Contractor Safety Manual

Central U.P Gas Limited

Kanpur

Year: 2020
 

Contents
Sr. No Topic Page no.
1 Introduction 3
2 Objective 4
3 Scope 4
4 HSE Policy of CUGL 4
5 Contractor Selection 5
6 HSE Management System 5
7 HSE Plan 6
8 Contractor HSE Organization & Responsibilities 6
9 Safety Training &Toolbox Talk 9
10 Issue of I card 10
11 General Safety Requirement 10
11.1 Safety Work Permit 10
11.2 Work Site Safety 11
11.3 Work Clothing 11
11.4 Safety while Working at Height 12
11.5 Gas Cutting & Welding 13
11.6 Safety While Working with Machinery 15
11.7 Safety in Confined Space 16
11.8 Personal Protective Equipment 17
11.9 Safety in Grinding Operation 18
11.10 Electrical Safety 19
11.11 Safety in Excavation work 20
11.12 LCV Operation 21
11.13 Safety in Radiography 22
12 Disciplinary Action 23
13 Accident/ Incident Reporting & Investigation 23
14 Alcohol, illegal Drugs, Firearms 24
15 Emergency Evacuation 24
16 Housekeeping 24
17 Fire Prevention & Protection 24
18 Behaviour with Customer 25
19 Environmental Requirements 25
20 Legal Requirements 25
21 Requirement of First Aid 25
22 Annexure I- Work permit formats for CNG & 26
PNG
23 Annexure II- Specification of Rescue & 30
maintenance pulley kit
24 Annexure Ill- Specification of Coverall 34
25 Annexure IV — Specification of PPE’s 35
26 Annexure V- Accident Investigation Form 37
27 Annexure VI- Close out report on HSE 38
Performance related to various Contractors
28 Contractor certification 40
29 Annexure - VII Selection Criteria for Suitable 41
PPEs
 

1.Introduction
CUGL (Central UP Gas Limited), a joint venture between India’s two Navratna companies,
GAIL (India) Limited and Bharat Petroleum Corporation Limited came into existence on
25th February 2005. CUGL was constituted for developing City Gas Distribution project in
Kanpur. Kanpur (Manchester of East) was also known as CWANPORE at the time of British
India. This is famous industrial hub of North India. Later, CUGL has started City Gas
Distribution Project for supplying Natural Gas to Domestic/Gen-
set/Commercial/Industrial/Automobile sector in order to reduce pollution level in Bareilly
&Jhansi also. At present CUGL is supplying PNG to Domestic/Gen-
set/Commercial/Industrial sector in different areas of Kanpur, Unnao, Bareilly & Jhansi.
CUGL believe that HEALTH, SAFETY&ENVIORNMENT are inherent part of business.
Company is making its best efforts to provide a safe and accident free environment for its
employees, customers& society. Apart from providing an environment friendly fuel to the
customers, the company uses best international practice in laying its infrastructure. The
company make its best efforts to educate customers to handle the fuel.
The company makes a systematic approach to promote Health, Safety& Environment in and
around. The company follows safety management as HSE Policy, Work Permit system,
Personal Protection, Fire& Safety Education and Accident reporting investigation, Safety
Audit and emergency preparedness etc. Safety Of our Customers is of prime concern to us for
which we follow specific system approach.
CUGL strives to maintain a safe and healthy workplace for our partners and Contractor.
CUGL is committed to protect health and safety of everybody involved with company’s
activities and protects the environment in a sustainable manner. Hence Health, Safety, and
Environmental considerations are recognized as critical and integral to our core processes and
our day to day activities. All Contractors must report any unsafe act/condition or
environmental conditions which has or could have an adverse impact to human health or the
environment. Contractors are to ensure the health and safety of their workers and any person
likely to be affected by the workers actions. Contractors have the right to know about hazards
and the means used to control or eliminate the hazards. Contractors have the right to
participate in workplace safety activities and to refuse to work in an unsafe or
environmentally detrimental condition.
This document provides all Contractors with the minimum Health, Safety and Environmental
(HSE) standards required while working on and/or adjacent to Company premises. Non-
compliance of HSE standards is treated the same as non-compliance with any contract
provision and may result in work stoppage or Contractor removal from the premises.
Repeated non-compliance may result in Contractor dismissal and contract termination.
CUGL requires that Contractors meet all guidelines outlined & Pre-Job Requirements, of this
manual prior to commencing any work on Company premises/ Project site. As a part of this
commitment, CUGL ensures that contractors are aware of its policies, standards and requires
the contactors to comply with CUGL standards. It is the responsibility of the main contractors
to ensure that all their sub-contractors fully comply with CUGL HSE requirements.
Contractor is responsible for complying with applicable Indian, State and local HSE
regulations. Contractor must also comply with the requirements listed in the Contractor
Safety Manual and any site-specific and/or business unit policies and procedures that are
applicable in the scope of Work. It is the Contractor’s continuing and absolute responsibility
 

for all aspects of Contractor safety on their jobsites during the execution of work. Contractors
are important wing of CUGL& it is necessary that they know HSE norms and ensure healthy
ssafety practices in CUGL.

2. Objective
 To establish and communicate CUGL’s HSE expectations to its external contractors.
 To encourage the contractor to align their HSE practices to meet the CUGL’s HSE
standards.
 To reduce the actual and potential risks from contractor activities this is essential to
improve the overall CUGL’s HSE performance.
The purpose of this standard is to establish, implement and execute a practical, sound and
effective program for the prevention of incidents that cause or may cause injury to person or
damage to property. These safety requirements have been designed to assist all Contractors,
their supervisors and workmen to identify, evaluate, and subsequently adopt control measures
in various activities or conditions to reduce the possibility of any undesired incident within
their respective areas of contract responsibility.

3. Scope
The requirement of this manual is applicable to all contractors working within CUGL’s own,
leased, managed, or associated assets / project sites and office premises. Contractors include
short term, long term, Civil, Mechanical, Electrical and general to perform any job. All
Contractors are required to ensure that they and their employees, Sub contractors, suppliers,
vendors, and visitors, while on the job site or even off the job site, comply with the provisions
of this standard.

4. HSE Policy of CUGL

The management accepts the responsibility for Safety, Health & Environment Management
of the company. The subject being a line responsibility, every employee has been made
responsible and accountable for the protection of Safety, Health & Environment. The policy
of company is as follows:
 To give topmost priority to Safety& Health of all the personnel, property and protect
environment.
 To follow all applicable Codes, Standards & Safety practices in design, operation,
maintenance and modifications to ensure HSE protection.
 All planning, discussions and actions confirm our commitment towards Safety, Health
& Environment protection aspects.
 Safety Audit is carried out yearly and findings are documented for follow up actions
so as to restore safe conditions.
 Each Employee is fully informed for strict compliance of safety orders/rules issued by
the management.
 Health Check up of each employee is done annually.
 To train all employees in their respective areas of activities.
 Engineer In charges of projects ensure compliance of safety orders/rules & statutory
requirements by contractors, transporters, visitors and other agencies related to
contracts.
 Emergency drills are conducted every six months.
 Each employee is to abstain from unsafe acts and prevent unsafe conditions.
 

 It is compulsory for all employees to take active part on safety & health related
activities on & off the job. Compliance of safety observations is done in most
effective manner.
 To ensure compliance of Work Permit System.
 Use of Personnel Protective Equipments is compulsory while at work.
 Quality maintained in all areas of activities.
 To adopt such systems and methods so as to ensure continual improvement.
 Management ensures that efforts of each employee are directed to contribute for
achieving excellence in Safety, Health, Work Environment, Quality and Productivity.

5. Contractor selection
Selecting a qualified and skilled contractor is a major step toward achieving safe contractor
performance. Proper framing of the scope of work, pre-qualification criteria, special contract
requirement, experience profile of the contractor and its workmen/ supervisors etc is essential
for proper selection of a contractor.
The contractor’s safety standard can be judged by the following attributes:
 The contractor’s safety commitment, as demonstrated by its own safety programs
supported by their top management.
 Experience profile of the contractor, its supervisor and workmen.
 Past safety performance of the contractor as can be evaluated through old data
tracking or through documentary evidence submitted by the contractor such as
Accident data, Near-Miss data, safety violation during the job, system of safety
training, hazard identification and mitigation plan, safety meeting, safety promotion
program, safety enforcement and disciplinary action plan, safety standard available
with contractor for similar jobs etc.
 Availability of safety equipment/ appliances with the contractor.
 Availability of qualified and skilled safety personnel with the contractor to monitor
safety performance during the progress of the job.
 After completion of the work as per contract, performance towards Health, Safety &
Environment of the contractor will be evaluated & contractor assessment form will be
filled by the Engineer In-charge of CUGL as per format attached in Annexure VI.
This form will be used in future during selection of contractor for job allocation.

6. HSE Management System

Contractor must have a defined Health, Safety & Environmental Management system in
place aligned to CUGL requirements and demonstrate that it is implemented effectively. It
should typically cover the following elements
 Leadership & Commitment by higher management.
 HSE Policy
 Organization, Resources & Documentation related to HSE.
 Evaluation & Risk Management.
 Planning & Procedure.
 Implementation & Monitoring.
 Auditing & Review.
The contractor should have an HSE policy backed by their management’s commitment to
create a safe work environment. The policy should state the intention and methodology of
 

protecting the personnel at work site. Contractor shall demonstrate their HSE commitment in
protecting the people, environment and assets by implementing the HSE Management system
and various HSE programs that support their HSE Policy.

7. HSE Plans
Prior to the commencement of contractual activity, the contractor shall submit a written
Project-specific/Work Specific HSE plan to CUGL for review and approval. Contractor shall
prepare the Project HSE plan addressing their work activities, hazards and risk controls,
training needs identification, audits and safety promotional activities. Purpose of the project
HSE plan is to provide assurance of effective working of the interface between the HSE
Management Systems of CUGL and contractors at specific work I project level.
The Contractor’s Project specific plan shall address the following:
 Title page
 Project title and brief scope of work
 Organization chart
 Hazard identification plan (clearly identifying project related HSE risks, control
measures and persons responsible)
 Safety I Environmental policy and assignment of responsibilities
 HSE Training plan
 Management of sub contractors
 Safety inspections
 Safety reports and records
 Welding and cutting equipment
 Personal protective equipment
 Tools and portable power tools
 Ladders
 Electrical installation and equipment
 Cranes and rigging equipment
 Mechanical equipment
 Transportation
 Incident reporting and investigation
 Excavation
 Fire prevention
 First-aid facilities
 General safety rules
 Emergency response and evacuation procedures
 Environmental regulatory compliance requirements and compliance process
 Manual Handling
 Checklists

8. Contractor HSE Organization & Responsibilities.

Contractor shall submit the HSE Organization chart with responsibilities to CUGL Fire &
safety department and obtain approval prior to startup of job.
Typical requirement of Safety personnel
 

Employee strength (including Minimum requirement of HSE Personnel.

subcontractor)

No of Employee≤ 25 1 no. HSE Supervisor with background and

knowledge of Fire & Safety.

No of Employee 25-50 2 no. HSE Supervisor with background and

knowledge of Fire & Safety + 1 no. HSE
Engineer
No of Employee 50-500 1 no. HSE Supervisor for every 25
employees+ 1 no. HSE Engineer for every
100 workmen

The minimum qualification for Contractor safety personnel-

HSE Supervisor-
 Should be diploma holder in Engineering (Mechanical, Chemical, Electrical, Civil)
and one-year industrial safety diploma course from recognized institute.

HSE Engineer-
 Should be degree holder in Engineering (Fire & Safety) or degree holder in
Mechanical, Electrical, Civil or Chemical and one-year industrial safety diploma
course from recognized institute.
 Having two years of experience as a Fire & safety officer/ Engineer in oil & gas or
chemical industry,
Responsibility of HSE Supervisor-
The field HSE supervisor will assists the HSE Engineer.
This position is responsible for: -
 Ensuring all the workmen & supervisor with safety gears (Safety shoes, safety helmet,
cover all & other job specific PPE’s).
 HSE training (organize the training programs as per the training matrix).
 Daily workplace safety inspections (to identify unsafe acts, unsafe conditions and
take necessary actions).
 Identification of hazards and environmental impacts.
 Inspection of PPEs, tools / lifting accessories / slings / ropes/web belts/ D-shackles
etc. (visual inspection once in week for their soundness and validity).
 Maintain daily HSE logbook(site HSE observations and preventive actions taken).
 Checking availability of safety work permit & review of work permits as per permit
conditions.
 Reporting of Near miss incident, first aid & other incident to HSE Engineer.
 Identifying and correcting unsafe behaviours at work site.
 

 Training to their staff, supervisor & workmen regarding the operation & maintenance
of Fire fighting equipments.
 Daily toolbox talk must be conducted for the workmen.
Responsibility of HSE Engineer-
Contractor’s HSE Engineer assumes the lead safety position for the contractor organization
and is responsible for monitoring and administering a pro-active safety program designed to
provide assistance in recognizing, evaluating, and subsequently controlling or eliminating
hazardous acts or conditions He / She works in close coordination with CUGL HSE
Management and in conjunction with his / her Principal employer assisting in the
implementation of HSE programs. Broadly the responsibilities of HSE Engineer are:
 Administer appropriate safe work practices I procedures within the worksite.
 Ensure that necessary records are maintained as per applicable HSE regulatory
requirements and reports are submitted to statutory bodies as per the timelines defined
by them in the applicable acts / rules.
 Ensure that all mobile lifting appliances are subjected to third party inspections as per
statutory requirement & records are maintained by the responsible dept.
 Promote a high level of safety awareness of the project among the staff/workers
through orientation/refresher training programs.
 Site safety visit.
 Ensure the safety work permit system.
 Ensure Safety gears (safety shoes, safety helmet, Cover all & other job specific
PPE’s) by all the workmen & supervisor at job site.
 Certification & testing of Safety equipments & PPE’s.
 Conduct Weekly Safety inspections, track performance and report trends to his/her
site management.
 Maintain all HSE related records and files associated with the organization.
 Maintain pertinent information (i.e. phone number, locations) of Emergency Response
Services, physicians, and hospitals.
 Lead and assist in accident I incident investigations to ensure all accidents and
incidents are properly investigated including near miss incidents, first aid cases, all
recordable cases, property damage, etc. & reporting to CUGL safety executive.
 Evaluate subcontractor safety programs and performance and ensure they comply
with the statutory and HSE requirements
 Review the Supervisor HSE Logbooks.
 Training to their staff, supervisor & workmen regarding the operation & maintenance
of Firefighting equipments.
 

9. Safety Training &Toolbox Talk

Training
Before start of any job, all the contractor personnel must be trained in a language they
understand before issuing I Card for working at CUGL premises & project site. The content
of the training program should include the following:
 HSE management system of CUGL
 Safety standards and procedures relevant for carrying out jobs.
 Special precaution specific for a site I Work based on its hazard perception.
 Hands on training for use of fire extinguisher & PPE.
 Use of PPEs in general and any special PPE specific for a particular job.
 Emergency preparedness plans including evacuation plan of CUGL.
 Near miss & incident reporting.
This training is meant to make contractor and their employees familiar with existing safety
practices of CUGL.
Toolbox Talk
 Toolbox talks are quite effective means of communicating the workplace hazards
and appropriate controls to the workers.
 It helps in better understanding and ensures proper controls to reduce the risks.
 Contractor supervisor shall deliver the toolbox talk in a reasonably peaceful area,
before start of the activity.
 It should contain the brief work description, probable hazards, controls planned
and mitigation measures to be taken.
 Use & benefits of PPE’s & safety gears as per the job requirements.
 The duration of the toolbox talk should not exceed 15 minutes.
 A record for each toolbox talk should be maintained by the contractor indicating
the topic and number of personnel attended.
 The environment of toolbox talk shall be supportive to clear doubt, if any, raised
by workmen.
 The Contractor should ensure that Toolbox Talk are conducted on regular basis.
 

10. Issue of I Card

Issue of I card is more of a security issue than a safety issue. However, this system can also
be used effectively for safety interventions. Following may be adapted to use the I card for
safety controls:
 A photo I Card will be issued by the contractors for his supervisors/ workmen.
Photo I card will contain identification marks and can be referred for future
administrative controls.
 After imparting safety trainings, the I Card will be stamped as ‘Safety Training
given’ or separate Safety Training card shall be issued by contractor to supervisor,
Workmen and their employees. No contractor and their employees shall be
allowed to enter inside the CUGL premises or project site for carrying out jobs
unless the safety briefing has been given to them and stamping of, I card / Safety
training certificate has been issued to them.
 The validity of such “Safety Training card” shall be maximum 1 year & the next
due date for safety training shall be indicated in bold.

11. General Safety Requirement.

11.1 Work Permit System

The contractor Supervisors (or person in charge of the work) should ensure that:
 They have received training in the Safety work permit system as applied in that
location
 The people working for them have received adequate instruction in the system
 They discuss the job fully with the person issuing the permit
 The workmen are briefed on the details of the permit including any potential hazards,
and on all the precautions taken or to be taken.
 The precautions are maintained throughout the work activity
 The worker understands that if circumstances change work must be stopped and
inform the supervisor.
 The work group stays within the limitations set on the permit (physical boundaries,
type of work and validity time)
 On completion or suspension of the work the site is left in a safe condition and the
permit issuer is informed & permit has been returned for closing.
Individuals working within the Safety work permit system should ensure that:
 They have received instruction and have a good understanding of the safety work
permit system at the installation where they work
 

 They do not start any work requiring a permit, until it has been properly authorized
and issued
 They receive a briefing from the supervisor on the particular task and they
understand the hazards and the precautions taken or to be taken
 They follow the instructions specified in the permit. When they stop work, the site
and any equipment they are using is left in a safe condition
 If in any doubt or if circumstances change, they must stop work and consult with
their supervisor.
 Work Permit formats attached in Annexure –I

11.2 Worksite Safety

 It is the responsibility of each Contractor or his authorized I nominated representative
to inspect each work area at the beginning of each shift, and periodically thereafter,
to ensure safe working conditions are maintained.
 Contractor must provide good illumination for work to proceed safely.
 Contractor must ensure protection from severe weather conditions. (Extreme wind,
lighting storms, extreme heat, extreme cold etc...).
 The Contractor needs to evaluate /consider the environmental extremes of the
project, such as the ability of their workers to work in areas of excessive cold or heat.
 Based on that evaluation the Contractor must implement the appropriate procedures
to provide a safe a work environment.
11.3 Work Clothing-

 Every contractor will provide to his worker & supervisor, mm two nos. Cotton
Coverall, one safety helmet & one safety shoe every year for working at CUGL job
site. The specification & design of “Cotton Cover All” is attached in Annexure III.
 Where hazards exist due to moving parts on machinery or equipment, clothing and
hair must be maintained to avoid entanglement.
 Special work clothing must be worn where exposure to fire, extreme heat or cold,
corrosive chemicals, electrical hazards, body impacts, cuts from handled materials or
 

other specialized hazards are possible. See the premises or business unit’s site-specific
requirements for any additional needs, such as Fire-Resistant Clothing (FRC). The
Contractor is required to supply special work clothing, ensure it is in good condition
and properly worn, when and where required.
11.4 Safety while work at height: -

Ladder safety
 The design of ladder shall confirm IS 3696 (Part 2): 1991. Makeshift ladders shall
not be permitted.
 Metal ladder of aluminum alloy complying with the suitable grade of IS 617:1975.
 Ladder used at worksite should be capable to carry their intended load.
 Slip-resistant shoes, lashing or other effective means shall be used to avoid danger
or slipping.
 Overall length of stock ladders shall not exceed 10m.
 The overall height of step ladders shall not exceed 6m.
 Step ladders shall be provided with an automatic locking device or spreader to
hold it in open position.
 The overall length of the extension ladder shall not exceed 18m.
 No ladder having a missing, defective rung or one which depends for its support
solely on nails, shall be used. Defective ladders shall be promptly and properly
repaired or replaced.
 Special care should be taken while working near electrical line.
 Three-point contact while working on ladder shall be practiced.
 A ratio of 1:4 in distance of resting points in bottom and top ladder points shall be
maintained for stability.
Scaffold safety- Mobile scaffolding for temporary work
 Scaffolds shall be braced by cross bracing or diagonal braces or both, for securing
vertical members together laterally, and the cross braces shall be of such length as
will automatically square & align vertical members so that the erected scaffold
always plumb, square & rigid. All brace connections shall be made square.
 Platforms shall be tightly decked for full width of the scaffold and scaffold boards
shall be secured against displacement. Platforms shall be provided with guard rail.
 The force necessary to move the mobile scaffolding shall be applied near or as
close to the base as practicable and provision shall be made to stabilize the tower
 

during movement from one location to another. Scaffold shall only be moved on
level floors free from obstructions and openings.
 The wheels or casters shall be provided with rubber or similar resilient tires.
 Workmen shall not be allowed to ride on the mobile scaffold.
 All materials shall be removed before mobile scaffold is moved.
 The mobile scaffold in use shall rest upon a suitable footing and shall stand
plumb.
 The casters or wheels shall be locked to prevent any movement.
 Mobile scaffold shall also confirm to the applicable provision of tube & coupler
scaffolding.
 Special care should be taken while working with ladder & scaffold near electrical
lines.
 Care shall be taken to see that no part of scaffold struck by moving equipments &
no materials shall be dumped against it. Area should be barricaded while working
near moving vehicle.
 Scaffold should be designed to carry intended load. Safety for G.l Installation &
Maintenance work
 For working more than Ground + Three floor building height, rescue &
maintenance pulley kit must be used. One maintenance pulley kit for each team &
one rescue kit for three teams will be provided by contractor. The specification of
rescue & maintenance pulley kit attached in Annexure- II.
 For working below the above-mentioned height, suspended working platform with
lifeline (other than load carrying rope) & fall arrestor may be used. Working
platform & others load carrying equipment should be designed in such a way that,
it is able to carry the adequate load. Materials used for construction of working
platform should be of good quality. Suspended working platform must be tested
by third party before using it & it must be retested at every six months. All the
equipments must be thoroughly checked before using it by the contractor or his
representative. If any damage/cracks found the equipment, it must be discarded &
checked by third party before using next time.
 All the safety gears & equipments must be visually checked by supervisor at site
before using it.
 Stability of structure will be ensured by contractor or his representative
(supervisor) for carrying the suspended load.
 Work permit must be obtained for working at height.
 All the workmen for working at height must be medically & physically fit.
 Training must be given to all the workmen about the use & maintenance of safety
gears & equipments.
11.5 Gas Cutting & Welding
Gas cutting
 Oxygen has no smell, but whilst not inflammable itself, promotes & accentuates rapid
combustion, hence it can be highly dangerous, particularly in confined spaces, where
it may not dissipate quickly, because the addition of only a small amount of oxygen to
the normal atmosphere can create a violent risk from any stray spark or welding
flame.
 Acetylene is highly flammable and with air, forms an explosive mixture which can be
set off by any spark, flame or heat in the vicinity. It is therefore essential that all
 

joints, especially on the gas cylinder, are tight; that the hoses themselves are in good
condition and all the valves are turned off on completion of work.
 Liquefied Petroleum Gas (LPG) is a mixture of Butane & Propane. It is highly
inflammable and heavier than air. It flows along floors & tends to settle in low spots,
such as basements and pits. Thus, should be kept in mind to avoid accidental ignition
or suffocation hazards. Only industrial LPG cylinders will be allowed for gas cutting
operations.
 Acetylene cylinders are filled with a porous substance such as charcoal or kapok
substances, which is soaked with acetone. Because of their design they should always
be stored upright. The pressure in the cylinder is 250psi. Copper pipe must not be
used for connecting hoses together, as copper & acetylene can form copper acetylides,
which are sensitive explosive. Acetylene should not be used to cut silver also. Colour
code of Acetylene cylinder is maroon.
 Oxygen is supplied in cylinders pressurized to 2200psi & painted in black colour.
 All cylinders shall be protected against excessive rise in temperature.
 Cylinders stored in the open shall be screened against the continuous direct rays of the
sun.
 A serious accident may easily result if oxygen is used as a substitute for compressed
air. Oxygen shall not be used in pneumatic tools, to blow out pipelines, to dust
clothing or work, to create pressure or for ventilation.
 Oxygen cylinder & its parts should be free from grease, oil or any combustible
materials.
 Fuel-gas cylinders shall be handled carefully, (rough handling, knocks or falls are
liable to damage the cylinder, valve or safety device and cause leakage). Suitably
designed equipment (trolley with chain for tying the cylinder) shall be used for
transporting gas cylinders.
 Fuel- gas cylinder should be placed away from source of ignition.
 Regulators or automatic reducing valve shall be used only for the gas at pressure for
which they are intended.
 Always double stage regulators shall be used with flash back arrestors.
 During gas cutting, Suitable PPE’s should be worn.
 Blowpipe shall be shut off when not in use.
 Lighted blowpipe shall not be left on a bench or the floor as the force of flame may
cause it to move.
 Work piece shall be clamped and not held by hand.
 Hoses shall be kept away from the working area to prevent contact with flames, heat,
sparks or hot spatter.
 For cutting process SOP should be followed. SOP will be provided by concerned
Engineer/ In charge of CUGL.
 Firefighting equipment should be kept nearby to use in case of fire.
Welding
 All the moving & rotating parts of the welding equipment shall be guarded.
 In case of engine- run welding machines, refilling shall not be done while the machine
is running and spilling of oil be avoided.
 All welding cable shall be of completely insulated, flexible type, joint free & capable
of handling the maximum current requirement of the work in progress.
 Any current- carrying parts passing through the portion of the holder, which the
welder grips in his hand shall be fully insulated against the maximum voltage
 

encountered to ground. Insulation of all, metallic or current carrying parts, including

the jaws, which grip the electrodes, is recommended.
 Welding current should be returned to the welding machine by a single, cable from
the work to the welding machine. Connection of a cable from the welding machine to
a common conductor or structure on which the work rests, or to which the work is
connected may be permitted.
 Pipeline containing gases or flammable liquids or conduits carrying electrical
conductors shall not be used for a ground return circuit.
 Precaution shall be taken to prevent electric shock, where required ELCB/ RCCB to
be used.
 Welding equipment shall always be maintained in safe working order. Periodic
inspection shall be conducted.
 Either the work- piece shall be moved to a safe location for carrying gas cutting work
or Combustible materials and flammable materials shall be removed from the
workplace.
 If combustible materials that cannot be moved shall be protected from close contact
with flame, heat, sparks or hot slag. Suitable guards or covers such as fire-retardant
blankets shall be used.
 Fire extinguishers, fire buckets with water shall be kept nearby.
 Suitable PPEs should be used while welding.
 IS 818- 1968 Code of practices for safety & health requirements in Electric & Gas
welding & cutting operations should be followed.
 IS 3016-1 965 Code of practices for fire precautions in welding and cutting operations
should be followed.
 Welders shall be qualified in line with API 1104, or section IX of the ASME Boiler
and Pressure Vessel Code. Requirements in ASME Boiler & Pressure Vessel Code,
Section IIC and Section V or API 1104 shall apply for filler materials and
nondestructive examination of welds. Welder re-qualification shall be required if the
welder has not performed any welding for the welding process qualified for the past 6
months. (as per OISD 226).
11.6 Safety While Working with Machinery- (Hydra, JCB, Crane, Tractor etc.)
 All gears, pulleys, revolving shafts, couplings, belt Drives, chain drives and all other
rotating and moving parts of machinery shall be effectively guarded unless they are so
constructed, installed or placed as to be safe as if they were guarded.
 

 Fencing (Guard) of rotating, moving and other dangerous parts of machinery shall not
be removed while the machinery is in use or in motion and when removed, it shall be
replaced as soon as practicable and in any case before the machinery is again brought
into use.
 No part of machinery, while in motion or in operation shall be examined, lubricated,
adjusted or repaired except by authorized workmen.
 All the limit switches & safety devices should be in working condition. It must be
checked about its working before using the equipment.
 Electric power shall be shut off and relevant fuses removed when repairs are carried
out to any electric machinery.
 Where the machinery in use is mobile type and during the course of operation it has to
shift its location frequently, one 10 kgs stored pressure type Dry chemical powder fire
extinguisher shall be carried on the machine at a suitable position on the machinery so
as to ensure its easy availability.
 Only competent and reliable persons shall be employed as drivers of earth moving
and lifting machinery or as signallers to give signals to the driver.
 The Operators/ Drivers shall possess valid License.
 All the documents related to vehicle & legal document should be available with
operator & should be presented when asked by CUGL representative.
 The driver shall not leave his cabin while the engine or motor is running or the load is
suspended, and in no case, shall the machinery be left unattended, even for short
periods, until all loads are removed.
 Before leaving the machine, the operator shall switch off the electric power supply or
stop the engine apply appropriate motion brakes and locks to keep the machine in safe
condition.
 No unauthorized person shall operate the machines.
 The driver/operator and signaller shall have good vision and undergo the medical test
for vision once in a year.
 Hydra should be used only for lifting purpose; it must not be used to carry the load
from one point to another point.
11.7 Safety in Confined Space-
 

Workplace, having restricted means of entry & exit and not designed for continuous human
occupancy. Such as Steel valve chamber.
Hazards
1. Oxygen deficiency
2. Flammable gas
3. Toxic gas (Carbon monoxide, Hydrogen sulphide, welding fumes)
4. Electricity
5. Mechanical Hazard
Safety requirement
 Work permit must be obtained for working in confined space. Work permit for
working in confined space will be issued at site after physical verification.
 Entrant, the employee who will physically enter the confined space to perform work,
shall be explained about the hazards and the relevant precautionary measures related
to confined space.
 There shall be an attendant employed and he shall be outside the confined space and
monitor the entrants.
 All person entering a confined space shall wear Full- body harness with a lifeline
where entrances are restricted to prevent normal removal of a person. In such cases,
one end of the lifeline shall be with attendant to facilitate removal of person.
 Before the initial entry is made into any confined space the atmosphere shall be tested
to determine whether it is safe for entering without wearing breathing apparatus or
whether it is hazardous & require the wearing of breathing apparatus.
11.8 Personal Protective Equipment-

 All the personal protective equipments should be of good quality & reputed make &
shall have the national or international certification.
 All the required & appropriate/ suitable PPEs will be provided to his workers by his
contractor. If the contractor does not provide the required PPEs to his workmen,
 

thejob may be suspended. In case of urgent nature of job & depending upon the
availability of PPE’s with CUGL, the same may be provided by CUGL& the
deduction will be made from the contractor’s account.
Helmet
 Safety Helmets are intended to protect the head from injuries caused by falling or
flying objects, impacts, electrical shock, by bumping the head against a fixed object.
 A safety helmet should be worn by all persons at all times whenever there are
overhead hazards.
 Safety helmets shall be certified to IS 2952 or internationally recognized such as CE.

Hearing Protection
 The surest method of preventing occupational deafness is to reduce noise at the source
by engineering methods. However, in certain workplaces, engineering methods may
not be sufficient enough to reduce the noise level reaching the user below 85 dBA.
 In such workplaces, hearing protectors need to be used to reduce the amount of noise
reaching the ears.
 Ear plugs should be used in high noise area. Eye & Face Protection
 Eye & face protection devices should be used whenever workmen are exposed to
hazards, which could injure eyes and/ or face.
Hand & Arm Protection
 Hand & arm protection is necessary to protect the workers from potential injuries like
thermal & chemical burns, bruises, cuts, electrical shock and absorption of chemical
through skin contact.
Foot Protection
 Foot protection shall be used to protect the workers from the following injuries-
 Impact Injuries
 Compression injuries
 Electrical shocks
 Puncture
 Safety shoes should always be worn by all person whenever they are at CUGL
worksite.
 Using of gumboots should be ensured whenever required.
Fall Protection
Full body harness shall be used by all personnel when working or travelling in elevated area
more than 1.5m above ground level or adjacent surface where a fall exposure exists.
Specifications of PPE are given in Annexure-IV.
11.9 Safety in Grinding Operation-
 The wheels, which are properly labelled only, shall be used. Instruction given on the
wheel must be followed.
 Grinding wheel shall never be used after its expiry date.
 

 Abrasive wheels shall carefully be inspected and shall not be used, if they are
damaged any way.

 Wheel Guard shall be in position and fixed securely before starting the cutting- off or
grinding operation. Grinding machine shall never be used without wheel guard.
 Wheel guard shall be oriented such that it prevents operator getting hit by broken
pieces of wheel.
 PPEs required- Ear muffs, Gloves, dust mask, Leather apron or safety cloths, head
cover, footwear.
11.10 Electrical Safety

 Proper size cable shall be selected based on the current rating to avoid over heating of
cable.
 Double insulated three core/ four core cable only shall be used. Two core cables shall
not be used.
 Cable must be joint free in hydrocarbon areas.
 Only metal clad and interlocked type combined switch plug- socket units shall be
used. No loose wire shall be inserted in sockets without plugs.
 Cables shall be inspected before every use on all tools, lights and equipment.
 Insulation damaged cable will not be allowed for any work.
 

11.11 Safety in Excavation work-

 Valid work permit shall be obtained for any excavation prior to the job.
 Clearances from different department must be obtained for underground utilities.
Common buried services found in a construction site are:
 Water mains (Fire, Industrial and Common Services)
 Electrical cables (High Voltage and Low Voltage, Permanent and Temporary).
 Drainages and Sewers
 Fuel pipes (Oil, Gas and Chemical).
 Communication and Optic Fibre cables (Telephone and Instrumentation)
 Contractor/Subcontractor will be responsible for detecting, identifying and marking of
all buried services on work area affected by the excavation operation.
 Comply with hazard controls listed in the permit.
 Area around the excavated pit must be barricaded with sufficient height by
appropriate means like sheets etc. in case of Project site for construction of new CNG
stations, building etc so that no disturbance to the adjacent & from the adjacent should
be made.
 Deploy a competent supervisor at work site during the work execution.
 Safe means of access and entry / exit shall be provided for all the excavation.
 Excavation should be done in V shape to avoid collapse of soil.
 Excavation more than man height, escape route with two ladder & rope should be
provided.
 Excavated material should be kept at least 1.5 m away from the top edge of
excavation.
 No heavy equipment, vehicle is permitted near to the edge of the excavated area.
 Stop blocks will be used to prevent construction plants and equipment from coming
too close to the edge of an excavation.
 Excavation pit adjacent to public access will be adequately illuminated.
 Continuous mechanical ventilation will be provided in deep excavation to prevent the
buildup of toxic or explosive gases.
 Atmospheric monitoring will be carried out in advance of any work and throughout
the duration where work is being performed in a deep and narrow excavation.
 Workers working in excavation pit will be briefed on the potential hazards involved,
escape routes and the emergency and rescue procedures when the need arises.
 Adequate first aid and effective rescue equipment will be provided in close proximity
to an excavation.
 Workers will be trained in basic rescue procedures such as removing unconscious and
injured workers from an excavation.
 Excavation of depth exceeding man height will be adequately supported by shoring
kit or other suitable means to avoid collapse.
 

 Workmen working for excavation will use all the required PPEs.
 Area around the excavation to be cleared of all debris.
11.12 LCV Operation.
 LCV must be registered to carry CNG.
 LCV must be equipped with the necessary first aid, safety equipments to carry CNG.
 02 nos. 10 KG DCP Stored Pressure type Fire Extinguishers and 02 nos. Traffic
Cones, HAZCHEM sign & TREM card will be provided by CUGL for each LCV.
 Transporter or the owner must have full and adequate information about CNG.
 The driver must be trained in handling the dangers posed during transport of such
goods.
 LCV must be equipped with the safety equipments for preventing fire, explosion or
escape of CNG.
 LCV must be fitted with techno-graph — GPS system (an instrument to record the
lapse of running time of the LCV; time speed maintained, acceleration, deceleration,
etc.). GPS system should be available for monitoring at all the time and nonworking
of GPS for any LCV will be construed as deviation in operation of LCV.
 LCV must be displayed with class label at its three sides as per statutory requirement.
 Class label must not obscure any other markings required to be displayed. The surface
of the vehicle surrounding the label shall be of a colour that contrasts vividly with the
background of the class label.
 The company and the transporter shall lay down the route of each trip and the driver
shall be bound to take unless directed or permitted otherwise by the Police
Authorities. A timetable shall be fixed for each trip to the destination and back with
reference to the route so laid.
 The driver must undergo the course on driving of vehicle carrying hazardous goods
from an institute recognized by the transport authority.
 A TREM (Transport emergency) card must be provided to the driver, which he shall
keep in the cabin at the right-hand side of the dashboard so that it is available for
ready use at the time of transportation.
 Display of EIP (Emergency information Panel) must be ensured with three sides of
LCV vehicle.
 Driver shall observe at all times the directions necessary for preventing fire,
explosion or escape of CNG while LCV is in motion, and when parked it must be at a
place safe from fire, explosion and any other risk, and at all times the vehicle remains
under the control and supervision of the driver or some other competent person above
the age of 18 years.
 The Driver should be imparted Live Fire Fighting Training enabling him to handle
any fire emergency before deploying for job.
 The Drivers shall wear Cotton uniform & safety shoes all the time on duty. Road
safety sign & signals to be followed.
 Driver will not be allowed to work in drunken condition & alcohol/drugs are not
allowed during the working hours.
 Contractor must ensure the safety of man and machine all the time. The contractor
shall always remain liable to CUGL for any loss or damage caused to any building,
plant, machinery of CUGL due to careless, negligent, inexperienced act or default of
the contractor, his/their agents, representative or employees. CUGL shall be the sole
judge as regards the quantum of loss or damage and it shall be entitled to deduct from
the amounts payable hereunder to the contractor, the cost of repairs or the amount of
loss or damages. Any third-party loss to life or property shall be the responsibility of
 

the LCV contractor. Any third-party loss of life or property resulted due to negligence
of driver or fault of the vehicle shall be the responsibility of the LCV contractor.
 Duty Hours: Transporter shall maintain driver duty hours as per motor vehicle act and
other statutory regulations. However, CUGL will levy penalty as per statutory norms
where driver works beyond 16 hours in a day. Transporter shall submit attendance
sheet and weekly roster of driver to CUGL on start of every month. The driver duty
hours shall fulfil requirements of statutory regulations.
 Contractor shall take suitable Group Personal Accident Insurance Cover for taking
care of injury, damage or any other risks in respect of his Engineers and other
Supervisory staff who are not covered under other relevant clauses. The policy shall
cover third party liability. The third party (liability shall cover the loss/ disablement of
human life (person not belonging to the Contractor) and cover the risk of damage to
other materials/ equipment/ properties during construction, erection and
commissioning at site.
 The Contractor shall also arrange suitable insurance to cover damage, loss, accidents,
risks etc., in respect of all his plant, equipments and machinery, erection tools &
tackles and all other temporary attachments brought by him at site to execute the
work.
Qualification of driver:
 Educational qualification: Minimum 8th Pass
 Driving License: The drivers MUST HAVE valid driving licenses issued by
competent authority for driving medium/ heavy goods carrying vehicle.
 Hazardous goods driving certificate: The driver must have a valid certificate for
driving hazardous goods vehicles from govt/ PSU approved training school/institute.
 Medical fitness: The drivers must be medically fit and shall have a certificate issued
from registered doctor. The certificate shall be revalidated on annual basis or as per
doctor’s advice.
11.13 Safety in Radiography operation.
 Site radiography needs to be done in an area where specific protection measures and
safety provisions are in place, i.e. in an area designated as a controlled area.
 The boundary of the controlled area has to be demarcated; when reasonably
practicable, this is done by physical means. This may include using existing structures
such as walls, using temporary barriers, or cordoning the area with tape.
 Notices are displayed at the controlled area boundary at suitable positions. The
notices bear the national radiation symbol, warnings and appropriate instructions in
the local language.
 In all cases adequate warning is to be given. Visible or audible signals or both are
used where a radiographic source is exposed, or an X ray machine is energized, and
surveillance is compromised. The use of visible and audible signals will help to
reduce the likelihood of accidental exposures to radiation.
 Before the start of radiographic work, the area is to be cleared of all people except for
authorized personnel.
 The boundary should be clearly visible and continuously patrolled to ensure that
unauthorized people do not enter the controlled area.
 Whenever it is possible to take advantage of existing shielding, such as walls, vehicles
or shielded enclosures or similar structures to reduce radiation dose levels,
 

radiography personnel need to arrange the disposition of the equipment and parts
within the shielding afforded.
 Personal dosimeters such as film dosimeters or direct reading dosimeters are to be
worn when radiographers are working with ionizing radiation. A personal dosimeter is
worn only by the radiographer to whom it is issued, and it is securely stored in a non-
radiation environment when not being worn.
 Personal dosimeters are to be regularly assessed for the radiation to which they have
been exposed, as required by the Regulatory Authority. Direct reading dosimeters
have to be periodically assessed by the radiographers to monitor doses received
during radiography.
 Storage facilities for radioactive are designed to restrict exposure, keep radiographic
sources, exposure containers and control sources secure against theft or damage, and
prevent any unauthorized persons from carrying out any actions which would be
dangerous to themselves or the public. Clear warning notices are to be displayed at
the storage facilities.
 A suitable storage facility for radiographic sources, exposure containers, control
sources and ancillary equipment is one that provides protection from the prevailing
environmental conditions. Resistance to fire is considered in constructing the storage
facility in order to minimize loss of shielding and containment. The storage facility is
to be located at a remote distance from corrosive and explosive hazards in line with
the guidelines of sourcing Agency.

12. Disciplinary Action

 If any Contractor allows workers to work in unsafe conditions or violates
environmental permits or regulations, CUGL may remove the Contractor or any of its
individual workers from Company premises or Penalty may be imposed to the
contractor as decided by Engineer/ In charge of CUGL for that particular site.
 Immediate and permanent removal may occur if any of the following activities are
observed:
 Openly exhibits disregard, defiance, or disrespect for the safety program
 Violates established safety or environmental rules, regulations, procedures or codes
 Participates in fighting, violence, threats of violence, theft, or destruction of property
 Possesses weapons including but not limited to firearms or knives not typically used
in conjunction with normal work tasks.
 Falsifying documents or information.

13. Accident I Incident Reporting and Investigation

 The Contractor must immediately report all accidents/incidents and near misses to the
Company Representative.
 The Contractor must investigate all accidents/incidents that result in, or have the
potential to result in, injury or illness, property damage, process/product loss or harm
to the environment.
 The investigative process must include the identification of root causes or causal
factors that contributed to the occurrence. The Contractor must determine the
necessary corrective actions and ensure closure/completion in timely manner. In
addition to the Contractor’s analysis/investigation, CUGL retains the right to conduct
their own investigation for any illnesses, injuries, fatalities, incidents or near misses
occurring on its premises.
 

 The Contractor must conduct the thorough investigation required by and submit a
copy of the written report to the CUGL Representative, unless otherwise specified,
within 48 hours of occurrence. Contractor must maintain injury logs for their
respective workers.
 Incident Investigation format attached at Annexure -v

14. Alcohol, illegal Drugs and Firearms

Contractor must develop and enforce a policy that prohibits the possession,
distribution, promotion, manufacture, sale, use, and use of illegal drugs, drug
paraphernalia, controlled substances, alcoholic beverages and weapons by workers
while on Company premises or during work at site.

15. Emergency Evacuation

 In the event of emergency, the Contractor and their personnel are to follow the
direction of Company emergency action plan.
 Familiarize your workers with the emergency plan systems used at each specific
work location. If any Contractor suspects that an emergency condition exists, they
must immediately contact the CUGL Representative.

16. Housekeeping
 Good housekeeping is mandatory. Work areas must be kept neat, clean, and orderly.
 If a Contractor’s work area is not kept clean, CUGL may have the area cleaned and
charge the cost to the Contractor.
 CUGL may also stop work until the area has been cleaned.
 Keep work areas, passageways, fire exits, fire lanes, and stairs in and around the
buildings and structures always clear of debris.
 Properly store all tools and equipments after use.
 Keep walkways free of cords, cables, obstructions, and debris.
 Changes in walkway elevations or dangerous depressions must be cleared marked
with cones, barricade tape or other appropriate warning signs.
 Clean the work area daily and dispose of debris in dumpsters, or off site in accordance
with the environmental regulations.
 Contractor must remove all unused material and equipment upon the completion of
the work.

17. Fire Prevention and Protection

 CUGL utilizes the Hot Work Permit system for all working involving open flames,
welding, cutting, grinding or brazing. A Fire Watcher is an individual who has been
designated for monitoring the hot work site where open flames are present, where
work on in-service equipment is being performed or where sparks have the potential
for landing on adjacent in-service equipment. This individual must be capable of
evaluating unsafe conditions and taking necessary actions to mitigate and
communicate the conditions. The Fire Watcher shall have no other assigned duties
while conducting this task.
 Obtain appropriate Work Permit from respective Control room to perform work
activity.
 Make sure that fire fighting equipments are available near work area for emergency
situation.
 

 Make sure that workers engaged in activities are capable to use of fire fighting
equipments in case of fire or emergency.
 Smoking is not allowed near work locations or near flammable materials.

18. Behavior with customers

 While dealing with customer (on the job on behalf of CUGL like- attending
complaints, repair, while filling the CNG etc.) Contractor & his team, representative,
supervisor & workmen should follow the dress code &behavior with the customers
should be polite & soft.

19. Environmental Requirements

 Contractors are required to comply with all applicable environmental laws, rules and
regulations over the specific location of where work activities are being performed.
 Contractor must review and comply with all applicable environmental conditions,
laws, regulations and Company requirements prior to the start and during work.
 Contractor must participate in and comply with all applicable work-specific
environmental training prior to commencing work.
 Contractor shall use only approved access roads and stay within approved and
designated working, staging, temporary use, and parking area boundaries.
 Contractor must handle, treat, characterize and dispose of all waste in accordance with
all applicable federal and state/provincial regulations and any specific contract
requirements, such as CUGL approval of the disposal site. Trash, debris, and other
wastes shall not be burnt or otherwise disposed on site without proper permission.
Waste materials must be secured while on the worksite.
 Contractor shall maintain a clean and safe worksite. Trash and debris will be collected
at the end of each day & disposed of properly.

20. Legal Requirement

 Contractors & their representative shall comply with all applicable health, safety &
Environment legal requirement. For example- Factory Act-1948, PNGRB Guidelines,
Gas cylinder Rules, BOCW Act & Rules etc.

21. Requirement of First Aid

 First aid will be provided by CUGL for contract worker working at CNG stations,
CUGL Offices &CUGL stores, however for the contract worker working at PNG
sites, first aid will be provided by Contractor as per statutory requirement.
 

22. Ann
nexure-I Work
W Perm
mit Formaat
CNG Hot
H Work Permit
P
 

CNG Cold Work

k Permit-
 

Energy
y Isolation Work Perrmit
 

Laying & Testing

g work Peermit
  

23. Annexure- II, Specification of Rescue & Maintenance Pulley Kit.

RESCUE & EVACUATION SYSTEM (ASCENDER-DESCENDER):
A unique multi-purpose system that provides functions including rescue and self-rescue,
ascending and descending and positioning at height so that person always descends in control
speed. It should have simple operation allowing just one person to control the rate of ascent
or descent speed effortlessly by holding rope with just two fingers. For positioning, the unit
should be able to locked-off with the Ascender handle. Reliable, simple and 2:1 hauling ratio
provides a system with multi-purpose capability.
This set is a combination of:
The Modular Evacuation and Rescue System with Special Dynamic Braid Rope, Karabiner,
Hooks, Ascending Handle, Full body Safety Sit Harness with front and back D anchoring,
Rope Grab Device with Rope, Parapet Wall Anchor System.
Material of Construction: The entire components of the Set should be CE certified &
manufactured as per EN I ANSI norms and the Parapet Wall Anchoring System should be
ANSI/ OSHA certified. Copy of the certificates to be submitted to CUGL F & S Dept.
Items Specifications:
a) The Evacuation and Rescue System of 100 M Range -Qty. - I Pc.
Portable, Easy to handle & Easy to install (Speedy implementation) to carry out rescue
operation.
• Breaking of descending load is by the friction of the rope on the drum, while a
ratchet gear facilitates ascension.
• During Descent or Ascent System can be stop effortlessly by simply holding
control rope with Two Fingers.
• Maximum Permissible Load - 250 Kg
• Net Wt. of the Device not more than — 2 Kg (Without Rope)
• Pulley reduction Ratio - 2: 1
• Range—ICC mts
• Rope made from Polyamide Material — 9 mm diameter Braided Rope, Breaking
Strength of Rope more than 1200 daN (Kgf)
• Rope should have Resistance to the Aging effect — long life of the product.
• Twist Lock Carabineer Hook with 18 mm opening minimum, made from High
strength Steel with electro zinc plated. Breaking strength more than 2500 daN.
• Should be CE EN 341 class A and EN 1496 class B marked.
b) Ascention Handle - for easy Ascending — Oty. — I Pc.
• Clamp handle operating on Braided rope Diameter 8 to 13 mm.
• Abseiling on fixed rope
• Progression on oblic rope
• Body green anodized aluminum cut fold
• Should be CE EN 567 marked.
c) Full Body Safety Sit Harness with front and Back Anchoring—Oty — 1 Pc.
 

• One dorsal D-ring of forged alloy steel, One sternal D-ring for fall arrest, One
ventral D-ring for rope access, Two lateral D-rings for work positioning
• Adjustable shoulder, thigh & chest straps
• Waist belt with 2 holder loops & rings at back
• Dual color scheme
• Soft padding on shoulder, waist & led straps
• Universal size
• Should be CE EN 361, 358 & 813 marked
d) The second line of protection - Rope Grab with 100 mts. Rope and Hooks. — Oty. — I Set
• Advanced blend of rope grab fall arrestors and anchorage line to operate as a
second line of protection.
• Gravity locking & double security opening.
• 100 mts. long 12 mm Braided polyamide rope with more than 2000 Kgf Strength
with karabiner — Test certificates to be provided.
• Should be EN 353-2:2002 marked
e) Second line of protection for Parapet Wall anchoring - 12mm Braided Rope Adjustable
Lanyards with Hooks for anchoring — 10 Meters Length Strength more than 2000 Kgf. —
Qty.— I Set
f) Parapet Wall Anchor — Qty. — I Set
• Non penetrating design does not penetrate the working surface reducing the
possibility of damage
• Adjustment range to fit from 1’ to 14.5’ wide parapet wall. Fall arrest rated for
one user.
• No tools required for installation.
• Breaking Strength more than 5,000 lbs. (2200 Kgf) and workable load more than
310 Lbs. (140 Kgs.)
• Safety Locking Pins with locking Arrangement
• Parapet Wall Strengthening System should be provided.
• Device Weight not more than 13 Kg
• Should be ANSI Z359.1 and OSHA marked
MAINTENANCE PULLEY KITS (ROPE DESCENDER SYSTEM:
A unique multi-purpose system that provides functions including rescue and self-rescue,
ascending and descending and positioning at height. Its simple operation allows one person to
control the rate of descent or ascent with the Ascender handle. For positioning, the unit can
be locked-off with the Ascender handle providing a brake on the line. Need Secondary line of
Protection.
Material of Construction: The entire components of the Set should be CE 0120 certified and
manufactured as per EN norms.
a. Steel Screw Locking Karabiner — Qty — 4 Pcs.:
The MOC of Karabiner should be Steel of 10 mm dia round bar with opening of minimum 17
mm with weight not less than 160 gms, oval shaped and should be steel screw locking type
confirming to EN 362: 2004 (Class B) and EN marked.
 

b. Work Positioning Lanyard — Qty — I Pc.: -

The rope should be of 12mm Braided Rope, ends should be stitched and covered with
polyethylene protective sleeve, abrasion resistant with Karabiners provided at both ends for
attachment, length should be 2 meters with breaking strength minimum 22 KN. The product
should be EN 358 marked.
c. Grip Descender with 100 mts. long rope — Qty — I Set:
The grip descender made of high strength aluminum alloy with system strength more than 12
KN should be equipped with steel Karabiner for attachment with the harness of user. It
should move along with the user climbing down and locks whenever the lever is set free or
pressed towards the user’s body. It should have double safety locking system. It should be
capable of using on 10.5 mm dia and 11 mm dia Kernmantle rope of 100 mts. length. The
weight should be not less than 350 gms. The product should be EN 341 marked.
d. Anchorage Web Sling — Qty — 2 Pcs.: -
Made of polyester (High tenacity polyamide) should be EN 795 marked with 1.2-meter
length, 44 mm wide polyester having D-Ring at one end and textile loop on another end.
e. The second line of protection - Guided Type Fall Arrestor — Oty — I Pc.: -
• Advanced blend of rope grab fall arrestors and anchorage line
• Gravity locking & double security opening.
• 100 mts. long 12 mm Braided polyamide rope with more than 2000 Kgf Strength
with karabiner
• Should be EN 353-2:2002 marked.
f. Full Body Sit Harness — Oty — I Pc.: -
One dorsal D-ring of forged alloy steel, One sternal D-ring for fall arrest, One ventral D-ring
for rope access, Two lateral D-rings for work positioning
• Adjustable shoulder, thigh & chest straps
• Waist belt with 2 holder loops & rings at back
• Dual color scheme
• Soft padding on shoulder, waist & led straps
• Universal size
Should be CE EN 361, 358 & 813 marked
g. Ascender—Oty— 1 Pc.:
• Clamp handle operating on Braided rope Diameter 8 to 13 mm.
• Abseiling on fixed rope
• Progression on oblique rope
• Body green anodized aluminum cut fold
• Should be marked with CE & EN 567 Standard.
h. Parapet Wall Anchor— Qty. —1 Set:
• Non penetrating design does not penetrate the working surface reducing the
possibility of damage
 

• Adjustment range to fit from 1 to 14.5 wide parapet wall. Fall arrest rated for one
user.
• No tools required for installation.
• Breaking Strength more than 5,000 lbs. (2200 Kgf) and workable load more than
310 Lbs. (140 Kgs.)
• Safety Locking Pins with locking Arrangement
• Parapet Wall Strengthening System should be provided.
• Device Weight not more than 13 Kg
• Should be ANSI Z359.1 and OSHA marked
 

24. Annexure III-

Technical Specification of Coverall
1. Fibre Composition 100% Cotton

2. Colour Blue

3. Weave 3/1 Twill

4. Mass per unit area, mm. 225 gIm2

5. Tensile Strength, kg

Warp 111+-5

Weft 52+-5

6. Tearing Strength, N, mm,

Warp 35

Weft 30

7. Dimensional changes after washing, %, max.

Warp 2

Weft 2

8. Colour fastness to light 4-5

9. Colour fastness to washing

Change in colour 4

Staining 4

10. Colour fastness to perspiration

Change in colour 4

Staining 4

11. Rubbing

Dry 4

Wet 4

12.Ends/dm 460+-5

13.Pics/dm 250+-5

14.Count of Yarn 20+-5% (Warp)

22+-5% (Weft)

15. Dye Chemical Vat Dye

 

25. Annexure- IV
Specification of PPE’s
SAFETY SHOES
 Shoe- derby shoe occupational footwear as per ISO: 20347, anti static, high voltage
resistant
 Upper leather- Buff Barton
 Sole- oil & skid resistant P.U
 Manufacture- shoe to be manufactured by direct moulded system after strobel lasting
on lasts confirming to h fitting.
 Toe puff- good quality fibre thermoplastic.
 Lining- fabtexgreycolour
 Heel grip- leather lining
 Insole- antistatic
 Eyelets - 3 nos.
 Thread—nylon
 Electric resistant - 100 0 to 1000 MD
 High voltage - up to 15k volt
 Size-38to46(4to12)
Helmet, industrial safety (v-guard)
Advance vented protective cap with 4-point fas-trac suspension padded for comfort & helmet
should have cooling vents for improved air circulation. Approval ANSI/ISEA Z89.1 .2009.
Helmet, chemical resistant HDPE
Safety helmet made of chemical resistant HDPE with structured brim designed for additional
side, protection designed to take clip on accessories. Safety helmet made of chemical
resistant HDPE with structured brim designed for additional side, protection designed to take
clip on accessories.
Ear plug - high quality foam, non-irritant and allergy-free material, suitable for protection
against long term, exposure to, medium noise levels. Corded in fluorescent orange colour.
Chemical splash protective goggle- Soft vinyl frame, high- impact polycarbonate lens, can
be worn over prescription spectacles, indirect ventilation, approvals: VJTITST/1
/STRUCT/SP-834/2047/89
Cotton hands gloves - netted cotton gloves H.D.
Safety goggles- lens material -polycarbonate, spherical refractive power tolerance: -
within0.06/m
Astigmatic refractive power tolerance: -within 0.06/m
Difference in prismatic refractive power
Tolerance: - horizontal base out0.75cm/m
Horizontal base-in=0.25cm/m
 

Vertical=0.25cm/m
Optical glass: -1
Maximum spectral transmittance in the ultraviolet: -313nm (0.0003%)
Maximum spectral transmittance in the ultraviolet: - 365nmclear:10%, smoked:0.30%
Luminous transmittance: -clear=74.4%-100% smoked=29.1-43.2%
Lens scale number: - clear=2-1 .2&2c-1 .2 smoked:5-2.5
Resistance to low impact energy of high-speedparticles: -with stands the impact of 6mm
nominal diameter steel ball, weighing 0.86 gala speed of 45m/sec. The impact is carried out
after conditioning the eye wear to temp.55degrees centigrade, and- 5 degrees centigrade.
Weight: - 24 gms. Smoked lens filters out more than 99% of UV rays
Gum boots - full size gum boots with lining up to knee and anti- skid sole black color
Full body harness-
Light weight full body harness easily adjustable, durable with specially designed seat strap
for optimizing comfort and energy absorbing dorsal d-ring for user safety to be used for
confined space entry and for protection against falling from height.
 Must ensure adequate distribution of fall impact to the various parts of human body
 Should have not less than 2-meter polyamide rope attached with self closing auto
locking steel hook.
 Must have adjustable primary straps of not less than 44 mm polyamide webbing &
secondary straps of not less than 20mm equipped with shoulder, waist & thigh straps
differentiated by a different colour.
 Must have seat strap which must be ideally positioned for more comfort. Must be
provided with two chest attachment textile loops and a dorsal attachment steel d-ring
 Must be provided with tool holder loops and rings.
 Must confirm to EN361 & EN358 standard and must submit a test certificate from
authorized govt. Agency.
 The harness shall withstand a minimum 15 KN load when tested as per BIS3521.
 

26. ANNEXURE —V
INCIDENTINVESTIGATION Format no. F02(f&s-p-02)
FORM
CUGL

Reference No. Central U.P GAS LIMITED Date:

FIRE & SAFETY DEPARTMENT
INCIDENT INVESTIGATION REPORT
1. Location/Site:
2. Date and time of Incident:
3. Incident Category:
4. Brief description of incident:
5. Cause of Incident:
6. Injured personnel:
 Name
 Natureofinjury
 Occupation
 Company
 Employee number
7. Loss I damage - estimated value (Assets and I or Environment):
8. Estimated period of installation I equipment shutdown:
9. Immediate action taken:
10. Persons I groups notified:
11. Other Parties informed:
12. Suggestions I Recommendations (if any):

Name & Signature of Investigating Person

 

27. Annexure -VI

Close out report on HSE performance related to various contractors
Name of the work…………………………………………….
Location………………………………………………………
Duration of work: From …………. To………………………
Date of successful completion………………………………….
Report by: Name/Design. /Mob…………………………….
Assessment Grade: A- Outstanding; B- Very Good; C- Good; D- Satisfactory; E-Not
satisfactory

Sr.No Name of Address Agency Tel. Overall Remark

agency owner No Assessment
Grade

Format for HSE Performance Assessment

Sr.No. Parameters Performance Marks 0—8 Remarks, if any

0-Worst / 8-
Excellent

1 Agency had its own HSE

Mgmt. System aligned to
CUGL requirements
(Yes/No)
2 No. of induction programs …../.....
conducted/HSE awareness or
training programs done
(Nos.)
3 No. of HSE meetings done …../.....
(Nos.)
4 No. of Toolbox meetings …../.....
done (Nos.)
5 Using of appropriate PPE’s …../.....
&
6 following of Work Permit …../.....
System.
7 No. of fatal accidents (Nos.) …../.....
8 No. of non-reportable …../.....
accidents (Nos.)
investigated/ Nos. reported
(Nos.)
 

9 Follow of Legal compliances

10 Nos. of times Safety
normsdeviated or penalty
11 Housekeeping
12 Others (4 marks)

Performance assessment grade

Grade: A (More Than 90), B (More Than 80); C (More Than 65); D (More Than 50), E (Less
Than 50);
Overall Remarks about assessment on HSE performance:

Overall HSE performance assessment (Grade A/B/C/D/E)

Signature of Engineer In-charge (CUGL)
Name
Designation
Signature of HOD
Name
 

28. Contractor Certification.

I/We hereby Certify that I/We have read and understood the CUGLContractor Safety Manual
and I/We will follow the HSE Standards while working at my job.

Signature with Stamp. Date

Name of Contractor