entire project span. • Regular distribution of standard quality soap / sanitizer to all employees of the company for Hygienic up keeping. • Provided Medical facilities to employees their dependent family members including Hospitalization at companies authorized reputed hospitals. An in- house dispensary facility is available with part time doctor and trained staff to take care of emergency services of employee’s health. 3 .3.10 Hazardous substances • Hazardous, inflammable and/or toxic materials such as solvent coating, thinners, anti termite solutions, water proofing materials shall be stored in appropriate containers preferably with lids having spillage catchment trays and shall be stored in a good ventilated area. These containers shall be labeled with the name of the materials highlighting the hazards associated with its use and necessary precautions to be taken. Respective MSDS (Material Safety Data Sheet) shall be made available at site may be referred whenever problem arises. Download HSE Docs hseprof.com
- 123. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 37 OF 63 • Where contact or exposure of hazardous materials are likely to exceed the specified limit or otherwise have harmful effects, appropriate personal protective equipments such as gloves, goggles / face-shields, aprons, chemical resistant clothing, respirator, etc. shall be used. • The work place shall be checked prior to start of activities to identify the location, type and condition of any asbestos materials which could be disturbed during the work. In case asbestos material is detected, usage of appropriate PPEs by all personnel shall be ensured and the matter shall be reported immediately to PDIL /Owner. 3 .3.11 Slips, trips falls The contractor shall establish a regular cleaning and basic housekeeping program that covers all aspects of the workplace to help minimize the risk of slips, trips falls. The contractor shall take positive measures like keeping the work area tidy, storing waste in suitable containers harmful items separately, keeping passages, stairways, entrances exits especially emergency ones clear, cleaning up spillages immediately and replacing damaged carpet / floor tiles, mats rugs at once to avoid slips, trips falls. 3 .3.12 Radiation exposure • All personnel exposed to physical agents such as ionizing non-ionizing radiation, including ultraviolet rays or similar other physical agents shall be provided with adequate shielding or protection commensurate with the type of exposure involved. • For Open Field Radiography works, requirements of Bhabha Atomic Research Centre (BARC) /Atomic Energy Regulatory Board (AERB) shall be followed. Download HSE Docs hseprof.com
- 124. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 38 OF 63 • The Contractor shall implement an effective system of control (as described in the AERB regulations) at site for handling radiography-sources for avoiding its misuse theft. • The contractor shall generate the “Permit for radiation work” before start of work. • In case the radiography work has to be carried out at day time, suitable methodology to be used so that other works, people are not affected. 3 .3.13 Explosives / blasting operations • Blasting operations shall be carried out as per latest Explosive Rules (Indian / International) with prior permission. The Contractor shall obtain license from Chief Controller of Explosives (CCOE) for collection, transportation, storage of explosives as well as for carrying out blasting operations. • The Contractor shall prepare exclusive method statement (in cognizance with statutory requirements) for diffusing unfired explosives, if any, at project site before carrying out actual task. Nowhere blasting shall be carried out by the Contractor or its agency without the involvement of competent supervisor and licensed blaster / shot blaster. 3 .3.14 Demolition /Dismantling • The contractor shall adhere to safe demolishing/ dismantling practices at all stages of work to guard against unsafe working practices. • The contractor shall disconnect service lines (power, gas supply, water, etc.)/ make alternate arrangements prior to start of work and restore them, if required as directed by PDIL /Owner at no extra cost. • Before carrying out any demolition/ dismantling work, the contractor shall take prior approval of PDIL /Owner. For revamp jobs in operating plants where location of underground utilities is not known with certainty, the contractor Download HSE Docs hseprof.com
- 125. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 39 OF 63 shall depute an experienced engineer for supervision and shall make adequate arrangements for Firefighting First-Aid during the execution of these activities. • The Contractor shall arrange approved Job Safety Analysis (JSA) /Method Statement for the specific demolition /dismantling task and corresponding action plan commensurate with hazards /risks associated therein. In no case any activity related to demolition /dismantling shall be carried out by the Contractor without engaging own supervision /field engineer. 3 .3.15 Road Safety • The Contractor shall ensure adequately planned road transport safety management system. • The Contractor shall also ensure a separate pedestrian route for safety of the workers and comply with all traffic rules regulations, including maintaining speed limit of 20 kmph or indicated by owner for all types of vehicles /mobile machinery. The maximum allowable speed shall be adhered to. • The vehicles shall be fitted with reverse warning alarms flashing lights /fog- lights and usage of seat belts shall be ensured. • In case of an alert or emergency, the Contractor must arrange clearance of all the routes, roads, access. The Contractor shall deploy sufficient number of traffic controllers at project site routes /roads /accesses, to alert reversing movement of vehicles machinery as well as pedestrians. • Dumpers, Tippers, etc. shall not be allowed to carry workers within the plant area and also to from the labour colony to from project sites. • Hydras shall only be allowed for handling the materials at fabrication /storage yards and in no case shall be allowed to transport the materials over project / plant roads. • The Contractor shall not deploy any such mobile machinery / equipments, which do not have competent operator and/or experienced banks-man / Download HSE Docs hseprof.com
- 126. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 40 OF 63 Signalman. Such machinery /equipments shall have effective limit-switches, reverse-alarm, and front rear-end lights etc. and shall be maintained in good working order. • The Contractor shall not carry-out maintenance of vehicles /mobile machinery occupying space on project /plant roads and shall always arrange close supervision for such works. • For pipeline jobs, the contractor shall submit a comprehensive plan covering transportation, loading /unloading of pipes, movement of side booms, movement of vehicles on the ROW, etc. • Contractor’s shall arrange /install visible road signs, diversion boards, caution boards, etc on project roads for safe movement of men and machinery. 3 .3.16 Welfare measures Contractor shall, at the minimum, ensure the following facilities at work sites: • A crèche at site where 10 or more female workers are having children below the age of 6 years. • Adequately ventilated /illuminated rooms at labour camps its hygienic up- keeping. Reasonable canteen facilities at site and in labour camps at appropriate location depending upon site conditions. Contractor shall make use of “industrial” variety of LPG cylinder satisfactory illumination at the canteens. Necessary arrangement for efficient disposal of wastes from canteens urinals /toilets shall also be made and regular review shall be made to maintain the ambience satisfactorily hygienic shall also comply with all applicable statutory requirements. Adequately lighted ventilated Rest rooms at site (separate for male workers and female workers). Urinals, Toilets, washing facilities, adequate lighting at site and labour camps, commensurate with applicable Laws /Legislation. • Providing water, milk, Lemon water, glucose etc. to employees working at heat treatment Dusty areas. Download HSE Docs hseprof.com
- 127. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 41 OF 63 • Provided purified drinking water to all employees of company. • Providing of Personal Protective equipment as per requirement of employees according to their respective working areas. • Companies Transportation has been provided to all employees for safe transportation of employees from their residence to workplace back. 3 .3.17 Environment Protection Contractor shall ensure proper storage and utilization methodology of materials that are detrimental to the environment. Where required, Contractor shall ensure that only the environment friendly materials are selected and emphasize on recycling of waste materials, such as metals, plastics, glass, paper, oil solvents. The waste that cannot be minimized, reused or recovered shall be stored and disposed of safely. In no way, toxic spills shall be allowed to percolate into the ground. The contractor shall not use the empty areas for dumping the wastes. The contractor shall strive to conserve energy and water wherever feasible. The contractor shall ensure dust free environment at workplace by sprinkling water on the ground at frequent intervals. The air quality parameters for dust, poisonous gases, toxic releases, harmful radiations, etc. shall be checked by the contractor on daily basis and whenever need arises. The contractor shall not be allowed to discharge chemicals, oil, silt, sewage, sullage and other waste materials directly into the controlled waters like surface drains, streams, rivers, ponds. A discharge plan suggesting the methods of treating the waste before discharging shall be submitted to PDIL /Owner for approval. For pipeline jobs, top soil shall be stacked separately while making ROW through fields. This fertile soil shall be placed back on top after backfilling. For offshore construction barges, arrangements shall be made for safe disposal of human, food other wastes and applicable laws in this regard shall be followed. Download HSE Docs hseprof.com
- 128. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 42 OF 63 3 .3.18 Rules Regulations All persons deployed at site shall be knowledgeable of and comply with the environmental laws, rules regulations relating to the hazardous materials, substances and wastes. Contractor shall not dump, release or otherwise discharge or disposes off any such materials without the express authorization of PDIL/Owner. An indicative list of Statutory Acts Rules relating to HSE is given under Appendix-D. 3 .3.1 9 Weather Protection Contractor shall take appropriate measures to protect workers from severe storms, rain, solar radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses, Sun screen lotions, respirators, dust masks, etc. and rearranging /planning the construction activities to suit the weather conditions. Effective arrangement (without creating inconvenience to project facilities permanent installations) for protecting workmen from hailstorm, drizzle in the form of temporary shelter shall be made at site. 3 .3.20 Communication All persons deployed at the work site shall have access to effective means of communication so that any untoward incident can be reported immediately and assistance sought by them. All health safety information shall be communicated in a simple clear language easily understood by the local workforce. For information to all, typical subjects that should be communicated are: - Inside the company (Top to down) Download HSE Docs hseprof.com
- 129. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 43 OF 63 a. Quality Policy b. HSE Policy contents c. Environment Policy d. HSE Objectives e. Safety Cardinal Rules f. HSE Target – reached or missed g. Praises Warnings to personnel for HSE Management h. Safety Walk Through Reports and safety defects i. HSE Audit results j. Revised Statutory Health Safety provisions, if any k. H S publicity l. Suggestions Inside the Company (Bottom to up) a. Complaints b. Compliances on safety defects / shortfalls c. Suggestions d. Proposals for changes improvements e. HSE Reports (including near-miss reports) 3 .3.21 Confined Space Entry The contractor shall generate a work permit before entering a confined space. People, who are permitted to enter into confined space, must be medically examined certified by registered doctor, confirming their ‘medical fitness for working in confined space’. All necessary precautions mentioned therein shall be adhered to. An attendant shall be positioned outside a confined space for extending help during an emergency. All appropriate PPEs and air quality parameters shall be checked before entering a confined space. It shall be ensured that the piping of the equipment which has to be opened is pressure- free by checking that blinds are in place, vents are open and volume is drained. Download HSE Docs hseprof.com
- 130. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 44 OF 63 Inside confined space works, only electrical facilities /installations of 24V shall be permitted. Contactor shall ensure usage of safe suitable arrangement of oxygen supply for individual workmen (during the course of work in confined space), if oxygen concentration is found to be less than 19.5% (v/v) there. 3.3.22 Heavy Lifts • The contractor shall submit detailed rigging studies plan for PDIL/ Owner approval prior to lifting equipment which cannot be erected with a crane of approx. 100 Ton capacities due to constraints of its dimensions, location of foundation height, approach weight. Contractor shall generate the format for “Permit for heavy lift /critical erection” Prior to actual lifting activities; contractor shall check the validity of the crane inspection certificate issued by statutory / competent authority. This requirement shall also apply to all rigging equipments utilized for the job. • The contractor shall, at all times, be responsible for all rigging activities. • The Contractor shall ensure medical fitness of all workmen who are engaged /involved in erection of equipments, vessels etc. and such fitness checks shall be carried-out every six months interval with the help of a registered medical practitioner record shall be maintained Adequate safety measures such as positive barricading, usage of appropriate PPEs, permit to work, etc. shall be taken during all heavy or critical lifts. • For lifting any material (irrespective of shape, size or volume), at any height, it is always advisable to prepare a Plan of Erection (POE) taking into consideration hazards risks associated therein – this can enable people to put their own experiences of various natures side-by-side establish a practical method for risk-free erection /lifts. The contractor shall prepare POE shall document the same, when risks are identified as “medium” or “high” and the same shall be approved by its competent /qualified engineer. Download HSE Docs hseprof.com
- 131. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 45 OF 63 3 .3.23 Key Performance Indicators The contractor shall measure an activity in both leading trailing indicators for statistical and performance measurement. The activities pertaining to key performance indicators are covered in Monthly HSE Report. The contractor shall try to achieve a statistically fair record and strive for its continual improvement. Leading Indicators viz:- - Number of Safety Inductions carried-out at site (for workmen staff members) - Number of HSE inspections carried out. - Number of “Safety Walk Through” carried-out by site-head. - Number of HSE shortfalls / lapses identified per contractor closed-out in time. - Number of Safety Meetings conducted (in-house / with contractors) - Number of HSE Audits made (internal external) vis-à-vis non conformances raised - Number of HSE Trainings conducted at site for supervisors workmen - Number of HSE Awareness / Motivational program conducted by contractors - Study of Near miss case reported - Encouragements /Awards /Recognitions to workmen, job supervisors field engineers. - Suggestions for improvement Trailing Indicators viz:- - Calculation of HSE statistics viz frequency rate, severity rate, LTA free man-hours, etc - Analysis of incidents / accidents (nature, severity, types etc.) - Study of Incident / Accident with respect to :- Download HSE Docs hseprof.com
- 132. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 46 OF 63 - Variety - Period of the year / project span - Timings of the incident / accident - Age profile of victims - Body parts involved - Penalty levied for causing incident / accident 3 .3.24 Unsuitable Land Conditions Contractor shall take appropriate measures and necessary work permits /clearances if work is to be done in or around marshy areas, river crossings, mountains, monuments, etc. The Contractor shall make right assessment and take all necessary action for developing work areas to make them safe suitable for crane operations or other vehicular movement before carrying out any project related activity /operation. Contractor shall take all necessary actions to make the surroundings of its site establishments (site office, stores, lay-down area etc.) work-worthy safe and secure. 3 .3.25 Under Water Inspection Contractor shall ensure that boats and other means used for transportation, surveying investigation works shall be certified seaworthy by a recognized classification society. It shall be equipped with all life saving devices like life jackets, adequate fire protection arrangements and shall posses’ communication facilities like cellular phones, wireless, walkie-talkie. All divers used for seabed surveys, underwater inspections shall have required authorized license, suitable life saving kit. Number of hours of work by divers shall be limited as per regulations. PDIL /Owner shall have the right to inspect the boat and scrutinize documents in this regard. 3 .3.26 Excavation Download HSE Docs hseprof.com
- 133. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 47 OF 63 The Contractor shall obtain permission from competent authorities prior to excavation wherever required. The Contractor shall locate the position of buried utilities (water line, cable route, etc.) by referring to project /plant drawing / in consultation with PDIL /Owner. The Contractor shall start digging manually to locate the exact position of buried utilities thereafter use mechanical means. The Contractor shall keep soil heaps at least 1.5 M away from edge or a distance equal to depth of pit (whichever is more). The Contractor shall maintain sufficient “angle of repose” during excavation – shall also provide slope or suitable bench as decided by PDIL /Owner. The Contractor shall arrange “battering” or “benching” wherever required for preventing collapse of edge of excavations. The Contractor shall identify arrange de-watering pump or well-point system to prevent earth collapse due to heavy rain /influx of underground water. The Contractor shall arrange protective fencing / barricading with warning signal around excavated pits, trenches, etc. along with minimum 2 (two) entries, exits / escape ladders. The Contractor must avoid “underpinning” /under-cutting to prevent collapse of chunk of earth during excavation The Contractor shall use “stoppers” to prevent over-run of vehicle wheels at the edge of excavated pits /trenches. The Contractor shall arrange strengthening of “shoring” “strutting” proactively to avoid collapse of earth /edges due to vehicular movement in close proximity of excavated areas /pits /trenches, etc. 3. 4 Tool Box Talks (TBT) Contractor shall conduct daily TBT with workers prior to start of work and shall maintain proper record of the meeting. A suggested format is given below. The TBT is to be conducted by the immediate supervisor of the workers The Download HSE Docs hseprof.com
- 134. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 48 OF 63 Contractor shall conduct TBT before start of every morning or evening shift or night shift activities, for alerting the workers on specific hazards and their appropriate dos don’ts. The Contractor shall provide sufficient rests to the site workmen and their foremen to avert fatigue thereby endangering their lives during the course of site works. The topics during TBT shall include. - Hazards related to work assigned on that day and precautions to be taken. - Any forthcoming HSE hazards /events /instruction /orders, etc. The above record can be kept in local language, which workers can read. These records shall be made available to PDIL /Owner whenever demanded. TOOL BOX TALK RECORD Date Time Work Location Subject (Nature of work) Presenter Hazards involved Precautions to be taken Worker's Name Signature Section Remarks, in any 3. 5 Training Induction Program • Initial induction of workers into Construction oriented activities and appraising them about the methodology of works and how to carry-out safely and the same should not be inter mixed with Tool Box Talks or HSE Training. In this regard careful action should be made maintained for imparting HSE induction to every individual, irrespective of his task /designation /level of Download HSE Docs hseprof.com
- 135. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 49 OF 63 employment, whereas, HSE Training should be imparted to specific person / group of people who are to carry-out that specific task more than once – for example, Riggers must be trained for working at heights, welders must be trained for work in confined space, fitters/carpenters, mesons must be trained for work at heights, etc. • Contractor shall conduct Safety induction program on HSE for all his workers and maintain records. The Gate Pass shall be issued only to those workers who successfully qualify the Safety induction program. • The Contractor shall brief the visitors about the HSE precautions which are required to be taken before their proceeding to site and make necessary arrangements to issue appropriate PPEs like Aprons, hard hats, ear-plugs, goggles safety shoes etc., to his visitors. The Contractor shall always maintain relevant acknowledgement from visitor on providing him brief information on HSE actions. • Contractor shall ensure that all his personnel possess appropriate training to carry out the assigned job safely. The training should be imparted in a language understood by them and should specifically be trained about - Potential hazards to which they may be exposed at their workplace - Measures available for prevention and elimination of these hazards The topics during training shall cover, at the minimum: - - Why safety should be considered during work - explanation - Education about hazards and precautions required - Employees’ duties responsibilities - Emergency and evacuation plan - HSE requirements during project activities - Fire fighting and First-Aid - Use of PPEs - Occupational health issues – dos don’ts - Local laws on intoxicating drinks, drugs, smoking in force Download HSE Docs hseprof.com
- 136. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 50 OF 63 - Common environmental subjects – lighting, ventilation, vibration, smoke /fumes etc. • Records of the training shall be kept and submitted to PDIL /Owner. • The Contractor shall make regular program for conducting Safety Training on various topics related to various activities their safe-guarding utilizing experienced persons /outside agency /faculty. A program for Safety Training (indicative list as per Appendix –E) shall be furnished by the Contractor in its HSE Plan. • For offshore and jetty jobs, contractor shall ensure that all personnel deployed have undergone a structured sea survival training including use of lifeboats, basket landing, use of radio communication etc. from an agency acceptable to Owner /PDIL. ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING PLANT As a minimum, the contractor shall ensure adherence to following safety requirements while working in or in the close vicinity of an operating plant: • Contractor shall obtain permits for hot work, Cold work, Excavation, Confined Space, Lifting activities, Work at Height, Electrical work and Radiography work from Owner. • The contractor shall monitor record and compile list of his workers entering the operational plant /unit each day and ensure record their return after completing the job. • Contractor’s workers and staff members shall use designated entrances and proceed by designated routes to work areas only assigned to them. The workers shall not be allowed to enter units' area, tanks area, pump rooms, etc. without work authorization permit. Download HSE Docs hseprof.com
- 137. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 51 OF 63 • Work activities shall be planned in such a way so as to minimize the disruption of other activities being carried out in an operational plant/unit and activities of other contractors. • The contractor shall submit a list of all chemicals /toxic substances that are intended to be used at site and shall take prior approval of the Owner. • Specific training on working in a hydrocarbon plant shall be imparted to the work force and mock drills shall be carried out for Rescue operations /First- Aid measures. • Proper barricading /cordoning of the operational units /plants shall be done before starting the construction activities. No unauthorized person shall be allowed to trespass. The height and overall design of the barricading structure shall be finalized in consultation with the Owner and shall be got approved from the Owner. • Care shall be taken to prevent hitting underground facilities such as electrical cables, hydrocarbon piping during execution of work. • Barricading with water curtain shall be arranged in specific /critical areas where hydrocarbon vapors are likely to be present such as near Horton spheres or tanks. Positioning of fire tenders (from owner) shall also be ensured during execution of critical activities. • Emergency evacuation plan shall be worked out and all workmen shall be apprised about evacuation routes. Mock drill operations may also be conducted. • Flammable gas test shall be conducted prior to any hot work using appropriate measuring instruments. Sewers, drains, vents or any other gas escaping points shall be covered with flame retardant tarpaulin. • Respiratory devices shall be kept handy while working in confined zones where there is a danger of inhalation of poisonous gases. Constant monitoring of presence of Gas /Hydrocarbon shall be done. • Clearance shall be obtained from all parties before starting hot tapping, patchwork on live lines and work on corroded tank roof. Positive isolation of Download HSE Docs hseprof.com
- 138. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 52 OF 63 line/equipment by blinding for welding/cutting/grinding shall be done. Closing of valve will not be considered sufficient for isolation. • Welding spatters shall be contained properly and in no case shall be allowed to fall on the ground containing oil. Similar care shall be taken during cutting operations. • The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust pipe and got it approved from Safety Department of the Owner. • Plant air should not be used to clean any part of the body or clothing or use to blow off dirt on the floor. • Gas detectors should be installed in gas leakage prone areas as per requirement of Owner's plant operation personnel. • Experienced full time safety personnel shall be exclusively deployed to monitor safety aspects in running plants. Self Assessment and Enhancement The contractor shall develop a method of check balance through self assessment enhancement techniques and shall explore the opportunities for continual improvement in the HSE systems. 3. 8 HSE Promotions The contractor shall encourage his workforce to promote HSE efforts at workplace by way of organizing workshops /seminars /training programs, celebrating HSE awareness weeks National Safety Day, conducting quizzes essay competitions, distributing pamphlets, posters material on HSE, providing incentives for maintaining good HSE practices and granting incentives /bonus for completing the job without any lost time accident. 3. 9 Lock Out and Tag out (LOTO) for isolation of energy source Download HSE Docs hseprof.com
- 139. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 53 OF 63 • Contractor shall follow the LOTO /Isolation procedure of owner for all energy source isolations and installed/under purview by /of owner i.e. “Brown field” For the other entire energy source (not under purview of client/owner) i.e. “Green field” Contractor shall develop a system to ensure the isolation of equipments, pipelines, Vessel, electrical panels from the energy source covering following as minimum:- - Identification of all energy source viz electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravitational, radiation and other forms of stored or kinetic energy. - Establishing the energy isolation devices viz: manually operated electrical circuit breakers, disconnection switches, blind flanges, etc - Lock Out and Tag out log book - Installation of Lock Out devices for preventing the inadvertent release of stored energy and Tag Out devices (“Danger”, “Do Not operate” or Do not Remove” tags) to indicate that testing, maintenance or servicing is underway and the device cannot be operated until the tag out device is removed. - Permit for isolation and de-isolation of energy source. - Availability of competent persons like experienced operators at substations, pump house, units, etc, supervisors, etc. Contractor shall ensure that all the sources are locked out and tagged properly before giving clearance to start the job. After the completion of job, contractor shall ensure all tools and tackles are removed and nobody is present in the working area and signing on LOTO log book. Only on confirmation of above the contractor will remove their lock and tag from the isolation points and give instructions for energizing the same. Only the person carrying out the task shall himself carry the key for the lock in /Lock out. Download HSE Docs hseprof.com
- 140. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 54 OF 63 4. 0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR On Award of Contract The Contractor shall submit a comprehensive Health, Safety and Environment Plan or program for approval by PDIL /Owner prior to start of work. The Contractor shall participate in the pre-start meeting with PDIL /Owner to finalize HSE Plans which shall including the following: - HSE policy Objectives - Job procedure to be followed by the Contractor for construction activities including handling of equipments, scaffolding, electric installations, etc. describing the risks involved, actions to be taken and methodology for monitoring each activity. - PDIL /Owner review/audit requirement. - Organization structure along with responsibility and authority, on HSE activities. - Administrative disciplinary steps involving implementation of HSE requirements. - Emergency evacuation plan / procedures for site and labour camps - Job Safety Analysis for high risk jobs. - Procedures for reporting investigation of accidents and near misses. - HSE Inspection. - HSE Training programs at project site. - HSE Awareness programs, at project site. - Reference to Rules, Regulations and statutory requirements. - HSE documentation viz reporting, analysis record keeping. During Job Execution Contractor shall implement approved HSE management program including but not limited to as brought out under para 3.0. Contractor shall also ensure: Download HSE Docs hseprof.com
- 141. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 55 OF 63 • To arrange workmen compensation insurance, registration under ESI Act, third party liability insurance, registration under BOCW Act, etc, asapplicable. • To arrange all HSE permits before start of activities (as applicable), like permits for hot work, working at height, confined space, Radiation Work Permit, Demolishing / Dismantling Work Permit, Permit for erection/modification dismantling of scaffolding, Permit for heavy lift/critical erection, Permit for energy Isolation De-isolation”, storage of chemical / explosive materials its use and implement all precautions mentioned therein. In this regard, requirements of Oil industry Safety Directorate Standard No.:- 105 Work Permit Systems” shall be complied with while working in existing Oil, Gas or Chemical processing plants. List of the persons involved shall be maintained as annexure to the work permit issued for a particular activity. • To submit, timely, the completed checklist on HSE activities, Monthly HSE report (use of web based package (www.pdil.co.in/conthse) is compulsory wherever the facility is available else a hard copy is to be submitted), accident/ incident reports, investigation reports etc. as per PDIL/Owner requirements. Compliance of instructions on HSE shall be done by contractor and informed urgently to PDIL /Owner. • Provide posters, banners for safe working to promote safety consciousness. • That his top most executive at site attends all the Safety Committee /HSE meetings arranged by PDIL /Owner and carries out safety walk through regularly. Only in case of his absence from site that a second senior most person shall be nominated by him, in advance, and communicated to PDIL/Owner for performing the tasks. • Appraise PDIL /Owner on HSE activities at site regularly. • Display at site office and at prominent locations HSE Policy, caution boards, list of hospitals, emergency services available, safety signs like Men at work, Speed Limits, Hazardous Area, various do’s don’ts, etc. Download HSE Docs hseprof.com
- 142. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 56 OF 63 • Identify access, analyze mitigate the construction hazards incorporate relevant control measures before actually executing site works. (HIRAC = Hazard Identification, Risk Analysis and Control). • Arrange testing, examination, inspection of own as well as borrowed construction equipments / machinery (stationary mobile) before being used at site and also at periodical interval, through own resources and also by 3 rd party competent agencies (as deemed fit in statutes). Records of such test, examination etc. shall be maintained shall be submitted to PDIL /Owner as when asked for. • Carryout audits /inspection (internal external) at his works as well as sub contractor works as per approved HSE plan /procedure /program submit the compliance reports of identified shortfalls for PDIL /Owner review. • Arranging HSE training for site workmen (of his own sub contractors) through internal or external faculty at periodical intervals. • Assistance cooperate during HSE audits by PDIL /Owner or any other 3 rd party and submit compliance report. Generate submit of HSE records /report as per this specification. • Carry-out all dismantling activities safely, with prior approval of PDIL/Owner representative. • The Contractor shall ensure that “Hot works” and painting works do not continue at the same place /location at project site for which chance or probability of “fire” incident exists. During Short Listing of the Sub-Contractors The contractor shall review the HSE management system of the sub-contractors in line with the requirements given in this specification. The contractor shall be held responsible for the shortcomings observed in the HSE management system of the sub-contractor(s) during execution of the job. Download HSE Docs hseprof.com
- 143. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 57 OF 63 APPENDIX-A A. IS CODES ON HSE - SP: 53 Safety code for the use, Care and protection of hand operated tools. - IS: 838 Code of practice for safety health requirements in electric and gas welding and cutting operations - IS: 1179 Eye Face precautions during welding, equipment etc. - IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels. - IS: 1989 (Pt -II)Leather safety boots and shoes - IS: 2925 Industrial Safety Helmets - IS: 3016 Code of practice for fire safety precautions in welding cutting operation. - IS: 3043 Code of practice for earthing - IS: 3764 Code of safety for excavation work - IS: 3786 Methods for computation of frequency and severity rates for industrial injuries and classification of industrial accidents - IS: 3696 Safety Code of scaffolds and ladders - IS: 4083 Recommendations on stacking and storage of construction materials and components at site - IS: 4770 Rubber gloves for electrical purposes - IS: 5121 Safety code for piling and other deep foundations - IS: 5216 (Pt-I) Recommendations on Safety procedures and practices in electrical works - IS: 5557 Industrial and Safety rubber lined boots - IS: 5983 Eye protectors - IS: 6519 Selection, care and repair of Safety footwear - IS: 6994 (Pt-I) Industrial Safety Gloves (Leather Cotton Gloves) - IS: 7293 Safety Code for working with construction Machinery Download HSE Docs hseprof.com
- 144. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 58 OF 63 - IS: 8519 Guide for selection of industrial safety equipment for body protection - IS: 9167 Ear protectors - IS: 11006 Flash back arrestor (Flame arrestor) - IS: 11016 General and safety requirements for machine tools and their operation - IS: 11057 Specification for Industrial safety nets - IS: 11226 Leather safety footwear having direct molded rubber sole - IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage system - IS: 13367 Code of practice-safe use of cranes - IS: 13416 Recommendations for preventive measures against hazards at working place B. INTERNATIONAL STANDARDS ON HSE - Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092, BS 1542, BS 679, DIN 4646/ 58311 - Safety Shoes : ANSI Z 41.1, AS 2210, EN 345 - Hand Gloves : BS 1651 - Ear Muffs : BS 6344, ANSI S 31.9 - Hard Hat : ANSI Z 89.1/89.2, AS 1808 , BS 5240, DIN 4840 - Goggles : ANSI Z 87.1 - Face Shield : ANSI Z 89.1 - Breathing Apparatus : BS 4667, NIOSH Welding Cutting : ANSI Z 49.1 - Safe handling of compressed: P-1 (Compressed Gas Association Gases in cylinders 1235 Jefferson Davis Highway, Arlington VA 22202 - USA) - Full body harness : EN-361, ANSI Z 359.1 - Lanyard : EN-354 - Karabiner : EN-362 and EN-12275 Download HSE Docs hseprof.com
- 145. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 59 OF 63 APPENDIX-B DETAILS OF FIRST AID BOX Sr. No. DESCRIPTION QUANTITY 1 Small size Roller Bandages, 1 Inch Wide (Finger Dressing small) 6 Pcs. 2 Medium size Roller Bandages, 2 Inches Wide (Hand Foot Dressing) 6 Pcs. 3 Large size Roller Bandages, 4 Inches Wide (Body Dressing Large) 6 Pcs. 4 Large size Burn Dressing (Burn Dressing Large) 4 Pkts. 5 Cotton Wool (20 gms packing) 4 Pkts. 6 Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle 7 Mercurochrome Solution (100 ml.) 2% in water 1 Bottle 8 Ammonia Solution (20 ml.) 1 Bottle 9 Pair of Scissors 1 Piece 10 Adhesive Plaster (1.25 cm X 5 m) 1 Spool 11 Eye pads in Separate Sealed Pkt. 4 pcs. 12 Tourniquet 1 No. 13 Safety Pins 1 Dozen 14 Tinc. Iodine/ Betadin (100 ml.) 1 Bottle 15 Polythene Wash cup for washing eyes 1 No. 16 Potassium Permanganate (20 gms.) 1 Pkt. 17 Tinc. Benzoine (100 ml.) 1 Bottle 18 Triangular Bandages 2 Nos. 19 Band Aid Dressing 5 Pcs. 20 Iodex/Moov (25 gms.) 1 Bottle 21 Tongue Depressor 1 No. 22 Boric Acid Powder (20 gms.) 2 Pkt. 23 Sodium Bicarbonate (20 gms.) 1 Pkt. 24 Dressing Powder (Nebasulf) (10 gms.) 1 Bottle 25 Medicinal Glass 1 No. 26 Duster 1 No. 27 Booklet (English Local Language) 1 No. each 28 Soap 1 No. 29 Toothache Solution 1 No. 30 Vicks (22 gms.) 1 Bottle 31 Forceps 1 No. 32 Note Book 1 No. 33 Splints 4 Nos. 34 Life Saving/Emergency/Over-the counter Drugs As decided at site Note: The medicines prescribed above are only indicative. Equivalent medicines can also be used. A prescription, in this regard, shall be required from a qualified Physician. Download HSE Docs hseprof.com
- 146. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 60 OF 63 APPENDIX-C TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS Fire Extinguisher Water Foam CO2 Dry Powder Multi purpose (ABC) Fire Originated from paper, clothes, wood D D Can control minor surface fires Can control minor surface fires D Inflammable liquids like alcohol, diesel, petrol, edible oils, bitumen X D D D D Originated from gases like LPG,CNG, H2 X X D D D Electrical fires X X D D D LEGEND: D: CAN BE USED X: NOT TO BE USED Note: Fire extinguishing equipment must be checked at least once a year and after every use by an authorized person. The equipment must have an inspection label on which the next inspection date is given. Type of extinguisher shall clearly be marked on it. Download HSE Docs hseprof.com
- 147. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 61 OF 63 APPENDIX-D LIST OF STATUTORY ACTS RULES RELATING TO HSE - The Indian Explosives Act and Rules - The Motor Vehicle Act and Central Motor Vehicle Rules - The Factories Act and concerned Factory Rules - The Petroleum Act and Petroleum Rules - The Workmen Compensation Act - The Gas Cylinder Rules and the Static Mobile Pressure Vessels Rules - The Indian Electricity Act and Rules - The Indian Boiler Act and Regulations - The Water (Prevention Control Pollution) Act - The Water (Prevention Control of Pollution) Cess Act - The Air (Prevention Control of Pollution) Act - The Atomic Energy Act - The Radiation Protection Rules - The Indian Fisheries Act - The Indian Forest Act - The Wild Life (Protection) Act - The Environment (Protection) Act and Rules - The Hazardous Wastes (Management Handling) Rules - The Manufacturing, Storage import of Hazardous Chemicals Rules - The Public Liability Act - The Building and Other Construction Workers (Regulation of Employment And Condition of service) Act - Other statutory acts Like EPF, ESIS, and Minimum Wage Act. Download HSE Docs hseprof.com
- 148. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 62 OF 63 APPENDIX-E TRAINING SUBJECTS / TOPICS (For contractors’ personnel) 1. The Law Safety – Statutory Requirement / Applicable statutes / Duties of employer / employee 2. Policy Administration – Why HSE? / Duties Responsibilities of Safety Personnel at project site / Effect of incentive on accident prevention 3. HSE Supervision – Duties of Supervisor / HSE integrated supervision / who should be held responsible for site accidents? 4. Safety Budget /Cost of Accidents – Direct costs /Indirect costs 5. Hazard Identification /Type of hazards /HIRAC 6. Behavioral Safety Motivation 7. Housekeeping – Storage /Stacking /Handling of materials /Hydra handling 8. Occupational Health in Construction sector 9. Personal Protective Equipments – Respiratory Non- respiratory 10. Electricity Safety – ELCB /Fuse /Powered tools /Project illumination 11.Handling of Compressed Gas – Transportation /Storage /FBAs /Fire prevention 12.Machine Safety – Machine guarding /Maintenance 13.Transportation – Hazards risks in transp. of materials /ODC consignments 14.Cranes Other Lifting machinery – Legal requirements vis-à-vis essential safety requirements. 15.Communication – HSE Induction /TBTs /Safety Committee /Safety meeting / Safety propaganda /Publicity. 16.Excavation – Risks Dangers /Safety measures 17.Working at Heights – Use of ladder /Work on roofs /Scaffolds /Double harness lanyards /Lifeline /Fall arrester /Safety Nets /Floor openings 18.Hazards in Welding important safety precautions 19.Gas Cutting – Hazards safety measures 20.Fire prevention fire protection Download HSE Docs hseprof.com
- 149. TITLE: REPLACEMENT OFSINGLE WALL AMMONIA STORAGE TANK BY DOUBLE WALL STORAGE TANK IN GNFC AMMONIA PLANT AT BHARUCH-GUJARAT DOCUMENT NAME: ENVIRONMENT HEALTH SAFETY PLAN PC-00187-PVPM- HSE-001 0 DOCUMENT NO REV SHEET 63 OF 63 APPENDIX-F LIST OF PROCEDURES (MINIMUM) TO BE FORMING PART OF HSE PLAN:- A. HSE Management Procedures: • HSE Risk Management (including JSA/HIRA) • HSE Legal Compliance and Other Requirements • HSE Objectives Performance • HSE Training and Competence (including Induction) • HSE Motivation Award Scheme • HSE Audits • HSE Meetings • HSE Sub Contractor Management • HSE Emergency Management • HSE Incidents Reporting and Management • HSE Reports • HSE Management System Review • HSE Change Management • HSE procedure for Behavior based Safety • First Aid Management • Roles, Responsibility, accountabilities and Authorities B. Job procedures /Safe Operating procedures • Setting Up Site Signage’s • Handling of Electrical Appliances • Working at Height • Confined Space Entry • Permit to Work (including hot works) • Housekeeping • Lifting Operations • Transportation of materials including Manual Handling • Compressed Air Tools and Units • Earthmoving Operations excavation • Scaffolding • Fire Prevention/Protection • Hazardous Substance handling Storage • Radiation Hazard • Personal Protective Equipment ******** Download HSE Docs hseprof.com
- 150. Page 1 of2 PROJECTS DEVELOPMENT INDIA LIMITED Date: Project No.: PC-00187 SHEET 1 OF 20 SAFETY TALK TOPICS SR. NO. SAFETY TALK TOPICS SR. NO. SAFETY TALK TOPICS 1 Accident/Incident Prevention 21 Importance of Checklist 2 Ammonia (NH3) Safety 22 Incident reporting 3 Are we Safe or just Lucky? 23 Industrial Radiography Safety 4 Attitude and Behavior 24 Job Safety Analysis (JSA) 5 Back Safety 25 Knowledge of LSC rules 6 Barricade and Signage 26 Ladder Safety 7 Blinding Safety 27 Look out for Your Co-Workers 8 Breathing Apparatus 28 Machine guarding safety 9 Carbon Monoxide Poisoning 29 Manual Material Handling 10 Chemical / Toxic Handling 30 Material Safety Data Sheet - MSDS 11 Chain and Sling Safety Tips 31 Modification of Tools or Equipments 12 Chemical Safety 32 Near Misses are Lucky Escapes - Report them 13 Compressed Gas Cylinders 33 Over Confidence can kill you 14 Confined Space Entry 34 Personal behavior 15 Crane Operation 35 Personal Hygiene 16 De-blinding Safety 36 Personal Protective Equipment (PPE) 17 Donning and doffing of safety harnesses 37 Pinch Points 18 Dust mask Cartridge filter mask 38 Preventing Strains and Sprains 19 Electrical Safety 39 Eye and Face Protection 20 Emergency Response Evacuation 40 Fall Protection Prevention 41 Falling Objects 66 Prohibited Items Inside Plant Download HSE Docs hseprof.com
- 151. Page 2 of2 PROJECTS DEVELOPMENT INDIA LIMITED Date: Project No.: PC-00187 SHEET 2 OF 20 42 Fatigue 67 Respiratory Protection 44 Fire Prevention and Extinguishing 68 Responsibilities of Fire Watch 45 Fire Safety 69 Responsibilities of Permit Receiver 45 Foot and Leg Protection 70 Responsibilities of Standby Man 46 Forklift Safety 71 Risk Assessment 47 General Safety 72 Safe Handling of Flammable Liquids 48 Grounding of Equipments 73 Safe Storage of Flammable Liquids 49 Hand and Finger Protection 74 Safety is everyone's responsibility 50 Hand tools Power Tools 75 Scaffold Safety 51 Hazard Recognition 76 Short cuts 52 Hearing Safety 77 Site Safety Rules Regulation 53 Heat Stress 78 Sleeping at site 54 High Pressure Water Jetting 79 Slip, trip and fall hazards 55 Home Made Tools 80 Smoking safety 56 Horseplay 81 Static Electricity 57 Hot Bolting Safety 82 Take safety ownership of your job 58 Hot work safety 83 The Cost of the Accident 59 Housekeeping is safe keeping 84 Traffic Safety 60 Hurry Up can Hurt!!!! 85 Unsafe acts conditions 61 Hydro test Safety 86 Vacuum Truck Safety 62 If you are not sure! ASK! 87 What you do not know, can hurt you! 63 Responsibilities of Rigger 88 Why safety audit 64 Excavation Safety 89 Work Permit System 65 Construction site survey for visitors 90 Working at Height Download HSE Docs hseprof.com
- 152. PROJECTS DEVELOPMENT INDIALIMITED Date: Project No.: PC-00187 SHEET 1 OF 20 Lifting tackles Lifting tools LIFTING APPLIANCES cranes Hoists Chain pulley blocks Jib crane D-shackles Wire ropes Chains Clamps etc CLASSIFICATION OF LIFTING APPLIANCES LIFTING TOOLS AND TACKLES • Lifting tool: Lifting tool is device which is used to lift load such as • Crab • Winch • Teagle • Gin wheel • Jacks • Cranes etc • Chain block • Mono rail • Lifting tackle: Lifting tackle is device which is used to facilitates for lifting load suchas • Chain sling • Swivel • Ropes • D- shackles • Hooks • Clamps • Eye bolts etc Download HSE Docs hseprof.com
- 153. PROJECTS DEVELOPMENT INDIALIMITED Date: Project No.: PC-00187 SHEET 2 OF 20 INSPECTION OF LIFTING TOOLS TACKLES TPI – Third party Inspection • Third Party Inspection of any product is the Inspection Testing carried out by Any Person or Agency who is not Manufacturer or User of that particular product orservice. • Third Agency is always technically strong enough and competent to execute the checking and testing of all Technical Aspects of the equipment or service. • In case of Lifting Equipment Lifting Tools Tackles, Govt. Approved / Authorized Competent Person carry out Inspection and testing of the products and certify to use them. • State wise competent persons are authorized by State Govt. to carry out Inspection testing of various products. Why TPI? – • Carrying out TPI of Lifting Equipment and Lifting Tools Tackles is Statutory Norm / Requirement as prescribed in Factories Act. • Safety Level of the Equipment is enhanced, as competent person shall note down the loop holes during the inspection testing and recommend or suggest corrective measures. • Equipment Manufacturer shall issue Mfr. Test Certificate by Self Attested way and define products’ attributes. • However, as per the Law: Obtain ‘Form-10’ (In Gujarat it is ‘Form-10’) Certificate issued by TPI (Competent Person) from the date of installation or from the date when product is First Taken for Use. Procedure: Procedure of Inspection Testing is carried out strictly as per checklist developed individually. Competent Persons also offer their service as per the scope of work: 1). Thorough Inspection Testing: • Complete Technical Parameters are checked thoroughly. i.e. Brakes, Limit Switches, Wire Rope, Hook Blocks and other safety parameters. • Operational Parameters are checked and measured. • Load Testing at Proof Load and Over-Load. 2). Load Testing: Download HSE Docs hseprof.com
- 154. PROJECTS DEVELOPMENT INDIALIMITED Date: Project No.: PC-00187 SHEET 3 OF 20 • First all operating parameters are checked and then, Load Testing at Proof Load and Over-Load is carried out. ‘Form-10’ Certificate as per govt. Format is issued on successful Inspection Testing of the products. Note: Form-10 Certificate is issued by Competent Person as per State Govt. Format in Gujarat State. However, state wise this Form No. is different. Interval for Inspection testing: As directed in the Section-29 of Factories Act, these Tests are carried out annually and Register should be maintained for every product to keep record regarding Health of the Products. SECTION – 29 OF FACTORIES ACT - LIFTING TOOLS AND TACKLES 1. In any factory the following provisions shall be complied with in respect of every lifting machine (other than a hoist and lift) and every chain, rope and lifting tackle for the purpose of raising or lowering persons, goods or materials :- • All parts, including the working gear, whether fixed or movable, of every lifting machine and every chain, rope or lifting tackle shall be – • Of good construction, sound material and adequate strength and free from defects; • Properly maintained; and • Thoroughly examined by a competent person at least once in every period of twelve months, or at such intervals as the Chief Inspector may specify in writing, and a register shall be kept containing the prescribed particulars of every such examination; • No lifting machine and no chain, rope or lifting tackle shall, except for the purpose of test, be loaded beyond the safe working load which shall be plainly marked thereon together with an identification mark and duly entered in the prescribed register; and where this is not practicable, a table showing the safe working loads of every kind and size of lifting machine or chain, rope or lifting tackle in use shall be displayed in prominent position on the premises; • While any person is employed or working on or near the wheel track of a traveling crane in any place where he would be liable to be struck by the crane, effective measures shall be taken to ensure that the crane does not approach within 63[six meters] of that place. Download HSE Docs hseprof.com
- 155. PROJECTS DEVELOPMENT INDIALIMITED Date: Project No.: PC-00187 SHEET 4 OF 20 2. The State Government may make rules in respect of any lifting machine or any chain, rope or lifting tackle used in factories - • Prescribing further requirements to be complied with in addition to those set out in this section; • Providing for exemption from compliance with all or any of the requirements of this section, where in its opinion, such compliance is unnecessary orimpracticable. 3. For the purposes of this section a lifting machine or a chain, rope or lifting tackle shall be deemed to have been thoroughly examined if a visual examination supplemented, if necessary, by other means and by the dismantling of parts of the gear, has been carried out as carefully as the conditions permit in order to arrive at a reliable conclusion as to the safety of the parts examined. Explanation: In this section, - • lifting machine means a crane, crab, winch, teagle, pulley block, gin wheel, transporter or runway; • 64(b) lifting tackle means any chain sling, rope sling, hook, shackle, swivel, coupling, socket, clamp, tray or similar appliance, whether fixed or movable, used in connection with the raising or lowering of persons, or loads by use of lifting machines. ******** Download HSE Docs hseprof.com