PROCESS PLANT SHUTDOWN SAFETY

1. FIRE & SAFETY DEPARTMENT

2. Shutdown Planning

3. • Tool box talk record /register not maintained at all sites.
• Daily Housekeeping before start of job and after completion
of job not done.
• Drum storage/ management a major concern
Major Safety Concerns/ Non-compliance

4. Major Non Compliance
Scaffolds:
• Checklist for scaffold not filled by
contractor & IOCL Engg.
• Poor condition of scaffolds
• No base plate
• No tag , no railing, no proper platform, use of corroded/ bent pipes.
• No use of ladder for access
• Job without work permit and clearance

5. Hot works:
• No use of flash back arrestors on acetylene / oxygen
cylinders
• Damaged/ jointed gas cutting hoses
• No use of valve caps on transported/ idle cylinders
• No protection against fall of spark
• Helper without any eye protection
Major Non Compliance

6. Grinding :
• Without wheel guard
• Without face shield
• Helper using grinding job
• Spark not arrested at site
Major Non Compliance

7. Major Non Compliance
Working at Height:
• Workers working at height without safety harness/ not
anchoring their harness.
• Poor condition of safety harness
• Use of old screw type harness instead of hook type
• No provision of life line for working at pipe racks/ cable
racks.
• No access for approaching at pipe racks / cable racks.

8. Vehicular:
• Parking of vehicle at improper places.
• Entry of vehicle in plant without permit
• Flag man not available
• Fake/ No driving license with driver
• LMV driving license holder , drive HMV vehicle.
• Driving above speed limits
• Helpers driving vehicle instead of driver
• Poor tyre condition. Poor condition of trailers or hydra
• Area not barricaded. Slippers/ wooden blocks being used under crane jacks
• Guide rope not provided for suspended load
• Hydra/ Crane without reversing horn.
Major Non Compliance

9. Lifting Tools/ Tackles:
• Transportation of material with Hydra/ crane
• No area barricading before lifting job.
• Limit switches of hydra not working.
• No SWL/ DOT marking on hydras.
• No safety latch on hooks
• There is no correlation of lifting tools & tackles with their certificate.
Lifting tools used only as per judgment.
• Poor condition of canvas slings
Major Non Compliance

10. Confined Space:
• No record of persons going in & coming out during confined
space entry.
• No dedicated stand by person outside confined space
• Workers not aware of hazards inside particular vessel/
column etc/ no took box talk
Major Non Compliance

11. Excavation:
• No barricading of excavated area.
• Road excavated without road blockage permit.
• Excavation permit not renewed after expiry
• Excavated material kept near excavation site.
• Sometimes excavation done without taking permit
• Escape ladder not used in excavated pit/trench
• People walk on piled up earth , having chances to slip and fall in trench
• Water accumulation in excavated pit/trench from open fire water nozzle
• Accumulation of oil and water in trench , if not stopped/checked
Major Non Compliances

12. Hydro Jetting:
• No area barricading
• No face shield
• No coverall
• No foot valve
• No stand by person
• Slippery area/ Chocked drains
• Firewater misuse/ wastage without any job
Major Non Compliance

13. Work Permit:
• Doing job without any permit
• Job without clearance.
• Clearance given on expired permit .
• Permit conditions are not full-filled like fire water hose /
stand by person etc.
Major Non Compliance

15. Scaffold safety measures
Right-Angle (Double, 90 Degree, Load Bearing, or Standard) Coupler
A load bearing coupler used for connecting two tubes together at right angles. It is a critical component in the scaffold structure
and must resist both slip and distortion.
After Before

16. BOX CLAMP: End-to-End (Sleeve) Coupler :
A device used for externally joining two (2) scaffold tubes co-axially end to end. The steel divider is located centrally to ensure
equal insertion of each tube.
After Before

17. LADDER CLAMP:
A device used for externally joining Ladder fitting on scaffold
After Before

18. Base Plate:
A steel plate providing a flat bearing surface with a spigot or screw jack for distributing the load from posts (standards). It has an
integral spigot and fixing holes for use with sills.
After Before

19. Top rail
Mid rail
Without top and mid rail
Guardrail system:
Each person who could fall more than 1.8 m. (6 ft.) shall be protected from falling by means of guardrail systems or personal fall
arrest systems.
After
Before

20. Toe boards :
shall have no more than 6 mm. (1/4”) gap above the working surface and should withstand a force of at least 23 kg
(50 lbs).
After
Before

21. Fabricated Scaffold Plank, Deck, or Platform
A scaffold platform unit equipped with end hooks that engage the scaffold bearer (transom).
Used wire for plank
locked
After Before

22. “Safety On Wheels”
Immediate Corrective Action
Agency/ W.O : Sandip Nanavati/24823166
Location: DHDS Pump House Area
Safety on wheels:
Gujarat Refinery new initiative for contractors safety
(PPEs Compliance at site).

23. Contractor worker Helmet Testing

24. Contractor worker Helmet Testing on 20.6.2018
TOTAL NO. OF HELMETS – 54
HELMET PASS IN TEST – 16
HELMET FAIL IN TEST – 38
0
1
2
3
4
5
6
7
8
9
Total
ARIHANT FAB
BANSAL
BM UTILITY
GAYATRY
IRON ENGG
JJ RAVAL
KOYALI CATTEL FEED
KRUPALI CONST.
MARUDHAR
MN KAKA
BEFORE AFTER

25. TOTAL NO. OF HELMETS – 54
HELMET PASS IN TEST – 16
HELMET FAIL IN TEST – 38
1 1
2
4
1 1 1
7
4
1 1 1
4
1
8
2
3
1 1 1
5
2
1
0
1
2
3
4
5
6
7
8
9
Total
ARIHANT FAB
BANSAL
BM UTILITY
GAYATRY
IRON ENGG
JJ RAVAL
KOYALI CATTEL FEED
KRUPALI CONST.
MARUDHAR
MN KAKA
NAMAN ENGG
PATIL ENT.
PETRO TECH
PRASHANT BUILDING
PRASHANT CONST.
chart of various agencies found defective/ non standard helmets provided to the workers

26. “Preventable accidents,if
not prevented due to our
negligence , it is nothing
short of a murder’’
Dr. S.Radhakrishnan

27. DON’T ROLL THE DICE!!!
• Practice proper procedures
• Make sure everything is safe before anybody goes in!