Safety Training FOR Line Supervisors: For Award of Certified Environment and Safety Manager's Designation

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SAFETY TRAINING
FOR
LINE SUPERVISORS
For award of Certified Environment and Safety Manager’s designation
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TABLE OF CONTENT
Module one HSE Governance
Module two HSE reporting & monitoring
Module three Identification, evaluation and control of occupational

health & safety risks and environmental aspects and
associated impacts
Module four Procedure for identification, evaluation and control of

environmental aspects and associated impacts
Module five Identification and compliance of HSE legal requirements
Module six HSE objectives, targets and improvement agenda
Module seven Reporting of accidents, incidents, corrective and

preventive action
Module eight Training, awareness and competence for HSE
Module ten Emergency preparedness
Module eleven Generic emergency plan
Module twelve Contract HSE performance management process

Module thirteen HSE audit & inspection
Module fourteen: Industrial hygiene
Module fifteen Working at height/fall prevention
Module sixteen Confined space work
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Module seventeen Electrical safety
Module eighteen Safe lifting operations
Module nineteen Excavation work
Module twenty Personal protective equipment (PPE)
Module twenty one Energy isolation (LOTO)
Module twenty two Permit to work system
Module twenty three Hot works
Module twenty four Discharge of water
Module twenty five Air emissions control
Module twenty six: Conservation of soil and ground water
Module twenty seven Water supply & conservation
Module twenty seven Waste management
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Module One
HSE GOVERNANCE
1.0 Purpose
The purpose of the HSE Governance structure is to define the policy & principles of the
HSE Management System and to provide guidance & directions in implementing the
requirements of HSE Policy and its deployment in an organization.
2.0 Scope
Covers all Strategic Business Units SBUs/Corporate Functions and/or Sites in which an
organization operates.
3.0 HSE Organization & Responsibilities

3.1 Chairman & Managing Director
The C&MD shall approve the HSE policy and will Head the HSE Steering Committee.
3.2 Directors (Manufacturing, Service Businesses as it applies in the organization)

As Operational Directors they will define and approve the HSE systems & procedures for SBUs
under their control.
3.3 Director (HR&CA)

The Director (HR) will assist C&MD and the Operational Directors in setting and monitoring the
HSE policy and its implementation and ensure HSE training.
3.4 Director (Finance)

The Director (Finance) will ensure that all financial resources required for the proper
implementation of the HSE Policy are made available.
3.5 SBU / Corporate Function Heads

The SBU / Corporate Function Heads shall ensure that:
i) HSE at workplace is strictly adhered to in respect of all Units/Branches/Sites under their
control.
ii) HSE Review Meetings are conducted as laid down for their Business/Function
iii) HSE Objectives and targets are set for their respective SBU/Function.
iv) Resources, as required for proper implementation of HSE is made available
3.6 Unit/Branch/Site Heads

The Unit/Branch/Site Heads, as the case may be, will ensure that:
i) The HSE policy & procedure is fully and properly implemented as laid down
ii) Suitably trained and experienced HSE Representative(s) are in place
iii) Appropriate HSE training is carried out
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3.7 Corporate HSE Resource

The Corporate HSE Resource shall assist the Directors and the SBU/Function Heads in proper
implementation, monitoring and review of the HSE policy and processes, including HSE Audit
and Management Review.
3.8 Unit/Branch/Site HSE Representative

The Unit/Branch/Site HSE Representative shall assist in proper implementation of all
HSE regulations at workplace and report incidents and/or deviations, if any, with respect to HSE
policy & practice.
4.0 HSE Governance Structure & Process

4.1 HSE Governance Structure & Process
4.1.1 There will be a 3 tier HSE Governance structure as under:
i. The HSE Steering Committee (HSESC) at the Corporate level under the Chairmanship of C&MD
shall comprise of Director(HR), Director(MB), Director(SB), Director(F), and HSE Corporate
Resource. The committee should meet at least once in 6 (six) months and decide on policy
matters, review HSE & sustainability performance of the Company and provide necessary
guidance to the Business HSE Committees. The Corporate HSE Resource shall be the Convener
of the Committee.
ii. The Business HSE Committee (BHSEC) for each SBU under the Chairmanship of the SBU Head
shall comprise of the Unit/Branch/Site Heads, the SBU Head of Finance and the Regional HR
Head. BHSEC should meet once in a quarter and review HSE & Sustainability performance of
SBU as a whole, suggest means of improving the HSE performance of the SBU, disseminate
policies & procedures to Unit HSE Committees & take up specific HSE & Sustainability projects,
as required. The Regional HR Head shall be the Convener of this Committee.
iii. Each Unit, employing 20 or more persons, in whatsoever capacity, should have a Unit HSE
Committee (UHSEC), chaired by the Unit Head and comprising of at least 2 other Executives of
the Unit. This Committee will meet periodically, say once a month and review the status of HSE
in the Unit.
4.1.2 The status of HSE implementation in the Unit/SBU/Company should be communicated to

all employees and other relevant stakeholders after each review and be displayed in prominent
locations e.g. notice boards etc.
4.1.3 All employees should be briefed as to their personal responsibilities with respect to the
HSE policy and such responsibilities will be documented in an appropriate format such as job
descriptions, function descriptions or in the management system
4.2 Documented Management System

4.2.1 Documentation of systems and procedures should be developed and maintained to meet
the requirements of ISO 14001, OHSAS 18001, and IMS etc.
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4.3 Audits
4.3.1 Unit Heads will ensure that assessment/audit procedures and programs, appropriate to
the needs of the organization, are in place and implemented.
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Module Two
HSE REPORTING & MONITORING
1.0 Introduction
1.1 Purpose of HSE reporting
The main objective of HSE reporting is to support operational management: “we can only
manage what we can measure”. HSE reporting has been made to align with common
international standards as stated for example in the Global Reporting Initiative - Sustainability
Reporting Guidelines
The intention is to produce transparent, reliable, data every year which further help in
Sustainable reporting & help to achieve the vision of an organization which operates without
causing any harm & injury to people & no damage to environment.
Following information related to Health & Safety to be captured month wise from all units
1.2 HSE & Sustainability Monthly Information System
SBU : UNIT: Month:

Health & Safety data
Category Indicator Direct Indirect Cumulative Remarks
employee personnel for the
year
HS01 Number of Employees
HS02 Man Hours Worked
HS03 Fatalities
HS04 Loss Time Injury(LTI)
HS05 Injury Frequency Rate(IFR)
HS06 Lost days
HS07 Injury Severity Rate(ISR)
HS07 First Aid Case
HS08 Near Miss
HS09 Property Damage Case
HS010 Spillage of Oil
HS010 HSE training conducted (man
hrs)
Environment Data:
Category Indicator For the Month Cumulative for Remarks
the year
ENV01 Water Consumption
ENV02 Waste Water Discharged
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ENV03 HSD consumption in MT

ENV04 LDO consumption in FT
E NV05 FO consumption in MT
ENV06 Gas(LPG, Natural gas) consumption in MT
ENV07 Hazardous waste Generated in MT
ENV08 Hazardous waste disposed in MT
ENV09 Non Hazardous waste generated in MT
ENV10 Non Hazardous waste disposed in MT
ENV11 Electricity consumption from Grid in MWH
Specify if any special event like Mock Drill, Specific HSE audit, Health Camp, safety promotional events
organized in the month:
2.0 Definitions
1. Direct Employee: Employees who are on Company’s pay role.
2. Indirect Personnel: Personnel who may be engaged for and/or in connection with the
operation/activity of the Company but are not on Company’s pay role
3. Lost Time Injury (LTI): Any work related injury which results in a person being unfit for work
for a period of 48 hours or more immediately following the occurrence of the occupational
injury (as per the Indian Factories Act,1948) “The period of 48 hours” includes rest days,
weekend days, leave days, public holidays or days after ceasing employment.
4. IFR (Injury Frequency Rate):
Ie (LTI X 1000000) / Total Man hours worked (Own + Contract).
Definition as As per IS 3786
5. ISR (Injury Severity Rate):
Ie (Lost days X 1000000) / Total Man hours worked. (Own + Contract).
Definition As per IS 3786
6. Lost Days: The number of days lost beyond the day of injury to the employee, who was away
from work due to an occupational Injury
7. First Aid Case: Number of Occupational minor injuries suffered by employee or contractor
where first aid was administered & injured person resume work as usual.
8. Near Miss: An incident where no injury, ill health or fatality occurs, but which could have
easily resulted into an accident.
9. Hazardous waste: Any waste by means of its characteristics may cause danger to health or
environment. Example: used oil, waste oil, oily soaked jutes, filters, paint sludge, paint/oil
contaminated barrels, sludge from wet scrubber.
HSE Performance to be reviewed at the beginning of any business review.

Attached format to be used for reviewing & monitoring HSE performance:
HSE PERFORMANCE REVIEW
UNIT: SBU:
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Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec FY-
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Man Hours Worked
Leading Indicators
1 HSE Training(man Days
2 HSE Inspections
3 Safety Committee
Meetings
4 Tool Box Talk
5 Job Safety Analysis
6 Near Miss
Lagging Indicators
1 Fatality
2 Loss Time Injury
3 First Aid Incidents
4 Loss days
5 IFR(Injury Frequency Rate
6 ISR( Injury Severity Rate)
7 Spill in Lts
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Environmental
performance
1 Water intensity
2 Electrical intensity
3 Carbon Intensity
4 Waste generated
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Module Three
IDENTIFICATION, EVALUATION AND CONTROL OF OCCUPATIONAL

HEALTH & SAFETY RISKS AND ENVIRONMENTAL ASPECTS AND
ASSOCIATED IMPACTS
1.0 Purpose
To establish a procedure for identification of occupational health & safety risks and evaluate
the same for implementing control on significant risks
2.0 Scope
All activity carried out by the company and its contractors that have risk associated with
occupational health & safety of employees, contractors and visitors
3.0 Definitions
Hazard: Anything that has the potential to cause harm or injury, or damage to human, property
or the environment
Risk: The likelihood that an event will occur (i.e. the evaluation of a hazard)
Risk Assessment: Process of evaluating the risk arising from a hazard, taking into account the
adequacy of any existing controls and deciding whether or not the risk is acceptable
(Ref: OHSAS18001: 2007: Occupational Health and Safety Management Systems –
Requirements)
Workplace: Any physical location in which work-related activities are performed under the
control of the company (Ref: Adapted from OHSAS18001: 2007: Occupational Health and
Safety Management Systems – Requirements)
4.0 Responsibilities
4.1 Operational Managers/Functional Head
i) Ensure that risk assessments are performed
ii) Ensure that systems and / or controls are in place to manage the risks
iii) Ensure that adequate resources are available for risk management, including the provision
of personnel competent to perform
iv) Review the effectiveness of the risk control measures
4.2 Site Supervisors:

i) Ensure that systems and / or controls are in place to manage the risks associated with their
process
ii) Implement any actions necessary for risk management
iii) Provide feedback to the Senior Management within their organization, concerning the
effectiveness of the risk mitigation measures
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4.3 Site HSE Representative

i) Will provide guidance for preparation of risk assessments
4.4 Employees
All employees must participate in any identified training, to ensure the effective
implementation of risk control measures
5.0 Process
5.1 Workplace Risk Assessment
5.1.1 Risk Assessment
An identification of the hazards present in a workplace and an estimate of the extent of the
risks involved, taking into account whatever precautions are already being taken, involves:
i. Identification of all the hazards
ii. Identification of people at risk
iii. Evaluation of the risks and of existing precautions
iv. Recording and communication of the findings
v. Periodic review
In addition to this, the following should be considered:
vi. The human behavior of people involved
vii. Any external risk to the activity from other activities within the site or from other
organizations
viii. Management of change
ix. Ergonomics
x. Recent changes to the Management System
xi. Changes in legal requirements
5.1.2 When to Conduct a Risk Assessment

I. A Risk Assessment must be undertaken before the commencement of the activity so that
hazards are identified and control measures are determined to minimize the risks to personnel
and property.
II. Hazards must be identified during the planning stage of the activity. This will keep cost for
any subsequent modification to a minimum. A risk assessment must be carried out:
a. When required by legislation
b. For all new engineering design work and specifications
c. For all new / different site activities that could be deemed as hazardous
d. For all hazardous activities / processes
e. When new equipment or machinery is introduced
f. When required by a Permit to Work
5.1.3 Who should carry out a Risk Assessment?

The risk assessment is the duty of those, responsible for carrying out any activity in order to
protect employees and other persons affected by BL activities. A group of experienced qualified
employees of various departments, facilitated by unbiased leader, is formed to identify and
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evaluate risks in their respective area. The employees who carry out the task may also require
specialist guidance on certain aspects from an appropriate person e.g. the Site HSE
Representative / Qualified Medical Practitioner / Engineer.
5.1.4 Conducting the Assessment

I. Hazard Survey
All activities together with methods and systems of are to be subjected to a hazard survey. The
extent and depth of this survey will be dependent on the potential outcome arising from the
activity. Important criteria to be considered include:
a. Exposure of people (both the workforce and the public) to any dangers that may arise
b. Legal requirements
c. The value of the plant or equipment in financial and economic terms
d. Any inherent toxic, explosive or fire risk associated with any stage of the activity / process
II. Based on received information identify the significant risks that have potential impacts on
OH&S.
III. Hazards can result in different forms of harm. It is useful to record both the hazard and the
harm so that it is easier to identify the correct precautions to take. Hazard identification can be
helped by:
a. Viewing a situation or activity
b. Discussing it with those involved in the activity
c. Referring to:
i. Manufacturers’ or suppliers’ manuals or data sheets
ii. A checklist of hazards as an aide-memoir
iii. Accident/incident reports
d. Reviewing legislation and legislative guidance notes
IV. Hazard Analysis

The hazard identified must be analyzed. The main elements of this are probability, frequency
and severity.
V. Control Measures
If the risk assessment has determined that something needs to be done then the following two
questions must be considered and appropriate control measures implemented:
i. Can the Hazard be removed altogether?
ii. If not, how can the risks are controlled so that harm is unlikely?
In answering these questions the following “Hierarchy of Control” must be considered:
a. Elimination; b. Substitution; c. Engineering control

d. Administrative control; e. use of PPE
Once the control measures have been implemented the Risk Assessment process must be
repeated to quantify the residual risk and the risk from any new hazards introduced
inadvertently by the control measures. These risks should now be tolerable.
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5.1.5 Procedure for establishing significant risks.

Significant risks are established from list of the high risk level concerns as emerged from Group
Risk Assessment.
Short listing is done based on following criteria:
i. All risks with statutory compliance, if any
ii. Risks with Extreme and High risk level.
The process also considers relevant chemical hazard, physical hazard, biological hazard,
ergonomic hazard, Monotonous work, influence of shift work, overtime loading, fatigue and
other stresses. The process considers normal working / operating conditions, shutdown and
start up conditions as well as realistic potential significant risks associated with reasonable or
foreseeable emergency situations.
5.1.6 Risk Assessment Reviews

The risk assessment must be periodically reviewed and revised as necessary at least every 12
months, for example if there is a significant change to the work area or for any other reason
that it is suspected that the assessment is no longer valid. Reviews must be documented.
GENERAL RISK ASSESSMENT
Probability& Score
Frequency
Negligible 1
Low 2
Moderate 3
High 4
Definite 5
Severity Score
Minor 1
Moderate 2
High 3
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Major 4
Catastrophic 5
Probability & Definite 5 5 10 15 20 25

Frequency
High 4 4 8 12 16 20
Moderate 3 3 6 9 12 15
Low 2 2 4 6 8 10
Negligible 1 1 2 3 4 5
1 2 3 4 5
Minor Moderate High Major Catastrophic
Severity
Risk Level Risk Priority
Negligible Tolerable
Low Medium Priority
Medium High Priority
High Immediate
NOTE : Abbreviations
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R Routine Activity
NR Non Routine Activity
N Normal Condition
AB Abnormal Condition
E Emergency Condition
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Module Four
PROCEDURE FOR IDENTIFICATION, EVALUATION AND CONTROL OF
ENVIRONMENTAL ASPECTS AND ASSOCIATED IMPACTS
1.0 Purpose
To establish a procedure for Identification, Evaluation and Control of environmental aspects
and associated environmental impacts.
2.0 Scope
All activity carried out by the company and its contractors that have significant impact on the
environment.
3.0 Responsibility
3.1 Functional Heads are responsible for identifying the aspects in their respective areas and
evaluate the same for their impact on the environment
3.3 HSE representative are responsible for coordinating the Environmental Review and also for
guiding for the aspect / impact identification.
4.0 Description
4.1 Definition
Environmental Impact: Any change to the environment, whether adverse or beneficial, wholly
or partially resulting from a product’s environmental aspect
Environmental Aspect: Element of an organization's activities or products or services that can
interact with the environment. (Ref: ISO 14001:2004: Environmental management systems -
Significant Environmental Aspect: An environmental aspect that has or can have a significant
environmental impact.
Workplace: Any physical location in which work-related activities are performed under the
control of BL (Ref: Adapted from OHSAS18001: 2007:
Occupational Health and Safety Management Systems – Requirements)
SL. NO. ACTIVITY RESPONSIBILITY
4.2.0 Collect periodic information about various environmental aspects and Operational
their impacts related to activities, products or services during normal, Managers & MR
abnormal and emergency situations.
4.2.1 Use environmental impact analysis format (Annexure 1) for gathering
information from the concerned employees in the department.
4.2.2 The identification of significant environmental aspects are covered
where relevant:
a) Emission to air; b) Discharge to water
c) Waste stored; d) Contamination of land
e) Impact on communities; f) Use of raw material and natural
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resources; g) Concerns of interested parties
4.2.3 The identification also to cover applicable legislative and regulatory

requirements.
4.2.4 Identify all aspects with any impacts, whether beneficial or adverse.
4.3.0 Consider any accidents, minor or reportable as well as potential All concerned
emergency situations and assist the HOD in its review personnel
4.4.0 Based on the received / validated information, identify the aspects that Operational
have an impact on the environment. Managers & MR
4.4.1 The identified impacts be evaluated by discussion between HOD’s where

necessary
4.4.2 The criteria for evaluation are:
1. Legal Concern; 2. Probability; 3. Severity
4. Resource Savings Potential; 5. Interested Party Concern
6. Existing control measures
4.4.3 The environment impact rating should be achieved utilizing values for the
above six criteria, as provided in the “Environmental Impact Analysis
Format (Annexure 1)
4.4.4 Based on the above evaluation, the impacts are classified 1, 2, 3, 4, 5, 6.
The ranking of impacts can be done based on the product of 1, 2, 3, 4 & 5
of all aspects.
4.5.0 Compile the information and validate the information by visit to the site as MR(HSE)
applicable
4.6.0 Record the significant aspects in the Significant Environmental Aspects MR(HSE)
register
4.8.0 Maintain and review the environmental impacts register under following
circumstances When there is new information regarding environmental
a) Aspects/ Consequent impacts during audits or in the case of amendments
b) to the legislative requirements.
c) New process/ Activity introduction and/ or amendment to the existing
process / activity Change in ranking due to effective implementation of
Programme (s) related to an impact(s).
5.0 On establishing a new site, location or service contract (or an any existing site where a
review has not been performed), the Site HSE Representative or nominee, must conduct a
review of environmental aspects associated with BL activities on the site / location, as
described below. The results of the review must be recorded.
1. The site or location to be evaluated should be broken down into manageable areas for
examination.
2. Identify as many environmental aspects of the activity, product or service as possible. (See
Table 1)
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3. Identify as many environmental impacts (See Table 2) as possible associated with each
identified aspect, taking into consideration normal, abnormal and emergency conditions.
TABLE- 1 (Identification of Environmental Aspect)
Category Environmental Aspect
General Aspects Noise/ vibration
Size/ appearance of plant/ chimney/ building etc.
Road use
Releases of Discharge to ground

substances onto/
into Leaching (migration of liquid to the ground)
The ground
Leakage of oil/ chemical/ fuel/ process liquid
Spillage of oil/ chemical/ fuel/ process liquid
Releases of Discharge to sewer

substances to water
Discharge to surface water body
Leakage of oil/ chemical/ fuel/ process liquid
Spillage of oil/ chemical/ fuel/ process liquid
Releases of Release of asbestos

substances to air Release of Carbon Monoxide
Release of dusts/ particulates
Release of HCFC/ HFC
Release of SF6
Release of Nitrogen oxides
Release of Odour
Release of other hazardous substance
Release of ozone depleting substances (CFCs etc.)
Release of radiation/ radioactive particles
Release of sulphurous oxides
Release of visible plume
Release of VOC’s (Organic solvents)
Waste resulting Generation of difficult waste
from an activity , Generation of difficult waste
product or service
Waste disposal Incineration
Recovery of energy
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Recycling/ re-use
Resource use Use of energy/ fuel
Use of land
Use of raw material
Use of water
Table 2: Default List of Environmental Impacts

Environment Affected Environmental Impact
Emissions to Air (1) (a) Acid Rain
(b) Air Pollution / degradation of air quality
(c) Global Warming
(d) Ground level ozone formation
(e) Ozone layer depletion
Releases to Water (2) (a) Damage to sewers / sewerage systems
(b) Groundwater pollution
(c) Water pollution
Land Contamination (3) (a) Contamination of land
Natural Resources Usage (4) (a) Depletion of non-renewable resources
(b) Overuse of renewable resources
(c) Reduced depletion of non-renewable resources
(d) Sustainable use of renewable resources
Human / Nuisance (5) (a) Directly hazardous to health
(b) Loss of amenity
(c) Noise nuisance
(d) Odour nuisance
(e) Road congestion
(f) Visual impact
Ecological (6) (a) Hazardous to local Flora / Fauna
6.0 Reference
6.1 Clause 4.3.1 of ISO – 14001:2004
7.0 Record
7.1 Environmental Impact Analysis Register
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7.2 Significant Environmental Aspects Register

7.3 Impact Control Plan Register
Module Five
IDENTIFICATION AND COMPLIANCE OF HSE LEGAL REQUIREMENTS

1.0 Purpose
To ensure that legislation and other requirements applicable to HSE activities are identified,
reviewed and implemented.
2.0 Scope
All business locations and activities under the company and its control.
3.0 Definitions
None for this procedure
4.1 Operational Managers
Ensure that all site operations meet legislative requirements.

Ensure that HSE processes are established, implemented, maintained and are conforming to
appropriate codes, standards & legislation.
5.0 Process
5.1 Process Inputs
i. Registers of Risk & environmental aspects and impacts
ii. Consent Conditions
iii. Guidance and information from regulatory and local authorities
iv. Technical journals
v. Internet websites (e.g. Regulatory Bodies)
5.2. Company’s Register of Legislation
5.2.1 The Site HSE Representative must co-ordinate the compilation of a register of legal
requirements relevant to the Site activities
5.2.2 In order to ensure that the Site continues to comply with all relevant legislation and
requirements, The Site HSE Representative along with Operational Managers need to review
compliance on half yearly basis & sent a compliance status report to appropriate HSE
authorities.
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5.2.3 Employees must be provided with sufficient training to provide them with the knowledge
to ensure legal compliance.
5.2.4 Where changes in legislation have a significant impact on the business the appropriate
register must be revised in line with the periodic reviews
• Legislation-specific checklists may be developed for assessments and / or inspections.
Applicable Requirement (Rule License no/ Submission of Date Frequency Remarks /

Law no.) Forms of of Compliance
expiry renewal status
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Module Six
HSE OBJECTIVES, TARGETS AND IMPROVEMENT AGENDA
1.0 Purpose
To ensure that:
i. Improvements are made to protect employees’ health and safety and reduce adverse
environmental impacts.
ii. All company units have established HSE objectives and targets and have implemented
suitable action plans to ensure continual improvement within the business.
iii. Processes are monitored and evaluated in order to provide the basis for continual
improvement.
2.0 Scope
All business locations under the company’s control.
3.1 Business Head
Business Heads are responsible for
i. Deploying Business HSE policies, objectives and targets
ii. Co-ordination of the review of their HSE performance against objectives and targets
iii. Implementation of actions necessary for overall HSE improvement
3.2 Site Managers

Site Managers are responsible for ensuring that:
i. The requirements of this procedure are implemented
ii. Suitable business driven objectives and targets are established during the annual
HSE Management Review
iii. HSE performance reported to senior management.

The Site HSE Representative is responsible for:
i. Co-ordination of objectives and targets, using a suitable register.
ii. Periodic (quarterly as minimum) review of HSE programmes.
3.4 Employees
All employees:
i. Are encouraged to contribute to the improvement process and the identification of areas for
improvement.
ii. Must comply with the requirements of applicable elements of the management system.
4.0 Process
4.1 Performance Improvement
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Each Site must consider the following when defining objectives and setting targets:
i. Corporate, Business and Operational objectives and targets.
ii. The review of new, current or revised legislation.
iii. Environmental aspects Impact and risk assessments.
iv. The results of Site HSE inspections and audits
v. Accidents, incidents, near misses and dangerous occurrences
vi. HSE non-conformance reports including complaints from stakeholders
vii. Lessons learnt
viii. Existing objectives and targets, which have not been achieved
4.2 Performance Measurement

4.2.1 Performance improvement to be measured by continuous monitoring and measurement
of following parameters.
i. Management Commitment
ii. Cost of HSE
iii. Training
iv. Communication
v. Reporting of Accidents & Incidents
vi. Audit, Inspection
vii. Procurement
Viii. Waste Management
Ix. Water Conservation
x. Conservation of Energy
4.2.2 Details of specific measurements are mentioned in individual procedures.

4.2.3 If equipment is required to monitor or measure performance, the unit must establish a
procedure for that. Records of calibration and maintenance activities and results must be
retained.
5.0 Records
i. Defined Annual HSE objectives & targets.
ii. Evidence of continuous monitoring of the performance.
iii. Records of maintenance, calibrations etc.
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Module Seven
REPORTING OF ACCIDENTS, INCIDENTS, CORRECTIVE AND
PREVENTIVE ACTION
1.0 Purpose
To ensure that all HSE accidents and incidents are reported, investigated and actions taken so
as to prevent their re-occurrence
2.0 Scope
All operation sites, facilities & offices of a company.
3.0 Definitions
1. Accident: Any event which results in harm to personnel, damage to property, production loss
or causes damage to the environment.
2. Company Employee: Any person employed directly by the company including those on
contract.
3. Contractor Personnel: Any person employed by a Contractor or Contractor’s Sub-
Contractor(s) who are directly involved in execution of prescribed work under contract with the
Company. Workers in fabrication yards of contractors or any other party located at any of the
company sites come under this category. Fabrication yards of contractors / third party not
located in company site premises shall not come under this category.
4. Environment: Surroundings and conditions in which an organization operates, or which it
may affect, including all living systems, and other biodiversity.
5. Environmental Effect: The direct or indirect effect, of an organization’s activity, products or
services to the environment.
6. Fatality: Any work injury resulting in death of the individual irrespective of the intervening
period. Fatalities arising, for example, from natural causes, suicide, or inexplicable personal
behavior shall be excluded from this category.
7. Fire: Fire includes unintentional fire of any magnitude and unintentional electric arc. All fires
regardless of whether the fire was extinguished by an extinguishing medium or self
extinguished shall be reported as fires. Fires with no visible flame e.g. oil soaked insulation,
pyrophoric fires, smoldering in coke/sulphur piles or other self ignitable materials etc. are also
included in this category. The size and extent of damage shall not determine whether it shall be
classified as fire or not.
Grass fires in the plant areas shall also be included as they pose potential problems to the plant.
However, fires shall be classified as ‘Process /Plant Areas’ or ‘Non- Process /Non-Plant Areas’.
Fires are further classified into ‘Major Fires’ and ‘Minor Fires’ as below.
8. First Aid Case (FAC): Work related injury that requires one time treatment and subsequent
observation (for example minor scratches, burns, cuts, which do not ordinarily require medical
care) and does not result in a Medical Treatment Case (MTC).
9. Hazard: Potential to cause harm, including ill health or injury; damage to property, plant or
the environment;
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10. Immediate Cause: Is the direct reason why an incident has occurred. It can encompass
unsafe conditions (which are not under the control of the person in the workplace), as well as
unsafe acts (which are under a person's control).
11. Incident: Incident includes ‘Accident and Near Miss’; An Incident is an event or a chain of
events that has caused, or could have caused fatalities, injuries, and/or damage to assets, the
environment, or third parties.
12. Job Factor: Any circumstance that may cause or contribute to the development of an unsafe
condition.
13. Lost Time Injury (LTI): Any work related injury which results in a person being unfit for work
for a period of 48 hours or more immediately following the occurrence of the occupational
injury (as per the Indian Factories Act,1948) “The period of 48 hours” includes rest days,
weekend days, leave days, public holidays or days after ceasing employment.
14. Medical Treatment Case (MTC): Medical treatment case is not LTI but requiring medical
treatment from a professional physician or qualified medical person and
MTC case is more than a First Aid.
As a guide a "yes" answer to any of the following questions (due to work related injury) would
be a medical treatment case:
i. Treatment of infection?
ii. Antiseptic during second or subsequent visits to medical personnel?
iii. Treatment for second or third degree burns?
iv. Application of sutures (stitches)?
v. Application of butterfly adhesive dressing?
vi. Removal of foreign body embedded in the eye?
vii. Complicated removal of foreign bodies from a wound?
viii. Use of Prescription medications?
ix. Cutting away of dead skin (surgical debridement)?
x. Application of heat therapy during second or subsequent visits?
xi. Positive X-ray diagnosis (fractures, broken bones, etc.)?
xii. Admission to a hospital for treatment (more than observation)?
15. Loss of Consciousness: If one loses consciousness as a result of a work-related injury, even
for a short period, the case must be considered as an MTC.
16. Near Miss: A ‘Near Miss’ is an unplanned event, which under slightly different
circumstances could have resulted in harm.
17. Risk: Product of the chance that a specified undesired event will occur and severity of the
consequences of the event.
18. Spills/ leaks: Any loss of containment of hazardous, flammable or toxic gas, liquid or solid.
There is no difference between a leak and a spill. The type of containment shall not determine
whether to report or not - A spill even in a bounded area on concrete floor shall be reported
even though there is no environmental impact.
Spills are classified into ‘Major Spills and ‘Minor Spills’ as below. a.
Major Spill: A spill of 500 litres / kg or more & needs to be reported.
b. Minor Spill: A spill less than 500 litres / kg but more than 5 litres / kg, needs to be recorded
for investigation
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19. Release / seepage reaching outside plant boundary: Accidental release of liquid
hydrocarbons, contaminated / saline water or effluent which can cause negative impact on
company reputation should be considered as spills.
20. Work Related Activity: A work related activity is an activity in a work environment, which is
or ought to be subject to management controls. All incidents that occur in work related
activities are reportable.
4.1 Site Manager
a. Initiating the investigation of reported incidents
b. Ensuring that accident / incidents are reported within the company, as required
c. Ensuring the implementation of any corrective and / or preventative measures
4.2 HSE representative

a. Coordination of accident and incident reporting and investigation
b. Maintenance of accident and incident records
4.3 Employees
All employees have a responsibility to report accidents and incidents occurrences to the Site
Manager or HSE Representative.
4.4 Unit Head has the overall responsibility to ensure implementation of this Table – 1
(TABLE – 1) Reporting of Incidents (in Format I)
Report Responsibility Report to Time Line
1 Fatal, Serious Accidents, Unit/Establishment C&MD, D(HR&CA), Immediate

Major Fire or any incident Head Director
resulting in disruption of (I/C), SBU Head, RHR
Operation for more than 2 (Head)
days and Sr Manager (HSE)
Unit HR head All relevant Statutory Immediate

Authorities
2 LTI (Loss Time Injury). Unit Head C&MD, Director (I/C), SBU After 48 hrs of
Work related injury which Head, RHR (Head) and Sr the accident
results in a person being Manager (HSE) but within 72
unfit for work for a period hrs
of 48 hours or more
Unit HR head Factory Inspector
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3 Fire/Spillage (Greater Unit Head Director (I/C), SBU Head Within 24 hrs
than 200 lts) / Toxic and
release Sr Manager (HSE)
4 Incident leading to Unit Head Director (I/C), SBU Head, Within 24 hrs
property damage of more Sr
than INR 20,000/- Manager (HSE)
5 High potential near miss Unit Head SBU head & Sr Manager Within 24 hrs
(event which could have SHE
lead to major accident)
(TABLE – 1) Reporting of Incident Investigation (in Format II)
Investigation Report in Unit Head C&MD, D(HR&CA), Within 7 days

case of fatality & serious Director of the incident
1 accident (I/C), SBU Head, RHR
(Head)
and Sr Manager (HSE)
2 Investigation Report for

all other incidents Unit Head Director (I/C), SBU Head, Within 7 days
reported RHR (Head) and Sr of the incident
Manager
(HSE)
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Initial Incident Notification: Form No:
INITIAL INCIDENT NOTIFICATION REPORT
Classification of Incident (Type of Incident - Tick more than one if appropriate):

Near Miss: First Aid Case: Medical Treatment Case:
Lost Time Injury: Fatality: HIPO incident:
Oil Spill: Chemical Spill: Fire / Explosion:
Name of the company: Date & Time of Incident: Site/Location/Area/Plant:

(BL / Contractor): Date: (dd/mm/yyyy)
Time: (hh:mm)
Event Potential Category (Low / Medium / High):

Level of Analysis (Summary or Detailed):
Brief Description of Incident:
Name of Injured Sex Age Years of Designation

M/F Experience:
Location Status / Immediate Actions Taken:

Name of Reporter: Position:
Name of Supervisor: Position:
Signature of Unit Head:
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Summary Analysis Report/ Investigation Report Form No:
SUMMARY INCIDENT ANALYSIS
Reference (Incident Report no.): Date & Time of Incident: Plant/Location of Incident:
Type of Incident:
Near Miss: First Aid Case: Loss Time Injury
Minor Oil /Chemical spill: Minor Fire / explosion Others including minor traffic accidents:
No. of Persons involved Name of Contractor: Employee / Contractor:
Incident Details:
Immediate causes:
Basic causes & Root causes ( where applicable):
Sr. No. Corrective Action Responsibility Target Completion

Date
Prepared by: Approved by:

Name: __________________________ Name: ____________________________
Designation: _____________________ Designation: _______________________
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GUIDE WORDS FOR INVESTIGATIONS
Events Immediate Causes Basic Underlying Causes
1. Falls from height (from Unsafe Acts Personal Factors

different levels); 1. Operating equipment without authority; 1. Lack of knowledge/experience;
2. Falls from the same 2. Lack of planning; 2. Lack of relevant skills;
level (trips & slips); 3. Lack of warning/failure to observe 3. Stress;
3. Struck by; warning; 4. Improper motivation;
4. Exposure to sharp & 4. Inappropriate speed/mistiming; 5. Abuse/improper use of
sudden sound; 5. Bypassing or removing safety devices; tools/equip;
5. Long term exposure to 6. Using faulty tools/equipment; 6. Memory failure;
sound; 7. Lack of or inappropriate PPE; 7. Change of task
6. Exposure to variations 8. Failure to secure/improper loading; conditions/environment;
in pressure (other that 9. Incorrect lifting methods; 8. Pre existing personal condition;
sound); 10. Incorrect position for task; 9. Lack of capability (physical,
7. Repetitive movement 11. Not following procedures; mental etc);
with low muscle loading; 12. Inattention / poor judgments /decision 10. Time pressures
8. Overstress, making; (actual/perceived);
overexertion, overload; 13. Working on operating equipment; Job Factors
9. Other muscular stress; 14. Impaired ability; 1. Inadequate
10. Working in cramped 15. Horseplay /Taking shortcuts; Leadership/Supervision/Standard
conditions; Unsafe Conditions setting;
11. Contact or exposure 1. Inadequate or defective guards/barriers or 2. Lack of training;
to electricity; safety devices; 3. Inadequate engineering;
12. Contact or exposure 2. Unprotected height; 4. Inadequate purchasing;
to heat & cold; 3. Inadequate or incorrect 5. Lack of Maintenance/or wear
13. Single contact with isolations; and tear;
chemical substance 4. Damaged Tools/Equip; 6. Lack of routine inspections or
(excludes insects and 5. Congested workplace; hazard Identification;
spider bites & stings); 6. Lack of warning system; 7. Incorrect equipment;
14. Contact with, or 7. Inadequately controlled Fire and explosion 8. Inadequate tools/equipment;
exposure to, biological hazards; 9. Inadequate work standards or
factors; 8. Poor housekeeping; procedures;
15. Exposure to mental 9. Poorly controlled chemical, electrical or 10. Confusing/out of date or
stress factors; radiation hazards; procedures with missing steps;
16. Unspecified events; 10. Inadequately controlled temperature 11. Lack of employee input to
17. Caught in between; extremes; procedure development;
18. Excessive or irregular 11. Adverse weather conditions; 12. Ineffective communication;
hours of work; 12. Noisy workplace;
19. Breach of site Rules 13. Inadequate ventilation;
or Standards; 14. Inadequate /excessive light;
20. Environmental event; 15. Inadequate or defective PPE;
21. Spills (hydrocarbon,
chemical, other);
22. Gas leak;
23. Other Environmental
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Event;
24. Event leading to asset
damage /Production
25. Fire & explosion;
26. Event leading to
reputation damage;
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Module Eight
TRAINING, AWARENESS AND COMPETENCE FOR HSE
1.0 Purpose
To ensure that employees are competent and adequately trained to perform their duties safely.
2.0 Scope
It covers all the personnel working in the company including contractor’s personnel, whose
activities affect the environment health & safety of the company.
3.0 Responsibility
3.1 Unit Head
i. Oversee the training policy and the control of training records at site
ii. Ensure that all training, including site inductions, is conducted
3.2 HR Head
It is the responsibility of the Unit Head – HR to ensure that the procedure is updated.
The training plan covering all personnel is prepared, implemented and records are maintained
by the office of HR
Operational Managers
i. Ensuring delivery of job-specific induction training
ii. Setting of training objectives for employees within their scope of responsibility, in
iii. conjunction with the individual employees
iv. Evaluation of the effectiveness of the training administered, usually in conjunction with
The HR / Training Manager
i. HSE representative
ii. Performance of Site HSE inductions
iii. Assist HR in conducting HSE related trainings Employees
i. Identify and agree training requirements with their Manager
ii. Provide feedback concerning the effectiveness of any training received
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4.0 Training Modules for HSE Awareness
Module No. Training Title Target Group Remarks
M1 Safety Leadership Training All executives Once in every 3 years
M2 Hazard Identification & risk All executives at operational Sites & offices Once in every 3 years
assessment
M3 Techniques of root Cause All executives at operational Sites & offices One time
analysis
M4 Emergency Management All executives at operational sites & offices Once in every
two years
S1 Work at Height Executives, & supervisors & workmen at Every Year

Operational sites & offices
S2 Working at Confined spaces Executives, supervisors & related workmen Every year
at Operational sites & offices
S3 Electrical Safety & energy Executives, supervisors & related workmen Every year
Isolation at Operational sites & offices
S4 Use of Personal Protective Executives, supervisors & workmen at Every year

equipments Operational sites & offices
S5 Safety in Excavation work Executives, supervisors & related workmen Every year
S6 Safety in Lifting Operations Executives, & supervisors & Crane drivers & Every year
riggers at Operational sites
S7 Safety In Hot work Executives, supervisors & related workmen Every year
E1 Waste Management Executives, &supervisors & workmen at Every year

Operational sites & offices
E2 Environment Management Executives, &supervisors at Operational Every year

System sites
4.1 Induction Training

All new employees & contractors are to be told about the following as a minimum.
i. Security access/ egress control
ii. General hazard and risk associated with the site activities
iii. Requirements for first aid and welfare and how statistics are collected
iv. HSE legal requirements and those standards imposed by company on sites
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v. Work related significant risks and/ or environmental impacts and their personal contributions
to safe and environmentally improved site
vi. HSE policy and general site rules
vii. Permit system
viii. Emergency plans and procedures
ix. Disciplinary procedures
5.0 Records
Training Records
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Module Ten
EMERGENCY PREPAREDNESS
1.0 Purpose
To ensure that robust, clear and tested emergency plans exist and that suitable persons are
trained to implement them.
2.0 Scope
All business locations under your company control
3.0 Definitions
Emergency Organization: The personnel, systems and procedures put in place to ensure that
emergency conditions are managed efficiently and effectively.
4.1 Unit Head
Unit Head will ensure that adequate and appropriate resources are provided to ensure that the
requirements of this procedure are applied.

The Site HSE Representative will ensure that the requirements of this procedure are
implemented within the scope of the Site organization
5.0 Process
5.1 Development of a Site Specific Emergency Plan
A Site Specific Emergency Plan must be developed for each of the company business location &
new construction site.
5.2 Emergency Plan Scope

In most instances the scope of the emergency plan will be limited to fire related emergencies;
however, depending upon the geographic location of the Site other types of catastrophe must
be taken into consideration and emergency arrangements made proportionate to the identified
risk
Consideration should be given to the following:
• Flooding
• Earthquakes Risk
• Lightning
• Wind
5.3 Preparation of the Emergency Plan

The Site Manager or nominee will ensure the preparation of the emergency plan, using the
generic plan in module eleven
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5.4. Review and Approval Process

5.4.1 The emergency plan must be prepared, checked and approved as indicated below.
The same person must not do more than one of these functions.
• Prepared by: The Site HSE Representative
• Checked by: ESMI Organization HSE Representative
• Approved by: Site Manager / Organization Manager
5.4.2 The Site HSE Representative will control this document

Emergency Plan Implementation
5.5.1 The Site HSE Representative is responsible for the implementation of the emergency plan
at site. This includes:
i. Ensuring all personnel on site are aware of the emergency arrangements and receive an
induction detailing its requirements. In addition, the emergency plan must be posted in areas
where all employees and contractors can have access to it
ii. Ensuring necessary persons involved in the emergency team are appropriately trained and
that such training is upgraded, as required
iii. Other methods by which emergency arrangements may be tested / simulated include audits,
inspections and desk top reviews
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Module Eleven
GENERIC EMERGENCY PLAN (Insert Site Name)

Emergency Plan
1.0 Introduction
This plan has been prepared to provide information and guidance for responses to emergency
situations. This plan is not, nor is it intended to be, a substitute for good common sense, which
must prevail in any given emergency situation.
2.0 Scope
2.1 Types of Emergencies
This plan is intended to cover any potential emergency that may occur at the (insert
location/project) site including:
i. Serious Work Accident: A serious accident is any accident that involves either serious injury
requiring urgent medical aid, or involves entrapped persons whose health or safety is in
immediate danger.
ii. Non-Work Medical Emergency: A medical emergency is any situation where a person through
illness requires urgent evacuation to intensive or specialist medical care.
iii. Fire Emergency: Is any unwanted occurrence of fire that cannot be quickly brought under
control by use of a hand held fire extinguisher.
Iv. Environmental Emergency: An environmental emergency is any situation where there is a
serious risk to the environment, employees or the public due to spill or leak of a hazardous
substance.
v. Bomb Threat: Any received bomb threat will be regarded as an emergency.
Vi. Major Gas Leak: Any gas emission or leak either onsite or on neighboring sites
3.0 Communications
The site has set up suitable arrangements for contact with the site medical staff, fire crew and
emergency response team:
(Insert site Emergency Contact Numbers)
Site Contacts Internal Phone External Phone
EMERGENCY PHONE
Security
Company Reception
Site Nurse
Company Site Manager
Company HSE Representative
Etc.
Off Site Contacts Phone
Ambulance
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Fire Station
Police Station
Local Hospital Emergency Department
Customer
Government Authorities
Local Doctor etc.….
A Trained Emergency response team is set up as described below.
(Insert emergency organization and responsibilities; this will generally include the following
• The person raising the Alarm
• The Emergency Communication coordinator e.g. Security Guard
• The Emergency Response Team
• The Site Nurse
5.0 Evacuation Arrangements

The Site has made the following arrangements in case of evacuation:
i. Responsibilities as per the clause 4.
ii. Muster points have allocated and are indicated on the attached site plan.
(Provide the site plan)
iii. An alarm has been installed (if more than one alarm is present state sound of
alarm if different for each type of emergency e.g. gas leak, fire)
iv. An Evacuation Notice has been appended to the site notice boards
v. Simulation Exercises shall be conducted every (define intervals). (If alarm is also
Periodically tested also state time, day etc)
6.0 Containment
6.1 Spill kits are available at locations shown on the attached site plan for chemical/oil spills and
include the following items:
a. Oil/chemical absorbent material (mats, booms, sand etc)
b. Hand pump
c. Electric pump
d. Empty drums
e. Chemical resistant gloves
f. Chemical resistant overalls
g. Chemical resistant calf length boots
h. Chemical resistant face shield
i. Respirators with cartridges suitable for chemical mist
j. Hazard warning tape
6.2 Spill kits shall be inspected weekly to ensure that the inventory of the kit is as it should be
and to ensure that the location of the spill kit is appropriate to the site activities such as
storage, offloading and use of materials. Outfalls and interceptor pits shall be inspected daily as
part of the daily site inspection system.
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7.0 Emergencies
7.1 Medical
Contact the site medical staff and if casualty is in an obscure location or is trapped alert
emergency response team. Casualty must not be moved until examined by site medical staff
except where casualty is in further danger by not being moved e.g., likely collapse of nearby
structure etc. In case of multiple casualties summon Statutory
Emergency Services and where applicable notify the Regulatory Authority.
7.2 Fire
Call for assistance from the trained Emergency Response team. If a minor fire, try to extinguish
using fire extinguisher but ensure escape route away from the fire is available at all times. Hand
the situation over to the emergency response team on their arrival
7.3 Environmental
(i) Oil Spills
a) Call for assistance from the trained Emergency Response Team.
b) Use appropriate Personal Protective Equipment from the emergency spill kit and ensure oil
cannot enter storm water drains, rivers or run into the sea.
c) Bund area of spill as quickly as possible using sand, oil booms or other suitable material.
d) Use hazard-warning tape to cordon off the area and establish as no smoking, no source of
ignition zone, position foam filled fire extinguishers close to the area.
e) Arrange tanker if large spill or transfer to oil drums as soon as possible. Soak up remaining oil
with absorbent material and excavate contaminated soil.
f) Treat used absorbent material and contaminated soil as hazardous waste and dispose of
through a licensed contractor to a licensed facility.
g) Recovered oil should be considered for recycling.
h) At any time during this action that the emergency response team arrives, hand over to that
team informing them all that you know about the incident and what you have done in
preparation for their arrival. Stay available for investigation purposes.
(ii) Chemical Spills

a) Call for the emergency response team and take only that action required to prevent further
damage only if certain of the chemical, its toxicology and if you have appropriate PPE.
b) If there is a chemist on site seek immediate advise, if not refer to material safety data sheet
(MSDS) for information on safety precautions and whether or not it is necessary to evacuate
the area.
c) Wearing the correct personal protective equipment and at a safe distance from the chemical
try to divert flow path away from storm water drains, rivers or sea.
d) If possible create a bund using sand, chemical booms or other suitable material to contain
the chemical spill.
e) Use hazard warning tape to cordon off the area and have fire truck positioned close by and If
a significant or if chemical has entered storm water drain, river or sea contact the Statutory
Emergency Services and Environmental Agency.
f) Treat/neutralize chemical as advised by chemist or as stated on the MSDS.
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g) Arrange tanker if large spill or transfer too suitable drums as soon as possible.
Soak up remaining spillage with absorbent material and excavate contaminated soil.
h) Treat waste including absorbent material and excavated soil as hazardous and dispose of
through licensed contractor to licensed facility.
7.4 Bomb Threats

Terrorist threat / Bomb alert. (Try and obtain as much information as possible)
a) If a bomb, its exact location and time of detonation.
b) What demands are being made?
c) Make a note of any background noise on the phone
d) Make a note of sex and approximate age of the caller
e) If possible try and have someone else listen in on the call.
f) Once the connection has been broken do not hang up the phone.
g) Make a written record of the above including time of call and time of termination.
h) Contact the police.
i) Evacuate the site unless instructed otherwise by the caller or the police
7.5 Major Gas Leak

Depending upon the size, nature, location and type of gas involved, it may be necessary to
evacuate all personnel from the site as the first response. Should the
Emergency Commander take this course of action the Evacuation siren should be sounded and
the site evacuated. Consideration will need to be given immediately to ensuring that personnel
are moved to a safe distance up wind of the leak.
7.6 Natural Disasters (As applicable)

(Include information as necessary for the site, see example for earthquake:
If inside a building stay inside, take cover under a sturdy piece of furniture such as a table or
desk or crouch up against an internal wall and cover your head with your arms. If on a structure
such as the boiler get as close to a major structural item as
possible or under a vessel there may be a danger of falling objects such as partially secured
secondary steel work, pipes, pipe supports, scaffolding etc, (the structure should have been
designed to withstand an earthquake) crouch down and keep your hard hat in position.
If outside stay outside, move away from buildings, structures and overhead power lines.)
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Module Twelve
CONTRACT HSE PERFORMANCE MANAGEMENT PROCESS
1.0 Purpose
To ensure that contractors are adequately controlled, their safety assured and that
The company reputation is not damaged by their actions.
2.0 Scope
All BL contract orders for the supply and erection, commissioning and servicing
3.0 Definitions
Term Definition
Contractor: Any company appointed to carry out work on behalf of the company. This includes
i. All Annual Maintenance Contract
ii. Contractors appointed for high risk jobs, like Work at height, confined space entry,
excavation, hot work etc.
iii. Contractors appointed for electrical jobs, testing of pressure vessels, etc
iv. Contractors appointed for manual & mechanical material handling
4.1 Site Manager
The Site Manager is responsible for:
i. The conduct and control of all contractors. The responsibility for site activities will include
progress, identifying and initiating action to recover delays, delivery schedules, Contractor/
Subcontractor performance and HSE standards.
ii. Ensuring the implementation of the HSE Plan and/or method statements/ risk assessments
on site.

Monitoring of Contractor HSE performance
5.0 Process
5.1 Pre-Qualification
All contracted companies will be subject to pre-qualification criteria, if involved in high risk
activities
5.2 On-Site Management

5.2.1 All Contractors will be required to undertake initial induction or familiarization training
where their responsibilities will be explained.
5.2.2 Medical fitness certificate to be submitted for all contract workman engaged high risk
activities
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5.2.3 The Site Manager must review planning, progress and performance on site activities and
initiate appropriate actions to ensure timely completion of the activities.
5.2.4 Contractors will be represented at HSE meetings and progress meetings where they will
be consulted regarding reciprocal risks associated with ongoing activities in order that they can
be minimized.
5.2.5 Pre-Qualifying the Potential Bidder
Pre-qualification Criteria: To ensure consistent pre-qualification response from all

Contractors, the Contract Manager shall enclose the pre-qualification questionnaire to all
potential bidders, along with expression of interest.
The Manager shall evaluate the response to pre-qualification questionnaire from all the
potential bidders and provide feedback to Contracts Manager.
If required, Manager may contact the potential bidder for additional information and the
potential bidder is allowed to visit the site.
If requested, the Contract Manager shall arrange meeting between Manager and potential
bidder for clarifications. The minutes of meeting shall be documented.
6.0 Contract Scope & Specific Contract Requirements

The Contracts Manager shall forward the scope of work to Manager to develop Contract
Specific Requirements.
6.1 Standard requirements

While formulating the Contract Specific requirements, the Contract requirements shall be
considered in addition to the following factors,
a. nature of work activities (civil works, mechanical, material handling, maintenance
etc);
b. location & surroundings;
c. mobilization/ demobilization;
d. personnel competency requirements;
e. potential risks;
f. security threats & arrangements;
g. standards of equipment used;
h. regulatory requirements;
i. raw materials & consumables;
6.2 Techno-Commercial Bids & Standards

The Manager shall evaluate standards of each Contractor separately, against requirements
mentioned in tender enquiry and if required, on-site audit may also be carried out. A complete
report shall be forwarded to Contracts Manager along with short falls and recommendations.
This shall help the potential Contractor to improve and make the management more effective.
The minimum submission with bid document shall include,
a. policy;
b. risks management report;
c. manpower details like names, qualifications & experience;
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d. procedures & standards to be used;

e. competency & training;
6.3 Mobilization & Management Plan

Mobilization: The Contractor to whom Contract is awarded shall submit
Management Plan prior to mobilization. The Manager shall review and validate the
Contract Management Plan against the company Policy, Management Systems, procedures,
standards and regulatory requirements.
Pre-Execution Audit: In case high risk or major Contracts, the Manager may opt to carry out Pre-
execution audit, to check that Contractor is equipped to meet organizational standards. The
pre-execution audit shall be based on approved Management Plan.
Any issues, grossly affecting risk shall be addressed immediately with the consensus, mutual
trust, respect & cooperation.
6.4 Contract Execution & Performance Monitoring

The Contract shall submit the performance Monitoring Plan before commencing the work that
shall be approved by Manager. The Contract holder shall implement & monitor performance on
regular basis.
6.5 Contract Close Out & Performance Report

Site Restoration: The Contract Holder shall ensure that Contractor demobilizes from site or
place of work in accordance with all contractual terms & conditions.
The Manager shall inspect the site and ensure that all regulatory compliances related to site
restoration are completed. The Contract Holder shall ensure that Site
Restoration Certificate forwarded to Contracts Manager, before closing out the Contract.
Contract Performance Report: The Contracts Manager may ask Manager to prepare
Contract Performance Report in consultation with Contractor’s Representative,. This may be
used for future references while working with same Contractor or setting up performance
standards for different Contractor for similar work.
7.0 Pre-Qualification Questionnaire for Contractor

Guidelines for Completion of Questionnaire
i. The potential bidder is to ensure that the answers provided are focused against the activities
indicated in the pre-tender document.
ii. The information is supplied in the same format and sequence in which they appear in the
questionnaire. A minimum of 12 has to be obtained in the HSE prequalification questionnaire.
iii. Failure to supply information that accurately and fully covers the material requested may
result in an individual Contractor failing to meet minimum expectations and therefore being
disqualified.
iv. Contractor shall provide information that is authentic and documentary evidence.
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v. Even after getting pre-qualified, if it comes to the notice that non-authentic documents are
provided, the Contractor may be disqualified and if any Contract is in place, it may be
terminated immediately.
vi. The company shall have right to audit Contractors records to verify the authenticity of the
documents, during any phase of the Contract.
Housekeeping
Contractors shall ensure that their work area is kept clean, tidy and free from debris.
The work areas must be cleaned on a daily basis. Any disposal of waste shall be done by the
Contractor.
All equipment, materials and vehicles shall be stored in an orderly manner. Access to
emergency equipment, exits, telephones, safety showers, eye washes, fire extinguishers, pull
boxes, fire hoses, etc. shall not be blocked or disturbed.
Confined Space
Before commencing Work in a confined space the Contractor must obtain from BL a
Permit to Work, the Permit to Work will define the requirements to be followed.
As minimum Contractors must ensure the following:
i. Confined spaces are kept identified and marked by a sign near the entrance(s).
ii. Adequate ventilation is provided
iii. Adequate emergency provisions are in place
iv. Appropriate air monitoring is performed to ensure oxygen is above 20%.
v. Persons are provided with Confined Space training.
vi. All necessary equipment and support personnel required to enter a Confined
Space is provided.
Tools, Equipment and Machinery

The Contractor must ensure that all tools & equipment provided for use during the
Work is: suitable for its intended use; safe for use, maintained in a safe condition and where
necessary inspected to ensure this remains the case (any inspection must be carried out by a
competent person and records shall be available);
Used only by people who have received adequate information, instruction and training to use
the tool or equipment.
Provided with Earth leakage circuit breaker (ELCBs) at all times when using electric power cords.
Use of electrical tape for temporary repairs is prohibited.
Working at Height
Any Work undertaken where there is a risk of fall and injury is considered to be working at
height.
For any Contractor Personnel working at height, Contractors shall provide fall prevention
whenever possible and fall protection only when fall prevention is not practicable. Before
commencing Work in a height the Contractor must obtain from the company a Permit to Work,
the Permit to Work will define the requirements to be followed.
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Supervisor must be present at all point of time, to ensure no deviation occur during the course
of work.
Fall Prevention System
Fall prevention systems (e.g. fixed guardrails, scaffolds, elevated work platforms) must provide
protection for areas with open sides, including exposed floor openings.
Fall Protection Systems
Where fall protection systems are used then the Contractor must ensure the following is
applied:
i. Only approved full body harness and two shock-absorbing lanyards are used,
ii. Prior establishment of a rescue plan for the immediate rescue of an employee in the event
they experience a fall while using the system,
iii. Anchorage points must be at waist level or higher; and capable of supporting at least the
attached weight,
iv. Lifeline systems must be approved by the company before use.
v. Use of standard marked industrial helmet at all point of time.
Scaffolding
All scaffolds shall subject to a documented inspection by a competent person and clearly
marked prior to use. The footings or anchorage for scaffolds shall be sound, rigid and capable of
carrying the maximum intended load without settling or displacement. All scaffolding materials
should be of Mild Steel tubular type.
Guardrails and toe-boards shall be installed on all open sides and ends of scaffold platforms.
Scaffolds shall be provided with an access ladder or equivalent safe access.
Contractor Personnel shall not climb or work from scaffold handrails, mid-rails or brace
members.
Stairways and Ladders

Ladders should only be used for light duty, short-term work or access in line with the below and
the Site Requirements.
a. Fabricated ladders are prohibited.
b. Ladders will be secured to keep them from shifting, slipping, being knocked or blown over.
c. Ladders will never be tied to facility services piping, conduits, or ventilation ducting.
d. Ladders will be lowered and securely stored at the end of each workday.
e. Ladders shall be maintained free of oil, grease and other slipping hazards
f. Ladders will be visually inspected by a competent person and approved for use before being
put into service. Each user shall inspect ladders visually before using.
g. Ladders with structural defects shall be tagged "Do Not Use," immediately taken out of
service, and removed from the Site by the end of the day.
Roof Work/Access
Roof work and access to roofs must not be undertaken without prior authorization from the
company.
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Overhead Work
A secure exclusion zone shall be maintained by Contractor below overhead work to prevent
access. It is forbidden to work beneath a suspended load.
Lifting Operations
Cranes and Hoisting Equipment
Contractors shall operate and maintain cranes and hoisting equipment in accordance with
manufacturers’ specifications and legal requirements.
Only Contractor Personnel trained in the use of cranes and hoists are permitted to use them.
Lifting Equipment and Accessories

All lifting equipment / accessories e.g., slings, chains, webbing, chain blocks, winches, jacks etc
shall be indicated with their safe working load have an identification number visible on the unit
and be inspected and tested in accordance with legal requirements.
Damaged equipment / accessories and equipment shall be tagged “out of use” and immediately
removed from Site.
Lockout Tag out (“LOTO”)

Prior to performing work on machines or equipment, the Contractor shall ensure that it is
familiar with LOTO and Permit to Work procedures and that all of its affected
Contractor Personnel receive the necessary training.
Barricades
Floor openings, stairwells, platforms and walkways, and trenching where a person can fall any
distance shall be adequately barricaded and where necessary, well lit. Where there is a risk of
injury from a fall then rigid barriers must be used.
Barricades must also be used to prevent personnel entering an area where risk of injury is high
e.g., during overhead work activity or electrical testing etc. Such barricading must provide clear
visual warning..
Compressed Gas Cylinders

Gas cylinder shall be securely stored and transported, and identified and used in line with the
local requirements. Hose lines shall be inspected and tested for leaks in line with local
requirements. Flash back arrestor to be used to prevent any explosion due to back fire.
Electrical Safety
Prior to undertaking any work on live electrical equipment the Contractor must obtain a Permit
to Work from the company. Where ever possible live work should be avoided. Any control
measures highlighted shall be implemented prior to work commencing.
The below measures will be taken:
a) Work practices must protect against direct or indirect body contact by means of tools or
materials and be suitable for work conditions and the exposed voltage level.
b) Energized panels will be closed after normal working hours and whenever they are
unattended. Temporary wiring will be de-energized when not in use.
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c) Only qualified electrical Contractor Personnel may enter substations and/or transformer and
only after being specifically authorized by the firm.
Hot Works
A Permit to Work must be obtained from BL prior to any hot works (welding, grinding, open
flame work). Suitable fire extinguishing equipment shall be immediately available. Objects to be
welded, cut or heated shall be moved to a designated safe location, or, if they cannot be readily
moved, all movable fire hazards in the vicinity shall be taken to a safe place. Personnel working
around or below the hot works shall be protected from falling or flying objects.
Prior to the use of temporary propane or resistance heating devices approval must be obtained
from the firm.
Trenching, Excavating, Drilling and Concreting

A Permit to Work must be obtained from your company and all underground lines, equipment
and electrical cables shall be identified and located prior to beginning the work. The
Contractor shall assign a competent Contractor Personnel to all trenching and excavation work.
Safe means of access and egress shall be located in trench excavations. Daily inspections shall
be conducted by a competent Contractor Personnel for evidence of a situation that could result
in possible cave-ins, indications of failure of protective systems or other hazardous conditions.
Physical barriers shall be placed around or over trenches and excavations. Flashing light barriers
shall be provided at night.
Environmental Requirements Waste Management

The Contractor is responsible to remove any waste generated by the work being done on the
Site. The Contractor must dispose of the waste in line with the relevant local legislative
requirements. The waste disposal route shall be documented and made available for your
company to review at any time and may be subject to your company’s prior approval.
Wastes (includes rinse from washing of equipment, PPE, tools, etc) are not to be poured into
sinks, drains, toilets, or storm sewers, or onto the ground. Solid or liquid wastes that are
hazardous or regulated in any way are not to be disposed of in general site waste receptacles.
Spills
The Contractor is responsible for the provision of adequate spill kits/protection and the clean
up and disposal costs arising from such spills.
Emissions
The Contractor shall identify and quantify any emission sources associated with the Works. The
control measures associated with these emission shall be subject to the approval of the HSE
managers in the company. Emissions include but are not limited to noise, dust, fumes, vapors
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Module Thirteen
HSE AUDIT & INSPECTION

1.0 Purpose
To evaluate implementation of and compliance with the HSE management system and to
ensure it’s continued effectiveness and efficiency.
2.0 Scope
All business locations under the company control.
3.1 Operational Managers
• Ensure that HSE inspections are planned and performed.
Ensure adequate numbers of qualified HSE inspectors are available.

• Planning, performance, coordination and reporting of all site-specific HSE inspections.
• Performance of site inspections and safety tours.
3.3 Inspectors
• Planning and preparation of the inspection
• Performance of the inspection
• Compilation of the inspection report
• Expediting corrective actions to close-out
4.0 Process
4.1. Records of Inspections
The performance of all inspections, checks, assessments, site tours etc must be documented.
As a minimum, the following information must be recorded:
• Type of inspection performed
• Inspector name
• Date of inspection
• Areas inspected
• Findings of the deviations found.
4.2 Observance of activities or occurrences requiring immediate action

During site inspections potential hazards/ unsafe practices etc. may be observed which are
considered to be of a serious nature. In such cases work must cease immediately until
corrective action has been taken. The Inspector must also notify the Site Manager at the
earliest opportunity, who will monitor, advise and assist with any outstanding action.
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4.3 Senior Manager’s HSE Observation Tours

4.3.1 HSE observation tours are to be undertaken by all Senior Managers when visiting a site.
The aim is to observe behaviors or conditions on the site and to provide feedback on what has
been observed to enable improvement.
4.4 Site Manager Weekly HSE Tour

The Site Manager must perform a site HSE tour on a weekly basis. The inspection consists of a
walk around the site (typically not exceeding 1 hour). The Site Manager must be accompanied
by the Site HSE Representative who will note any observations.
Hazards must be dealt with quickly and on the spot, wherever practical.
4.5 General Planned Inspections

4.5.1 General Planned Inspections (GPI) should be conducted:
• Monthly in offices
• Weekly at site / manufacturing facilities.
4.5.2 The responsible manager for each area of work must conduct an HSE Inspection of the
work area. Opportunity should be given for worker representatives to be involved.
These inspections must as a minimum, address the topics on the GPI standard inspection
checklists, however, it is preferred that the site should create a checklist specific for their own
needs.
4.5.3 Details of the inspection must be recorded on a Site HSE Inspection Report. The extent of
the inspections may vary from site to site depending on the complexity.
4.5.4 The Site HSE Representative will support the area supervisors/workers representatives in
this task. The Site HSE Representative must collate all the inspection reports after the
inspection and review them.
4.6 Detailed HSE Assessment

The HSE Audit Protocol has been developed to evaluate the performance of HSE for all sites of
an organization. The Audit Protocol is broken down into segments:
I. HSE management
II. Health & Safety
III. Environment which are broken down into several procedures.
The management level for each theme is evaluated by a score from 1 to 4.
The general design approach of the HSE Audit Protocol is the following:
Level 1: The unit failed to take action as per the requirement of the theme. The level is called
“Lack of awareness”.
Level 2: Standards are established, the situation in relation with the theme is known.
Corrective action developed. The level is called “Awareness” and the level is called as
“Managed below ESMI Standard”.
Level 3: Implementation done as per the corrective actions developed as per requirement of
the theme, this level is called “maintained at per “ESMI Standard”
Level 4: Continuous improvement (proactive) is proved, HSE is included in the management,
and practices in place are optimized and are subject to benchmarking which situates them
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above good engineering practice and standard practices in the theme. The level is called
“Excellence/Best Practice”.
Scoring basis
• Assessor should have reasonable confidence that required processes are in place.
• It is the auditor’s role to recognize if missing information is not highly significant or if a
criterion is missing due to a gap in the system.
• Themes which are NOT ASSESSED shall be scored as N/A.
The score given for each chapter is the average of the theme’s scores.
Utilization & Frequency of Audit

The HSE audit protocol has been developed with the objective that it will become a tool for self-
assessment as well as formal Assessments and a management tool for the improvement of the
HSE, performance. Each Unit will be assessed by an external evaluator at least once a year. Each
unit should also make a self evaluation at least once a year as per Annexure A attached at the
end of this manual.
Significance of the HSE audit score:

The score obtained by the unit/establishment will have a direct link to the overall performance
of the unit & SBU.
5.0 Records:
1. Internal assessment records.
2. External assessment records.
3. GPI records.
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Module Fourteen:
INDUSTRIAL HYGIENE
1.0 Purpose
To ensure that all employees, indirect personnel and others who may be affected by the
company’s activities are adequately protected from chemical, biological and physical hazards
2.0 Scope
The procedure is applicable to a company’s facilities to fulfill the general and also the legislative
requirement.
3.1 Operational Manager

• Ensure that appropriate workplace risk assessments are performed
• Ensure adequate maintenance of protective equipment
3.2 Medical Officer

• Maintain a register of persons who may be potentially exposed and to review that register at
appropriate intervals
• Maintain appropriate documentation for twenty years.
4.0 Description
4.1. Definitions
4.1.1 Industrial Hygiene: The discipline of anticipating, recognizing, evaluating and controlling a
broad spectrum of biological, chemical, and physical hazards that can affect an employee's
health. Typically these may include: vapours, gases, mists, dusts, fumes, smoke, aerosols, high
frequencies of sound and light, ionizing and non-ionizing radiation and noise and vibration
4.1.2 Physical Agents: Sources of energy that may cause injury or disease e.g. noise, vibration,
radiation, and extremes in temperature and pressure
4.2 Risk Assessment
4.2.1 A workplace risk assessment must be carried out on all sites in order to identify potential
chemical, biological or physical hazards, detrimental to human health and the risk of exposure.
4.2.2 Risk assessments can be made as part of, or as an extension of a more general risk
assessment i.e. if a substance hazardous to health present in the workplace is also a risk to the
safety of employees, e.g. they are flammable, unstable etc, it may be beneficial to perform a
combined risk assessment.
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4.2.3 The risk assessment must include consideration of:

i. The hazardous properties of the substance or physical agent
ii. How the hazard arises i.e. produced or given off, e.g. as fumes, vapour dust etc by a process
or an activity or as a result of an accident or incident
iii. Information on health effects provided by the supplier, including information contained in
any relevant material safety data sheet
iv. The level, type and duration of exposure
v. The circumstances of the work, including the amount of the substance involved
vi. Activities, such as maintenance, where there is the potential for a high level of exposure
vii. Any relevant workplace exposure limit or similar occupational exposure limit
viii. The effect of preventive and control measures which have been or will be taken
ix. The results of relevant health surveillance
x. The results of monitoring of exposure
xi. In such cases, it is necessary for a company to carry out ambient air and work zone
monitoring and / or measurements to determine exposure, particularly where operations are
complex or specialized and the substances involved have an occupational exposure limit
4.2.4 The risk assessment must be reviewed regularly (at least annually) or if:
i. There is reason to suspect that the risk assessment is no longer valid
ii. There has been a significant change in the work to which the risk assessment relates
4.3 Hierarchy of Control
4.3.1 The following principles are adhered to in order to reduce the risk of exposure:
i. Remove any potential hazard through risk mitigation
ii. Substitute any known high-risk substance for a less hazardous substance
iii. Contain the hazard by separating the hazard from the person or by enclosing the person
from the risk
iv. Organize the work to reduce the exposure to the hazard
v. The use of personal protective equipment (PPE)
4.3.2 Control measures must be periodically reviewed, particularly where exposure level are
near to exposure limits subject to regulatory controls, which may change.
4.4 Monitoring of Exposure at the Workplace

Monitoring is done when any of the following circumstances apply:
i. When failure or deterioration of the control measures could result in a serious health effect,
either because of the toxicity of the substance or because of the extent of potential exposure,
or both
ii. When measurement is required so as to ensure that an occupational exposure limit or other
working standard is not exceeded
iii. As an additional check on the effectiveness of any control measure
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iv. When any change occurs in the conditions affecting employees' exposure which could mean
that adequate control of exposure is no longer being maintained, e.g. an increase in the
quantity of a substance used or changing systems of work or introducing new plant
4.5 Health Surveillance
4.5.1 All persons who are potentially at risk to significant exposure to chemical, biological or
physical hazards (or when there is a legal requirement to do so for a specific hazard) must be
entered into a register, which must be maintained and reviewed on a regular basis
4.5.2 Where PPE is the only source of protection, or if monitoring shows that an exposure
above legal requirements has taken place, then those persons exposed must also be subject to
health surveillance.
4.5.3 Local Exhaust Ventilation (LEV)

Where LEV or extraction fans are used to remove airborne substances from the breathing zone
of persons, the following must be adhered to:
i. Air monitoring must be carried out periodically
ii. The extraction systems must be subject to maintenance procedures
iii. Air monitoring and maintenance documentation must be retained for a period of twenty
years
4.6 Information and Training

4.6.1 Information, instruction and training provided will include:
i. Details of the substances or physical agents hazardous to health to which the employee is
liable to be exposed including:
a. The names of those substances / physical agents and the risk which they present to
health
b. Any relevant occupational exposure limit and other legislative provisions which
concern the hazardous properties of those substances / physical agents
c. Access to any relevant material safety data sheet
ii. The significant findings of the risk assessment
iii. The appropriate precautions and actions to be taken by the employee in order to safeguard
themselves and other employees at the workplace
iv. The results of any monitoring of exposure and collective results of any in health surveillance
undertaken, in a format calculated to prevent those results from being identified as relating to
a particular person
v. Why, how and when the hygiene measures provided must be used
5.0 Records
1. Records of Ambient Air and Work Zone Monitoring
2. Records of Health check-up
3. Pathological Test Reports
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Module Fifteen
WORKING AT HEIGHT/FALL PREVENTION

1.0 Purpose
To prevent injury and property damage when conducting work at height.
2.0 Scope
This procedure is applicable to “persons working at Height” in any organization and their
Contractors.
3.0 Responsibility
3.1 Functional heads / Departmental coordinator / Site Manager
The Site must ensure that arrangements are in place to ensure that:
i. All work at height is properly planned and organized
ii. All work at height takes account of weather conditions that could endanger health and safety
iii. Those involved in work at height are trained and competent
iv. The place where work at height is done is safe
v. Equipment for work at height is appropriately inspected daily basis
vi. The risks from fragile surfaces are properly controlled
vii. The risks from falling objects are properly controlled
3.2 All Employees

All employees have a duty to:
i. Report any safety hazard to their Supervisor
ii. Use any equipment supplied (including safety devices) properly
iii. Follow Safety training and instructions (unless they think that would be unsafe, in which case
they should seek further instructions before continuing)
4.0 Description
4.1. Definitions
Term Definition
Competent Person trained, experienced and authorized to carry out a particular

Person function
Fall Protection Equipment typically consisting of a Double hook full body harness, a lanyard not exceeding
Equipment 2 meters in length and a deceleration device.
The system needs to be attached to an anchor point capable of withstanding a load of at
least 2270 kg
Working at All working at height is above 2 m height where there is a risk of falling and a person can
Height become injured as per Factory Act. All high works which are not regular in nature should
to be covered under work permit system i.e. a work permit is to be issued and verified and
checked by authorized persons prior to start of work
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4.2 Process
4.2.1 Elimination or Minimization Programme for Work at Height
I. Minimization of work at height via:
a. Elimination of the need to perform work at height
b. By eliminating the risk of fall (i.e. implementation of fixed barrier’s, scaffolds, mobile
elevated work platform etc.)
II. Where reasonably practical as much work as possible will be done at ground level to
minimize working at height e.g. sections of steel work can be bolted together, pipes welded,
radiography carried out and the items painted before being lifted into position.
4.2.2 Actions Prior to Starting Work at Height

I. Prior to any person working at height a risk assessment must be carried out to identify the
risks and the safety measures necessary to eliminate or reduce the risk
II. Collective protection measures must always be considered in preference to individual
protection measures
III. Where it is not reasonably practicable to provide a safe working platform and a person has
to rely on the use of a double hook full body safety harness, life line with fall arrestor, a suitable
rescue plan must be considered along with the safety measures.
IV. A Competent Person must verify that the contents of this procedure have been
implemented before the commencement of any work at height. Work may only commence
with the written approval of the Competent Person.
4.2.3 Verification of Procedure Implementation

I. For all work of more than 1 day in duration, a systematic verification of the satisfactory
implementation of this procedure must carried out by Competent Person, at a frequency
appropriate the duration and risk of the task.
II. On completion of the work it must be formally verified by a Competent Person, that the work
place has been left in a satisfactory condition and that all persons have safely returned from the
workplace.
Note: Many accidents occur because floor gratings have been removed and not replaced, or
superfluous materials are left in elevated positions causing slip, trip and fall hazards
4.3 General Precautions

4.3.1 Fall Prevention
I. The first consideration must always to provide a safe working platform.
II. The sides of all stairways, floors/platforms, walkways, buildings, etc, from where a person
can fall and suffer injury or from where articles could fall and injure someone must be
protected with double guard rails and toe boards of at least 150mm in height.
III. With regard to permanent structures such as stairways and platforms, as much of the
permanent handrails as is reasonably practicable should be installed while the structure is at
ground level. Where this is not possible then handrails/guard rails must keep place with
construction.
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4.3.2 Floor Openings

I. All openings, through which a person can fall and suffer injury, must be covered and secured
using material that is sufficiently strong to support any forces that it may be subjected to. The
word “Hole” or “Opening” must be printed on the topside. If a cover is not used the opening
must be protected by rigid guardrails of adequate strength and toe boards.
II. When floor gratings are removed for fitting instrument cables etc, the area must be
physically fenced off and signs put in place. Rope or warning tape is not considered as being
adequate. Fences must not be removed before the floor is reestablished and inspected.
III. Collective safety measures, such as a safety net suspended beneath the area of work, must
be adopted for persons installing floor panels and the floor panels locked/bolted in position as
each one is fixed.
IV. Persons not connected with the works must be prevented from inadvertently walking into
the area until all panels are fixed and work complete. Double guardrails must be used for
closing off such areas and notices clearly displayed prohibiting unauthorized access.
4.3.3 Hand Tools

I. Precautions must be taken to ensure that portable tools, hand tools etc, used in elevated
work areas cannot fall onto people below. Safety nets and/or toe boards are suitable for this
purpose.
II. So far as is reasonably practicable, barriers must be erected below to prevent person walking
below such areas.
III. If none of the above is practical, then some form of protection from falling tools must be
implemented e.g. use of straps/ropes attached to the tools and some appropriate anchor
4.3.4 Fall Protection Equipment

I. Fall Protection Equipment must be inspected by the user & trained person daily.
II. Double hook full body Safety harnesses that have been used in a fall arrest situation must be
withdrawn from service and not reused/issued until after a full examination.
III. Records of the results of thorough examinations must be kept on site
IV. Lifelines fall arrestor used for the attachment of Double hook full body Safety harnesses
must be:
a. Horizontal lifelines must be made of steel rope 12 mm diameters (min)
b. Installed at waist height or above
c. Tensioned by use of a turnbuckle or similar
d. Designed to support the maximum number of workers
e. Securely anchored at both ends with triplicate wire rope clamps at points able to withstand
the dynamic load generated by a fall
V. All lanyards must be made of flame resistant materials. Inertia reels may be used to enable
more safe movement around certain areas.
VI. Safe access and egress must be provided to all places of work including access to lifelines,
fall arrestor.
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4.3.5 Adverse Weather Conditions

No one must be allowed to work on wet or work in exposed positions in the rain, scorching heat
or strong winds. Also, plant and equipment such as cranes, mobile elevating work platforms,
cradles etc must not be used in such conditions.
4.4. Ladders, Scaffolds and Work Platforms

4.4.1 Special Cases
Where the provision of a work platform is not reasonably practical and the work does not fit
into the category referred to in the paragraph above, alternative safety measures must be
agreed in advance with the company’s HSE Representative.
4.4.2 Ladders
I. Ladders can be used for light tasks of low risk and short duration but not more than one
person must be on the ladder and the ladder must be secured to prevent it from slipping
outwards and sideways. The employee must inspect the ladder before use. The person on the
ladder must wear a safety harness to prevent falling.
II. Ladders must be inspected at least once monthly, must be in good condition and must be
painted. Ladders must be installed at an angle of 4-1, must extend approximately 1m above the
working platform and must be secured so they cannot slip.
III. Vertical ladders installed for construction purposes at a height where a person can fall more
than 3 meters must have a cage/hoops or be fitted with a rappel line (vertical lifeline) as a
continuous/sliding anchor point for a safety harness.
IV. Vertical ladders over 9 meters long must have a platform every 9 meters and be offset at
every platform.
V. Self-made ladders are not allowed on site.
4.5. Scaffolds and Work Platforms

4.5.1 Material Examination and Storage
All material must be examined upon arrival at site or during unloading; any defective items
must be removed from the site or put into a specially designated and marked storage area.
4.5.2 Inspection
I. A register of all scaffolds erected and dismantled on site must be maintained
II. A trained and competent scaffold inspector must inspect erected scaffolds before first use
before use and at least once weekly thereafter. Additionally, Supervisors must inspect scaffolds
daily.
III. Inspections must also be carried out when a scaffold is substantially altered and after any
event or incident likely to have affected the stability of the scaffold such as strong winds or
being struck by a crane.
IV. Inspection reports must be kept until the work is completed. All other records of inspection
must be kept until the next inspection has been carried out.
V. A notice with warnings such as “scaffold under construction/dismantle - do not use” or a
scaf-tag showing that it has been inspected and passed “safe for use” or condemned as “unsafe
do not use” must be affixed at all scaffold access points.
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Scaf-tags must include the name of the inspector and the date of inspection.
4.5.3 Scaffold Erection

A. Scaffolds of “special” or “non-typical” design and any scaffold greater than 10-
metres in height must be designed by a suitably qualified engineer.
B. Persons erecting scaffolds, steel erectors and any other person likely to work in an area or in
circumstances where the provision of a work platform is not practical must use fall protection
equipment.
C. All work platforms must have a top guardrail fixed at a height of 1.1 m, an intermediate
guardrail and toe boards to all sides from where a person or articles can fall.
D. Work platforms made from loose planks or boards are forbidden.
E. Gangways must have guardrails and toe boards on all sides from where a person or articles
may fall.
F. Scaffolds erected around a structure, which may have electrical services, and where electrical
equipment is to be used for work must be earthed to protect persons from electric shock. The
earth cable must be routed to avoid damage from work equipment.
4.6. Roof Work

4.6.1 All persons required to undergo medical test & vertigo test.
4.6.2 All new persons required to safety training before start the job.
4.6.3 Every day before start the job required work permit checked & sign by safety person & to
be serve toolbox talk.
4.6.4 Persons use permanent ladder / temporary ladder with use life line, fall arrestor & double
hook full body harness for prevent fall arrest to climb up & get down.
4.6.5 Persons working on sloping roofs must use proper roof ladders designed to gain
anchorage from the opposing slope or must be connected to a double hook full body harness
with fall arrestor to lifeline positioned so that the person(s) cannot fall from the roof.
4.6.6 Persons working on fragile roofs must use crawling boards of sufficient length to span roof
trusses. Buildings with fragile roofs must have a notice clearly displayed at all access points with
the wording or similar “Danger Fragile Roof
4.7 Pipe line erecting & dismantling

I. All persons required to undergo medical test and vertigo test
II. All new persons required to safety training before start the job.
III. Gas & electrical shut down to be done for prevent fire hazards.
IV. Every day before start the job required work permit checked and signed by safety person &
to be serve toolbox talk for prevent accident
V. Persons use temporary ladder with use life line, fall arrestor and double hook full body
harness for prevent fall arrest to climb up and get down.
VI. While working at height near column is required scaffolding
VII. While working at height, move one place to another place required fall arrestor with
horizontal life line for one lanyard & other lanyard use to other anchor point with life line or
direct to anchor point or other mechanical means for preventing accident.
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4.8 Training
Training for working at height must include:
i. General Safety Needs, PPEs requirements, HSE policy
ii. Risk from performing work at height
iii. Details of the procedure for working at elevated work places i.e. Work permit, vertigo test,
iv. Safe use of safety equipment (fall arrestor, life line, double hook full body harness, safety
net)
v. Safe use of ladders
vi. Scaffolding erection
vii. Daily equipment checks including safety harness inspections
viii. Rescue techniques to rescue someone suspended from a safety harness or having fallen
into a safety net
ix. Actions to be taken in case of emergency
5.0 Records
I. Work permit
II. Competent persons list
III. Training records
IV. PPE inspection records.
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Module Sixteen
CONFINED SPACE WORK
1.0 Purpose
To ensure the safety of all personnel required to work in confined spaces
2.0 Scope
All business locations under your organization’s control where there are work areas that have
been classified as confined spaces identified via the risk assessment process.
3.0 Definitions
Term Definition
a. Authorized Person: A person appointed to carry out specific duties
b. Competent Person: Persons trained, experienced and authorized to carry out a particular
function
c. Confined Space: A space or structure that is, large enough that employees can bodily enter
and perform work and is not designated for continuous occupancy and has limited openings for
entry and exit and restricted natural ventilation, e.g. oil storage tanks, reaction vessels, inside
furnace, inspection pits, etc
d. LFL (Lower Flammable Limit): the concentration in air at or below which a flammable
substance will not burn when exposed to a source of ignition.
e. OEL (Occupational Exposure Limit): the maximum exposure a person can have to a chemical
substance without suffering any known adverse affects.
f. PTW: Permit to Work
4.1 Site Manager
Ensure that arrangements are in place to enable compliance with the requirements of this
procedure

I. Ensure that that this Procedure is audited at appropriate intervals
II. Ensure that a PTW System is in place
III. Ensure that Confined space Resister is prepared and maintained
5.0 Process
5.1 Alternative Methods
The decision to enter a confined space must be a last resort after having considered work
practices where entry would not be required i.e. could the confined space itself be modified so
that entry is not necessary; could the work done from outside (e.g. inspection, sampling and
cleaning operations can often be done from outside the space using appropriate equipment
and tools; remote cameras can be used for internal inspection of vessels)
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5.2 Confined Space Register

A written inventory of all confined spaces must be established and maintained for the site.
A register of all staff and contractors who are trained to perform work in confined spaces must
also be established and maintained.
5.3 Training
I. Everyone involved with preparation of confined spaces for entry; those required to enter a
confined space, Watchers and those that may have to enter in the event of an emergency must
be given appropriate training.
II. The person responsible for the completion of a confined space entry permit and / or the
Authorized Person must be suitably trained and competent within the permit system, confined
space entry requirements and the hazards associated with the work
III. Training must provide details of the risk assessment and will include as a minimum:
i. Confined space entry permits
ii. Use of barriers to prevent unauthorized entry
iii. Emergency entry and exit procedures
iv. Use of respiratory equipment.
v. Use of Safety Equipment
vi. Communication, including marking / identification of confined spaces
vii. Rescue drills
viii. Fire protection
5.4 Risk Assessment

If entry to a confined space is unavoidable a safe system of work and adequate emergency
arrangements must be in place before the work starts. The first step will be to perform a
suitable and sufficient Risk Assessment in order to identify any hazards, assess the risk and
determine precautions.
The following must be taken into consideration:
a. The task being performed
b. The working environment
c. Working material and tools
d. The suitability of those carrying out the task
e. Arrangements for emergency rescue
5.5 Hazards to be considered

5.5.1 If the atmosphere in the confined space contains toxic, flammable/explosive substances,
carbon monoxide gas, corrosive substances and/or low/ high oxygen levels, the confined space
must be emptied and flushed or purged. Fresh air (normal air in sufficient quantity to make the
atmosphere safe) must be provided. If this cannot be achieved, or if there is a risk that an
inappropriate atmosphere could evolve during the work, self contained breathing apparatus or
air hoods must be used along with other protective measures such as ensuring that ignition
sources or materials that may inadvertently cause ignition are not taken into the confined
space or the vicinity of an opening to the confined space
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Note: respirators must not be used if there is a risk of oxygen deficiency.

5.5.2 When providing fresh air, it must be ensured that the fresh air intake is not contaminated
by smoke, exhaust fumes from generator sets, etc. and that the intake is protected from
interference. Open vents must be prevented from being closed or obstructed and air
blowers/extractors must be safeguarded against disconnection.
Forced ventilation such as air blowers must be fitted with an alarm that will activate in the
event of a breakdown of the equipment or alternatively the equipment doubled up or a person
on standby close to the equipment. In the event of hearing the failure alarm or being alerted by
the person on standby, the confined space must be immediately evacuated.
5.5.3 Under no circumstances must oxygen be used to provide breathable air or to sweeten the
atmosphere. An oxygen-enriched atmosphere presents a serious risk of fire and explosion and
can cause normally stable materials to become highly combustible e.g. grease can become
liable to spontaneous combustion when oxygen-enriched.
5.5.4 If welding or burning must be conducted in the confined space consideration must be
given to the fact that the process could seriously reduce the breathable air and introduce
toxins.
5.5.5 Flammable substances and substances liable to give off gases, vapors or fumes including
substances being used in the confined space e.g. paints, resinous compounds etc, must be
continuously monitored to ensure that the OEL and LFL are not exceeded.
5.5.6 Gas/oxygen cylinders must not be taken into a confined space. If gas e.g. acetylene/
oxygen is required for welding or burning, the gas must be conveyed by a hoses of continuous
length with the cylinders on the outside of the confined space. When not in use the gas/oxygen
supply must be turned off at the nozzle/torch and cylinders and the hoses disconnected from
the cylinders or completely removed from the confined space after each shift.
5.5.7 Consideration must also be given to the tools, plant and equipment being taken into the
confined space e.g., if a flammable atmosphere, all electrical equipment/appliances must be
explosive proof or intrinsically safe, tools will need to be non-metallic and all other sources of
ignition prohibited. Smoking is prohibited in all confined spaces
5.5.8 Consideration must also be given to noise that may be generated from the work inside the
confined space and any work taking place on external surfaces of the confined space or
adjoining plant/apparatus. Noise in a confined space tends to reverberate and intensify.
Therefore noise that sounds to be at an acceptable level outside could be unacceptable inside.
When considering what action to take with respect to protecting persons inside a confined
space from a noise source, it must be appreciated that ear protection may make it difficult for
them to communicate with persons on standby duty on the outside.
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5.6 Confined Space Entry

5.6.1 Only Competent Persons will enter confined spaces. An Entry Log (or equivalent) must be
used to identify the persons inside the confined space at any time
5.6.2 Entry into a confined space may only be carried out under a permit to work. Prior to a
PTW being issued the following information must be taken into account:
i. A suitable and sufficient risk assessment must have been undertaken. Any requirements for
improvement must be carried out before the risk assessment and method statement are
accepted.
ii. The confined space must be isolated from the system. The physical opening of pipes and
ducts, leaving an air gap between the supply of materials and the confined space is the
preferred method but it is recognized that this is not always practical. Blanks may be fitted or
suitable valve locked shut
iii. Tests must be carried out to determine if the confined space is oxygen deficient and/or
contains flammable substances, toxic agents, carbon monoxide and/or harmful physical agents.
Any sludge or deposits that might be disturbed by personnel in the confined space must be
stirred up before the tests are carried out.
In the event that sources of possible supply could not be opened to the atmosphere, then
continuous monitoring is necessary.
5.6.3 A suitably trained person (Watcher) must be on standby outside the confined space entry
point to ensure that in the event of an accident inside the confined space, this person can raise
the alarm. Communication with the persons working in the confined space must be established
and monitored by the person on watch duty
5.6.4 The Watcher must:

i. Be able to account for everyone in the confined space at any time
ii. Not enter the confined space
iii. Not be involved at any other work activity whilst on watch
5.6.5 Where appropriate, persons entering a confined space must wear approved fall
protection equipment. A lifeline must be securely attached to the outside of the confined
space. When considering the use of lifelines, the complexity of the confined space needs to be
taken into account to ensure that the lifeline will be of assistance in an emergency and not
present a hazard. If entanglement is an issue the line should still be lowered into the space
complete with securing hook – ready for use
5.6.6 The watcher or rescue personnel with breathing apparatus must be available at all times.
5.6.7 If a hazard that was not taken into account in the original risk assessment emerges or if
conditions within the confined space change, the person in charge of the work in the confined
space must withdraw all personnel and report the matter to the BL Site Representative.
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5.7 Closing a Confined Space

Prior to closing a confined space the person in charge of the work must ensure that all
personnel, tools and equipment are removed from the confined space. All members of the
confined space working party must be accounted for and a physical inspection carried out.
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Module Seventeen
ELECRTRICAL SAFETY
1.0 Purpose
The purpose of this standard is to define a set of mandatory requirements to ensure safety of
personnel who work on or work with electrical equipment.
2.0 Scope
This standard applies to all employees
Strict adherence to the requirements of this Standard is mandatory.
3.0 Definitions
a. A competent person: is a person who possesses sufficient technical knowledge, experience
and skills, through qualification or training i.e. he is an electrical engineer (Degree or diploma
holder) with valid supervisory competency certificate issued by the State under the said
Country’s Electricity Rules (CER). The competent person must be experienced in working on a
specific electrical system or equipment and must be approved by the unit head to supervise the
electrical jobs.
He may be a company employee or a supervisor of a licensed electrical contractor possessing
the supervisory competency certificate. In the event of any State specifically not issuing such a
certificate, a similar certification from alternate
States may be obtained, as certification is considered necessary.
b. “Voltage” means the difference of electric potential measured in volts, between any two
conductors or between any part of either conductor and the earth as measured by a suitable
voltmeter and is said to be:
i. “Extra Low”: A potential normally not exceeding 50 volts A.C., or 120 volts D.C. between
conductors or between a conductor and earth.
ii. “Low” where the voltage does not exceed 250 volts under normal conditions subject,
however, to the percentage variation allowed under CER.
iii. “Medium” where the voltage does not exceed 650 volts under normal conditions subject,
however, to the percentage variation allowed under CER
iv. “High” where the voltage does not exceed 33,000 volts under normal conditions subject,
however, to the percentage variation allowed CER.
v. “Extra High” where the voltage exceeds 33,000 volts under normal conditions subject,
however, to the percentage variation allowed under CER.
4.0 Regulatory compliance

Unit shall receive, maintain and review, whenever due for renewal, all statutory approvals like
approval for connected load, electrical installation drawings and installation, NOC from State
Electricity Board (eg Nigeria Electricity Regulatory Commission) and electrical inspector for DG
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Sets as and when any change is made. Regular annual electrical inspection report by electrical
inspectors if carried out must be available with the unit. All electrical equipment and appliances
shall conform to applicable BIS standards / CER.
5.0 Electrical equipment - inventorization, checking and testing

The unit shall establish and maintain a department wise combined inventory and testing
schedule for all fixed electrical installations and portable electrical equipment / tools. All
requirements stipulated in the testing schedule shall be rigorously followed.
A formal visual inspection prior to undertaking a job shall be carried out by all personnel
working in electrical systems / equipment.
Units shall maintain an up to date single line diagram for all electrical distribution systems.
Electronic Equipment/Instrumentation items are also required to be handled by qualified and
trained personnel. These persons should be trained on safety aspects.
6.0 Training and competence

The electrical technicians shall be trained to carry out formal visual inspection of each type of
electrical equipment by the competent person(s). All personnel working on / with electrical
equipment shall be retrained once every year or whenever there is a major change introduced
in the electrical systems / equipment at the unit, whichever is earlier. The unit will document
these training interventions by way of a comprehensive and specific record.
7.0 EARTHING
7.1 Protection by providing earth conductors for all electrical apparatus and appliances is the
PRIMARY requirement. This shall be provided for all existing and new installations as stipulated
below:
i. All three-phase, medium and high voltage (>250 volts) equipment, all low voltage
(<250 volts) movable equipment, portable electrical tools & appliances (except portable hand
lamps of 50 volts and below) including their frames and metallic parts, and all plug sockets (low
and medium voltage) shall be earthed by two separate and distinct connections with earth
(double earthing).
ii. All two-phase (also referred to as “single phase”), low voltage (<250 volts) equipment and
their frames, including equipment considered generally inaccessible, shall be earthed by using a
minimum of one connection with earth through a conductor.
iii. All plug sockets shall be three-pin type, and the third pin shall be permanently and efficiently
earthed. All sockets which are not three-pin type must be phased out, and in the interim, shall
be provided with a separate conductor connected to earth.
iv. The effectiveness of earthing through exposed and extraneous conductive parts for all
electrical systems must be verified by measuring their resistance to earth.
Resistance of individual earth pit system must be measured and ensured to be < 2 ohms at all
times, and records maintained. Resistance of earth grid system shall be maintained at or below
1 ohm.
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v. All earthing conductors shall be checked for connection up to the earth grid once in twelve
months and findings recorded.
vi. The earthing shall be carried out using properly sized conductors and shall be visible for
inspection.
vii. All earthing pits should have free access for maintenance.
viii. Buildings and structures shall be protected against lightning as per IS 2309 –1989.
ix. During lightning, everyone working in open areas must be advised to come under shades
which are protected by lightning arrestors.
7.2 Secondary Protection through Residual Current Circuit Breakers (RCCBs) & Earth
Leakage Circuit Breakers (ELCBs):
RCCBs / ELCBs of adequate current rating shall be provided for:
i. All socket outlets in plants and office buildings including 3 phase socket outlets
(e.g., welding socket outlet)
ii. Movable/portable, electrical/electro-mechanical equipment e.g. welding machines, movable
plant & equipment etc.
iii. Air circulators and temporary construction power and lighting power distribution board.
7.3 Testing the RCCB: RCCB should be tested once in six month
Failed RCCBs shall be replaced promptly. In the event the RCCB cannot be replaced
immediately, the said connection should be isolated immediately & made inoperative.
Similarly, in the event of the RCCB’s failing at the time of periodic audits, root cause would need
to be ascertained as the period between failure & detection of failure of
RCCB is a risky proposition & should clearly deal with any emergent environmental reasons for
premature failures.
8.0 Working on or in the vicinity of live conductors

The risk associated with working on live conductors is extremely high. As a rule, no work shall
be done on live conductors.
Only in extremely rare and unavoidable circumstances may 'live-working' be justified, these
being limited to situations where the risk resulting from electrical isolation is greater than the
risk from working on the live conductor (e.g. where the isolation would result in the shutdown
of a critical safety system(s). Such situations should be covered by PTW to be authorized by the
Maintenance Head only. For trouble shooting on individual circuits, it may be necessary from
time to time to work on control circuits which are “live”.
PCC/MCC panels/equipment panels where control circuit is 240V to identify such locations &
draw up a comprehensive program for phasing out such circuits in favour of 110V control
circuits wherein the winding of the transformer is center tapped and earthed. Such control
supplies shall be protected by an ELCB of 30 mA sensitivity.
The decision to work on or near any live conductor must not be made on the basis of business
exigency or on economic grounds.
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9.0 Modifications to Electrical Systems or Equipment:

I. In general, electrical systems or equipment shall not be tampered with (including PCCs / MCCs
/ transformers etc.) and no unauthorized connections shall be permitted.
II. No modifications shall be carried out on fixed electrical installations or portable electrical
tools without a “modification note” prepared and authorized both by a competent person and
the maintenance head.
III. Modification note, when used, shall clearly identify the potential risks arising from the
proposed modification and the actions to be implemented to mitigate all identified risks.
Proposed modifications for equipment or a group of equipment.
V. Before energization of any new panel or after undertaking any major modifications to the
electrical switchgear, it is being mandated that pre-commissioning checks be completed &
formal records maintained.
VI. It is recommended that for any major panel modification at site, the jobs should be done by
the original manufacturer. Where it is logistically not possible for the panel to be modified by
the original manufacturer, it should be carried out by approved agencies. In all such cases, the
following procedure will apply:
VII. Specific drawing approval by competent person (with specialist consultation, wherever
necessary) before undertaking the modification
VIII. Carry out formal inspection of the modified panel at the works of the agency undertaking
the modifications, prior to dispatch of the panel to site.
IX. A relay coordination study would need to be carried & records maintained by all units
X. All electrical near misses / flashovers / burns to be reported.
10.0 Safe Systems of Work

I. A permits to work system, work method statement and a formal authorization to
start/undertake/finish work (e.g. Permit/License to Work) must be obtained from a
“Competent Person” before any work is undertaken on the following types of electrical
equipment:
a. Live Conductors excluding testing on equipment panel control circuit
b. Main incomer switches and/or switchboards
c. Equipment having two or more sources of supply
d. Cables and other equipment on the supply side of a main incomer switch
e. Generating sets started by manual initiation from a remote location, or automatically on
receipt of a remote signal
f. High-capacity rated uninterruptible power supply system
II. Description of work in PTW should be specific & clear.
It is proposed to introduce PPE by way of protective suits for any work in panel / MCC rooms.
III. Electrician and Electrical Officers shall use insulated hand gloves and insulated safety shoes.
IV. Use safety harness for working at a height of 6 Feet or above.
V. Insulated mats shall be placed in front and rear of main switchboard or any other control
switchboard of medium voltage and above.
VI. Standard first aid boxes containing materials as prescribed by St. John
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Ambulance or Indian Red Cross should be provided in easily accessible locations and shall be
periodically inspected to ensure that they are `fit and ready for use’ at all times of need.
VII. All temporary cables should be removed as soon as the work is over.
VIII. All cables for project construction power should be laid only overhead with robust supports
and not on the ground.
IX. Rotary moving parts of all electrical equipment shall have guards to adequately cover all nip
points.
X. Use multimeters (or series test lamps with fuse and two different coloured wires) with short
metallic lead for checking voltage and inspect the wires before every use.
XI. All measuring / test equipment like multimeters, tong testers etc. should be checked
periodically and log maintained. All worn out parts like test leads and clamps should be
replaced by genuine spares only.
XII. Ladders, when used, shall be insulated from earth.
XIII. “Danger Boards” should be permanently displayed on feeders where work is in progress.
XIV. Fuse pullers should be used while pulling out or replacing fuses, as it is very dangerous to
use pliers for this purpose. Fuse pullers should be of the switchgear manufacturer’s make e.g.
Siemens etc. and are easily available.
12.0 Systems for Equipment Isolation

The unit shall define the method of electrical isolation for access to every potentially dangerous
moving machinery and / or equipment for the purpose of its operation, servicing and/or
maintenance. This shall include either one of the following two alternatives namely a) removal
of fuses or b) ‘lock out and tag out’ system, for secure & effective energy isolation / de-
energisation of the system (electrical pneumatic/ hydraulic) until such work has been
completed and the normal safeguards e.g. guarding, can be fully restored. Test energisation
shall be carried out only by the competent person after ensuring that there is no danger to him
or other personnel in the vicinity of the equipment.
13.0 Electrical Maintenance:

Unit shall prepare and follow electrical maintenance schedule and carry out maintenance as per
site specific maintenance checklist.
Transformer oil break down value shall be checked once in a year.
Protective relays shall be checked and calibrated once in a year.
14.0 Access to Electrical Substations, Transformers, Switch Rooms and Similar Areas
I. Access to electrical substations, transformers, switch rooms and similar areas containing high
and low voltage equipment (e.g. main intake and distribution switchgear, motor control centers
and similar) must be restricted to a limited number of designated competent persons.
II. Access to such areas must be physically secured to prevent unauthorized access e.g.
doors/gates padlocked, and suitable prominent warning signs and information displayed.
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III. The key components of an electrical system (e.g. busbar systems, switchgear and control
gear, transformers, distribution boards and conductors) must all be clearly, legibly and durably
marked with information plates and site equipment reference labels.
IV. The operational state of electrical switchgear and control gear must be clearly shown by
indicators, except when the main contacts can clearly be viewed.
15.0 Records
Earth Pit test records.
ELCB test records.
Transformer oil test records.
PTW.
LOTO register.
Relay test records
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Module Eighteen
SAFE LIFTING OPERATIONS
1.0 Purpose
This procedure is prepared to ensure effective management on Lifting Operation and Lifting
Accessories to minimize risk due to the material handling operation.
2.0 Scope
The procedure is applicable to a company’s Facilities to fulfill the general and also the legislative
requirement.
3.1 Unit Head
i. Ensures that the procedure is followed during Lifting Operation
3.2 HSE Representative

i. Ensures that only trained personnel are engaged.
ii. Conducts awareness programme for the personnel engaged on such jobs
iii. Monitor and audit implementation of this procedure
3.3 Operational Managers / Maintenance Managers

i. Responsible for proper deployment of trained personnel.
ii. Ensure proper lifting accessories are present.
3.4 Competent Person

i. Responsible for periodic checking of lifting tools and accessories as per legal requirement.
3.5 Employees
Employees’ engaged in lifting operations must:
i. Never put any part of their body under a suspended load
ii. Never ride a load while it is being lifted
iii. Be aware of suspended loads, signals of the operators and any lifting equipment supports
iv. Use lifting equipment as instructed and report any defects
4.0 Description
4.1 Definitions
Appointed Person: A person with the training, practical and theoretical knowledge and
experience required for the planning, organization and control of lifting operations
Slinger and Signaler: Person who fastens the slings with the job and directs the operation of a
crane from the point near where loads are attached and detached
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Competent Person: Person trained, experienced and authorized to carry out a particular
function
Lifting Accessories: Equipment used to attach loads to machinery for lifting. Includes single
items (such as a shackle) or an assembly of items (such as lifting beam and slings), which may
be used to secure the load to the piece of lifting equipment. Other examples include: slings,
swivel or eye bolts, hooks, clamps
Lifting Equipment: Equipment for lifting and lowering loads e.g. cranes, passenger and goods
lifts, forklifts, scissor lifts, reach stakers. Also, includes attachments used to anchor, fix or
support the equipment (e.g. the runway of an overhead crane)
Rigging: Installation of the slings (or other lifting accessories) and fixing the load to the crane
SWL Safe Working Load: Sometimes referred to as “Rated Load”
Planning: Major rigging operations must be planned and supervised by competent personnel to
ensure that the best methods and most suitable equipment and tackle are employed.
Supply and Care of Rigging: Management must ensure that:
i. Proper rigging equipment is available
ii. Correct load ratings are available for the material and equipment used for rigging
iii. Rigging material and equipment are maintained in proper working condition
Rigging Operation: The Supervisor of the rigging operation is responsible for:
i. Proper rigging of the load
ii. Supervision of the rigging crew
iii. Ensuring correct assembly of rigging material or equipment as required during the operation,
such as the correct installation of lifting bolts
iv. Safety of the rigging crew and other personnel as they are affected by the rigging operation
4.2 Process
4.2.1 Control of Lifting Equipment
Golden Rules LIFTING OPERATIONS
Lifts utilizing cranes, hoists, or other mechanical lifting devices will not commence unless:
i. an assessment of the lift has been completed and the lift method and equipment has been
determined by a competent person;
ii. Operators of powered, lifting devices are trained and certified for that equipment;
iii. Rigging of the load is carried out by a competent person;
iv. Lifting devices and equipment has been certified for use within the last six (6)
v. months (at a minimum);
vi. Load does not exceed dynamic and/or static capacities of the lifting equipment;
vii. Any safety devices installed on lifting equipment are operational;
viii. All lifting devices and equipment have been visually examined before each lift by
ix. A competent person.
x. Ensure no one standing or working below suspended load.
4.2.2 Identification and SWL
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All lifting equipment must be clearly marked with a unique identifier and the safe working load
(SWL), where this is not possible, a coding system should be used which allows the user to
determine the SWL e.g. colour coding or attaching some form of label.
Where the safe working load depends upon the equipment’s configuration, this must be clearly
identified for each configuration. Alternatively this information must be retained with the
equipment.
Lifting beams must be clearly marked with their weight and SWL and must only be used for the
purpose for which they were designed.
The maximum SWL of most lifting equipment is determined from static loads and a safety
factor applied to account for dynamic motions of the load and equipment. In order to ensure
that the SWL is not exceeded during operation, allowances must be made for wind loading and
dynamic forces set up by the normal operational movements of the machine and load.
4.2.3 Register of Lifting Equipment

Each Site must keep a register of all items of lifting equipment, containing the following:
i. Identification details
ii. Date when equipment was purchased
iii. Copy of the Test Certificate (only equipment with current test certificates may be used)
iv. Date when equipment was first taken into use
v. Date of each examination, who carried it out and the certificate number
vi. Date of re-test
vii. Particulars of each defect found and the steps taken to remedy such defects
viii. Dates of any heat treatment or normalizing of chains or slings
4.2.4 Custom-made Lifting Devices

Any custom-made lifting device must be:
i. Designed by a qualified person
ii. Designed with a safety factor of 5
iii. Proof tested to 125% of rated capacity
iv. Marked with the rated capacity
v. Certified by a competent body
vi. Inspected every 6 months
4.2.5 Defective and Lost Lifting Equipment

Items of lifting equipment identified as not complying with legislative requirements, or by users
having doubts on its safety, must be quarantined and clearly labeled as defective to prevent
accidental usage
These items must then be either:
a. Repaired and, once repaired, re-certified by a Competent Person before being placed back
into service, or
b. Items that are lost are to be recorded as such in the lifting equipment register
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4.2.6 Handling and Storage

i. Wire ropes must never be allowed to lie on the ground for any length of time or on damp or
wet surface, rusty steel or near corrosive substances. They must be stored in a clean dry place;
wire rope slings must be cleaned after use, inspected and hung on pegs to prevent corrosion
and kinking
ii. Lifting accessories must be stored in conditions that do not lead to damage or deterioration.
iii. Slings must be hung up to prevent damage
iv. Chain blocks, turn buckles, chains and similar tackle should be hung up and lightly oiled
v. All rope must be kept away from flame cutting and electric welding operations
vi. Avoid contact between any sling and solvents and chemicals.
vii. Suitable precautions should be taken to prevent any sharp edges of loads coming into
contact with slings
4.2.7 Thorough Examinations and Inspections

Any new equipment that has not been used before are accompanied by a test
certificate/declaration of conformity, which confirms that the equipment has undergone a
thorough examination (not more than 12 months previously) and specifying the SWL, prior to
first use.
i. A thorough examination is to be performed following the repair or replacement of a
structural component
ii. All other lifting Equipment must undergo a thorough examination at least every 12 months
iii. For passenger lift in Administrative Building, it is ensured that the passenger lift is safe to use
and that it receives periodic thorough examinations and inspections, in accordance with local
regulations.
iv. Lifting accessories / attachments must be visually inspected on each occasion before use.
4.2.8 Planning and Control of Lifting Operations
I. Categorization of Lifting Operations

Lifting operations are categorized as under:
A. Routine – repetitive lifting operations, examples of lifting equipment generally provided for
routine lifting operations include:
i. Regular shop floor material movement
ii. Fork-lift trucks in a warehouse
iii. Construction site hoist
iv. Mobile elevated work platform (MEWP) used for general maintenance
v. A vehicle tail lift
B. Non-Routine – lifting operations which meet on or more of the following criteria:
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i. Operation involving more than one item of lifting equipment

ii. The load being lifted exceeds 5000kg
iii. Load either exceeds 50% of the crane safe working load SWL or is =>75% rigging SWL
iv. A critical component is being lifted
v. Operation with load tilting
vi. Lifting people or where there is a potential hazard for people
vii. Lifting near to existing buildings or hazardous installations (flammable liquids storages, high-
voltage line etc.)
viii. Non-routine operation carried out with mobile lifting equipment
ix. Operation carried out with temporary lifting equipment
x. Use of equipment not specifically designed for lifting (backhoe excavator)
xi. Lift of load without any defined hooking points
xii. Operation were operator cannot see the load
xiii. Operation needing assistants to guide the load during the load setting
II. Risk Assessment and Lifting Plans
A. Risk Assessments
i. A risk assessment must be prepared for all lifting operations.
ii. For routine lifting operations an initial risk assessment and lifting plan is required but need
not be repeated i.e. generic risk assessments and lifting plans may be used. However, they must
be subject to regular documented reviews (at least annually) to ensure that they are still valid.
iii. For all non-routine lifting operations a task specific risk assessment and lifting plan / method
statement must be prepared for every operation
B. Lifting Plans
Every lifting operation is planned and controlled by the concerned supervisor who ensures that
safe procedures are undertaken. Factors to be considered when planning lifting operation
include the following:
a. Identification of lifting operations to be performed and load characteristics −

Determine the load characteristics e.g. weight, centre of gravity, stability, and physical size.
Making ample allowances for unknown factors, and determine the available capacity of the
equipment being used. In cases where the assessment of load weight is difficult, safe load
indicators of weighing devices must be fitted. It is equally important to rig the load so that it is
stable. Unless the centre of gravity of the load is below the hook, the load will shift.
i. While planning for lifting a load the path of the lift must be considered
ii. Lifting equipment must be positioned to ensure that it is installed to reduce as low as is
reasonably practicable the risk of the equipment or load striking a person or from the load
drifting or falling freely, or being released unintentionally, and that it is otherwise safe
iii. Determine the means of communication e.g. line of sight signaler to crane driver or whistles.
Unless voice communication equipment (telephone, radio or equivalent) is utilized, signals
must be discernible or audible at all times. No response must be made unless signals are clearly
understood
iv. Ensure that the signaler is readily identifiable by and visible to the crane operator
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b. Identification and positioning of equipment to be used

i. Determine lifting equipment position i.e. where it is to be sited to make the lift
ii. Determine suitability of ground to ensure equipment stability i.e. is the ground sufficiently
competent to support the predicted ground loading imposed by the lifting equipment and the
load
iii. Determine access and egress route and any restrictions i.e. the route to the site if necessary
as well as the route from the site entrance gate to the identified lifting equipment operating
position
4.2.9 General Safety
I. Personnel Safety
The safety of personnel involved in lifting operations largely depends upon care and common
sense. The following practices must be followed:
A. Never
i. Exceed the SWL of the equipment being used
ii. Allow any person to be part of the load by riding on equipment being lifted
iii. Allow a load to be carried over the heads of any personnel
iv. Work under a suspended load unless the load has been adequately supported from the floor
and the supervisor in charge of the operation has approved all conditions
v. Leave a load suspended in the air when the hoist or crane is unattended
vi. Put any part of the body under a suspended load
B. Always
i. Examine all hardware, equipment, tackle and slings before using it and destroy defective
components
ii. Determine the load weight before rigging it
iii. Make sure that all personnel stand clear while loads are being lifted and lowered or while
the slings are being drawn from beneath the load. The hooks may catch under the load and
suddenly fly free
iv. Be aware of suspended loads, signals of the operators and any lifting equipment supports
II. Lifting Equipment Operators

i. Operators must not engage in any practice, which shall divert their attention during lifting
operations
ii. Operators must respond to signals from the signaler. When a signaler or a crane follower is
not required as part of the crane operation, the operator is then responsible for the lifts.
However, the operator shall obey a stop signal at all times, no matter who gives it.
iii. The operator must be familiar with the equipment and its proper care. If adjustments or
repairs are necessary, the operator must promptly report this to the Appointed Person, and
must also notify the next operator.
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iv. The operator prior to a new lift must test all controls. If any controls fail to operate properly,
they will be adjusted or repaired before operations are begun.
v. Where applicable, the manufacturer's balancing bar and lifting procedures must be followed.
Any deviation from the manufacturer's procedure must be promptly reported to the Appointed
Person
4.2.10 Hire of Lifting Equipment and Services

All mobile cranes and lifting equipment brought onto Site must have valid test certificates to
demonstrate they have been inspected before being allowed to operate on site.
If lifting equipment of services are to be hired / purchased, responsibilities for supply of
equipment, personnel and documentation must be agreed in the contract.
5.0 Records
1. Records of testing of Lifting Tools and Accessories
2. Training Records.
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Module Nineteen
EXCAVATION WORK
1.0 Purpose & Scope

To ensure that excavation work is controlled and managed safely.
2.0 Definitions
Competent Person- A person trained, experienced and duly authorized to carry out a particular
function.
Excavation- digging out in the earth including trenches, bore holes and cofferdams
3.0 Responsibility
3.1 Site Manager/Manager
Ensure that arrangements are in place necessary to ensure:
i. Pre-Planning of excavation works
ii. Obtaining records before the excavation work begins
3.2 Supervisors/Engineer
Before work commences, Supervisors must ensure that:
i. Any necessary surveys have been performed
ii. Risks assessments have been prepared
iii. Authorization from a Competent Person is obtained
iv. A Permit to Work has been obtained
4.0 Process/Description
4.1 Preparations for Excavation Work
Prior to commencement of any excavation works the following must be done:
I. Survey
A survey must be undertaken to find out if there are any underground services in the area. The
survey will include checking existing drawings, if doubt remains, hand digging pilot holes.
II. Risk Assessment

A risk assessment must be conducted. The assessment must take into account the likelihood of
underground services (electrical cables, gas/water pipes etc.), hazardous substances, depth of
the excavation, the possibility of water ingress, existence or previous excavations/foundations
etc.
III. Permit to Work (Excavation)

a. For excavation involving the following risks, a Permit to Work is required:
i. Excavations within 5 meters of underground services
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ii. Excavations deeper than 3 meters

iii. Excavations that may be deficient in oxygen or containing hazardous substances
iv. Other excavations of high risk, as determined by the Site HSE Representative and defined by
the specific risk assessment
b. Permits to Work must included the following, as a minimum:
i. Excavation location,
ii. Nature and the time of works
iii. The people involved
iv. The risk assessment
v. Required inspections (before, during or at the end of works)
vi. Emergency contacts
IV. Authorization
A Competent Person must review all risk assessments, method statements and associate
documentation, prepared for entry either by a company or their contractors, ensuring that all
the requirements of this document and any local requirements have been met, prior to
authorizing commencement of work in excavations.
4.2 Work in and Around Excavations

4.2.1 Collapse Prevention
The sides of all excavations must be prevented from collapse by one of the methods listed
below:
i. Battering - sloping the sides to an angle not steeper than 1.5 to 1, i.e., for every
300mm of depth, the excavation must be tapered back 450mm.
ii. Benching – excavating one or a series of horizontal levels or steps (depending on the depth of
the excavation) in the sides and ends of the excavation
iii. Shoring - supporting the sides and ends of the excavation using propriety trench supports,
shuttering or piling.
iv. A Competent Engineer must prepare designs for all excavations deeper than 3 meters. The
company undertaking the excavation must produce stability calculations indicating the safety
factors to be taken i.e. slope angles, shoring etc. for review and acceptance by a Competent
Person, before the work can commence.
4.2.2 Access and Egress (in and around the excavation)

a. All excavations must be provided with safe access and egress located within 7 meters of all
workers. Access and egress may be provided in the form of ladders, ramps or steps etc.
Note: Ladders must be secured and must extend at least 1 meter above the top of the
excavation.
b. Bridges / crossing points must be erected over excavations where persons need to cross and
must have guardrails strong enough to withstand approximately 100 kg horizontally.
4.2.3 Barriers
All excavations more than 1.2 meters deep must have rigid barriers and toe-boards around the
outside to prevent persons and material from falling into the excavation.
Barriers must be strong enough to withstanding approximately 100 kg horizontally.
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Excavations less than 1.2 meters in depth need not have a rigid barrier as long as they are
highlighted with warning tape at a distance of at least 1.5 meters from all edges of the
excavation.
4.2.4 Protection from Water Accumulation Hazards

Among the additional hazards stemming from water in an excavation are undermining the sides
and making it more difficult to get out of the excavation. Employees are prohibited from
working without adequate protection in excavations where water has accumulated or is
accumulating. If water removal equipment is used to control or prevent water accumulation, a
competent person shall monitor the equipment and its operation to ensure proper use.
Diversion ditches, dikes, or other suitable means shall also be used to prevent surface water
from entering an excavation and to provide adequate drainage of the adjacent area. A
competent person shall inspect excavations subject to runoffs from heavy rains.
4.2.5 Inspections
I. Work must not be carried out in an excavation where any supports or battering and / or the
excavation are more than 1.2 meters deep unless:
The excavation and any work equipment and materials which affect its safety, have been
inspected by a Competent Person:
a. At the start of the shift in which the work is to be carried out
b. After any event likely to have affected the strength or stability of the excavation, and
c. After any material unintentionally falls or is dislodged; and
II. Inspection reports must contain the following:
i. Organization and person on whose behalf the inspection was carried out
ii. Location of the place of work inspected.
iii. Description of the place of work or part of that place inspected (including any work
equipment and materials)
iv. Date and time of the inspection
v. Details of any matter identified that could give rise to a risk to the health or safety of any
person
vi. Details of any corrective action taken and any further action considered necessary.
vii. Name and position of the person making the report
4.2.6 General Precautions around Excavations

I. As a minimum requirement, material including spoil and backfill must not be stored within 1
meter of the edge of excavations. The actual distance necessary related to the particular
excavation and must be calculated at site considering the depth of the excavation and the
weight of the material.
II. Vehicles and construction plant must not be allowed to come within 2 meters of an
excavation unless working in connection with the excavation.
III. Vehicle / plant working in connection with the excavation must have a person controlling the
vehicles tipping material and their movement to prevent them from going so close to the edge
that it shall cause damage to the excavation.
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IV. Persons are not allowed to work or stand under loads being loaded or unloaded.
V. All persons in excavations must wear safety helmets, safety boots and any other personal
protective equipment as defined by the risk assessment.
VI. Persons entering bore holes or similar restricted excavations must do so in a safety cage, the
end of which must be attached to a winch or similar hoisting appliance at the top of the
borehole with a Watcher on emergency standby
4.3 Training
All persons required to work in an excavation deeper than 1.2 meters must be given
appropriate training by certifying organizations such as the Environment and Safety
Management Institute. The level of training will depend on the complexity of the excavation
but basic training must take account of the following:
i. Induction training for new persons
ii. Details of the risk assessment
iii. The dangers of working in excavations
iv. The safety arrangements
v. Daily inspections
vi. Who to contact in the event of emergency
vii. Fire protection
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Module Twenty
PERSONAL PROTECTIVE EQUIPMENT (PPE)

1.0 Purpose
To ensure that personal protective equipment is controlled, issued and maintained in good
condition to provide protection to personnel
2.0 Scope
This procedure is applicable to all the company’s sites for use and control of PPE.
3.0 Responsibility
3.1 Site Manager
The Site Manager will ensure that:
i. By personal example, PPE is correctly used at all times and when necessary, instigate
disciplinary action for deliberate contravention or miss-use of such equipment
ii. When a risk assessment has indicated that PPE is required, suitable PPE is provided and is
always easily available to all employees that need to use it
iii. Adequate information and training is provided to, and understood by, all employees who
need to use, maintain or select PPE

The Site HSE Representative will:
i. Provide guidance on selection, use and maintenance of PPE
ii. Provide training in use of PPE
iii. Monitor implementation of this procedure and investigate any reasons why it is not
iv. Records are kept of all training, including details of the names of the participants, the date of
the training, and the subjects covered
3.3 Employees
Employees will:
i. Only use PPE in accordance with the instructions provided and for the activities during which
they are designed to provide protection
ii. Attend training sessions and comply with the training, instruction and information provided
iii. Check the condition of their PPE before each time that they use it
iv. Clean, maintain and store their PPE in accordance with training and instructions
v. Report any losses, defects or other problems with PPE to their Supervisor or another
responsible person immediately.
4.0 Description
4.1 Definitions
Contractors: Any third party employee executing works on the company’s premises or sites
under the company’s supervision
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Personnel: Any of the organization’s personnel of all levels of the hierarchy and any contractors
under direct control of the organization, and agents representing such organization.
PPE: Personal Protective Equipment. All equipment which is intended to be worn or held by a
person at work and which protects them against one or more risks to their health or safety’,
e.g. safety helmets, gloves, eye protection, high visibility clothing, safety footwear and safety
harnesses
Lanyard: A line for connecting a full body harness to an anchorage point with an inbuilt device
that reduces the impact of a fall when used in fall arrest applications
4.2 Process
Assessing PPE requirement
Risk assessment is carried out to find out the requirement of PPEs and an effort is being made
to prevent workers from coming in contact with the hazards by guarding suitably at source.
When it becomes impractical to eliminate the cause of accident by engineering revision,
dependence on PPE’s is being chosen as the last resort.
Selection of PPE is based on,
(a) Degree of protection which a particular PPE might afford,
(b) The ease with which it may be used.
Basic requirement - The Company ensures that:
i. PPE’s are capable of providing adequate protection
ii. Only standardized PPE’s are procured
iii. The equipment is light in weight and able to give the maximum comfort to the users
iv. They do not restrict essential movement of the user
v. They do not produce any ill effect to skin or parts of the body in contact
vi. List of people requiring use of PPE is defined.
Types of PPE to be used:
Protection for: Hazards Options

Body Temperature extremes, adverse weather, chemical or Conventional cotton fabric
metal splash, spray from pressure leaks or spray guns, clothing for all workmen.
impact or penetration, contaminated dust, excessive wear Cotton clothing with high
or entanglement of own clothing. visibility tape for material
handling and HSE personnel.
Falls from height, where protection against falls cannot be Double hook full body safety
provided by other means harnesses
Breathing Dust, vapour, gas, oxygen-deficient atmospheres. Disposable filtering face piece
or respirator, half- or full-face
respirators, air-fed helmets,
Eyes Chemical or metal splash, dust, projectiles, gas and vapour, Safety spectacles, goggles,
radiation. face shields, Welding shields
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Feet and Legs Wet, electrostatic build-up, slipping, cuts and punctures, Safety boots and shoes with
falling objects, metal and chemical splash, abrasion. protective toe caps and
penetration resistant. Leather
leg guard
Hands and Arms Abrasion, temperature extremes, cuts and punctures, Gloves, gauntlets, armlets.
impact, chemicals, electric shock,
skin infection, disease or contamination
Head Impact from falling or flying objects, A range of helmets. Colour of
helmets can be decided
appropriately by unit
management.
4.3 Inspections
4.3.1 General Inspection of PPE
PPE users are responsible for inspecting issued PPE before each use and reporting any damage
to their Supervisor, who must arrange to replace or repair replacement of PPE, as appropriate,
if it is not functioning as required.
4.3.2 Inspection of Safety Harnesses and Lanyards

I. Inspection Regime
The following minimum inspection regime will be adopted for safety harnesses and lanyards:
a. User Inspections - each time the equipment is used
b. 6-monthly Inspection - by Safety Representative
II. Identification
All items of fall arrest equipment are indelibly and permanently marked with a unique
identification number, so that they can be readily associated with the respective
documentation. If marking is not evident, or obscured by dirt, the item of equipment must be
withdrawn from service immediately and referred to the safety representative who is
responsible for the six-monthly inspection.
III. Examples of Defects and Damage
Items of fall arrest equipment which have been used to arrest a fall must never be re-used, they
must be withdrawn from service immediately quarantined and destroyed after investigation.
The following defects and damage have the potential to result in the degradation and/or
weakening of the lanyard:
i. Cuts of 1 mm or more at the edges of webbing lanyards (e.g. where the lanyard may have
been choke-hitched around steelwork)
ii. Surface abrasion across the face of the webbing and at the webbing loops, particularly if
localized
iii. Abrasion at the edges, particularly if localized
iv. Damage to stitching (e.g. cuts or abrasion)
v. A knot in the lanyard, other than those intended by the manufacturer
vi. Chemical attack which can result in local weakening and softening – often indicated by
flaking of the surface. There may also be a change to the colour of the fibers
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vii. Heat or friction damage indicated by fibers with a glazed appearance which may feel harder
than surrounding fibers
viii. UV-degradation which is difficult to identify, particularly visually, but there may be some
loss of colour (if dyed) and a powdery surface
ix. Partially deployed energy absorber (e.g. short pull-out of tear webbing)
x. Contamination (e.g. with dirt, grit, sand etc) which may result in internal or external abrasion
damaged or deformed fittings (e.g. karabiners, screw link connectors, scaffold hooks)
4.4 Training
4.4.1 Anyone using PPE must be provided with adequate information and training in the use
and care of their PPE.
They are communicated the following:
i. Why it is needed, when it is to be used, repaired or replaced and its limitations
ii. Trained and instructed in how to use it properly
iii. PPE is the last resort after other methods of protection have been considered and so it is
important that users wear it all the time they are exposed to the risk
4.4.2 Site induction training must include a section, which ensures that all persons are aware of
the requirement to use appropriate PPE and the penalties for failure to use
PPE when required.
4.4.3 Records of all training given in the use and maintenance of PPE must be maintained
5.0 Records
Register for issue and distribution of PPE
Inspection of PPEs compliance
Inspection of PPEs quality
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Module Twenty One
ENERGY ISOLATION (LOTO)

1.0 Purpose
Energy Isolation procedures are followed in order to ensure the safety of employees at the
workplace. These procedures mainly aim to prevent the mishaps taking place on account of
accidental activation of equipments during installation or checking or maintenance.
2.0 Scope
Scope of this Procedure is limited to Employees or contractors concerned with the operation &
maintenance at a company’s Facilities.
3.0 Responsibility
Functional Head – Plant and Facility is responsible for maintenance and implementation of this
procedure and HSE representative is responsible for compliance of this procedure.
4.0 Description
4.1.1 Lock Out & Tag out (LOTO) or lock and tag is a safety procedure which is used in industry
to ensure that dangerous machines are properly shut off and not started up again prior to the
completion of maintenance or servicing work. It requires that hazardous power sources be
"isolated and rendered inoperative" before any repair procedure is started. "Lock and Tag"
works in conjunction with a lock usually locking the device or the power source with the lock,
and placing tag affixed to the locked device indicating that it should not be turned on.
This comes down to
1. Remove from operation equipment, a machine, an installation (or a part of it)
2. Disconnect the equipment, the machine, the installation from its energy sources
(Electrical, pressure, heat, etc)
3. Immobilize (Lock out) the disconnected parts and hang appropriate Tag Different Tag for
Electrical and other source of Energy.
4. Discharge all residual energy from the equipment, the machine or the installation. This is
done by the grounding (release of all residual electrical charges), by blowing out pressurized
lines, by releasing potential mechanical energy (height, springs etc) as is applicable.
5. Check for the absence of residual energy.
4.1.2 Preparation for Lockout

Employees authorized to perform lockout shall be certain as to which switch, valve, or other
energy isolating devices apply to the equipment being locked out. More than one energy source
(electrical, mechanical, or others) may be involved. Before lockout commences, job
authorization should be obtained
4.1.3 Sequence of Lock Out & Tag out (LOTO) Procedure
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1. The Area is to be inspected before initiation of work.

2. Required permission to keep the machine out of operation from Operating Department.
3. Examination of any Dangerous Operation (Height work, Confined Space etc.) that would be
required for LOTO.
4. If the equipment is operating, shut it down by the normal stopping procedure
(Such as: depress stop button, open toggle switch).
5. Operate the switch, valve, or other energy isolating devices so that the energy
Source (electrical, mechanical, hydraulic, and other) is disconnected or isolated from the
equipment. Stored energy, such as that in capacitors, springs, elevated machine members,
rotating fly wheels, hydraulic systems, and air, gas, steam or water pressure, must also be
dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down.
6. Lockout energy isolating devices with an assigned individual lock.
7. After ensuring that no personnel are exposed and as a check on having disconnected the
energy sources, operate the push button or other normal operating controls to make certain
the equipment will not operate.
CAUTION: Return operating controls to neutral position after the test.

8. The equipment is now locked out. [Lock should be with one key under the custody of the
person responsible for issue of Permit]
9. Appropriate Tag, duly filled in as mentioned earlier is to be hung with name,
Permit Number & Key Number.
5.0 Restoring Equipment to Service

1. When the job is complete and equipment is ready for testing or normal service, check the
equipment area to see that on one is exposed.
2. The Applicant on ensuring as above will apply for restoring the energy
3. When equipment is clear and duly signed Permit copy is returned, remove all locks. The
energy isolating devices may be operated to restore energy to equipment.
6.0 Record
The Details of Permits are to be entered in a Registrar with signature of authorized person [for
electrical, permit will be issued by statutory qualified person] issuing Isolation Permit.
7.0 Training:
The Person authorized for carrying out LOTO must undergo requisite training to make him
enable to carry out the job.
Refresher Training for Authorized Person to be conducted at least once in every three years by
professionals such as those certified by ESMI. General Awareness Training to be extended to
the person performing work with LOTO. Record for the training to be maintained by the
concerned agency in addition to Human Resources Department.
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Specimen for Lock out – Tag out
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Module Twenty Two
PERMIT TO WORK SYSTEM
1.0 Introduction
Permit-to-work (PTW) form an essential part of safe systems of work for various types tasks
involving risk to people, property and environment and which are generally concerned with
maintenance work, engineering work, project activities, equipment cleaning operations and
other high risk non-routine tasks. This document defines the
PTW procedure to be followed on identified items of equipment in a specified area and defines
the ownership of the item of equipment at any time.
2.0 Purpose
This procedure has been designed to ensure that a safe system of work has been defined for
the task so that work may be accomplished in a legal, safe environmentally acceptable and
efficient way.
3.0 Scope
This standard applies to all Company sites. It applies to all maintenance, construction,
demolition as well as non-routine high risk process activities like vessels cleaning and any non-
routine activity in a high risk areas like fuel storage area; corrosive chemical storage area.
The procedure is applicable to all such tasks apart from the following exceptions:
a) Simple, low hazard, tasks carried out under the direct supervision of the person who has
operating control of the asset. Such activities are specifically exempted in writing by the Unit
Head after consultation with safety representative / concerned manager and carrying out a risk
analysis study.
b) Maintenance tasks carried out within maintenance workshops/contractor sheds.
c) Minor adjustments done of packing lines by the operators themselves.
d) Routine operations which have no specific hazards associated with them and have no effect
on plant operations, e.g.
- Instrument chart changing
- Routine sampling
- oiling and greasing activities
- Cleaning / housekeeping activities in offices and amenities.
However it is essential that the persons carrying out these tasks are adequately trained and
fully aware of hazards in their operating area. Untrained persons should never be put on such
tasks.
4.0 Definitions
Permit to Work (PTW): A form, which sets out, agreed work to be done on identified
equipment, or in an identified area, and the precautions to be taken. It is a clear record that all
foreseeable hazards have been considered in advance and it provides a formal hand over
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mechanism of equipment/system between the owning group and another group responsible
for executing this work.
The formats specifying the minimum requirements are attached to this Standard and shall be
used with immediate effect to replace and align with existing formats being used by the Units.
Issuing Department: The group which has ownership and/or operating control of the asset to
be worked on or area (plant block) to be worked in e.g. Production department for production
halls.
Issuer: A trained person who is the designated in-charge of the issuing department in the
concerned shift and has been authorized in writing to issue PTW e.g. in case of production area
it could be the process officer.
Permit Approval and Authorization: A permit is approved and authorized after ensuring that all
possible hazards have been identified, safety precautions have been taken and these have been
explained to the persons carrying out the job. In case the issuer is overall in charge for getting
the job done and will hand over the permit directly to the persons carrying out the job, then he
approves and also authorizes the permit.
However for most engineering jobs (mechanical, civil, electrical, instrument maintenance
activities) it may be possible that the issuer will not be direct in-charge for carrying out the job
i.e. the job is actually carried out by a separate maintenance department and under overall
supervision of maintenance manager/officer.
Acceptor: A person who is the representative of the group responsible for the execution of
agreed work and who has been trained to be competent to control the work to be carried out,
and authorized in writing. A signature of acceptor is required on the Permit only if ‘contract’
workmen are carrying out the job.
6.0 Procedure
6.1.1 Unit Head shall….
i. nominate managers (department or functional heads) who have authority to appoint persons
who may issue or accept PTW in their areas of responsibility
ii. Define the plant area boundaries within which their teams will issue PTW
iii. Issue a register of any specific tasks exempted from this procedure in their areas of
iv. Responsibility, after consultation with the Safety representative and concerned managers
v. carry out random checks on PTW issued
6.1.2 Nominated Managers (department / functional head) shall…

i. ensure that persons are appropriately trained as Issuers and Acceptors of PTW prior to
appointment, and maintain up to date lists of such appointed personnel
ii. Carry out random checks on PTW issued on a daily basis and ensure that the PTW system is
operated effectively.
6.1.3 The Safety Representative shall…

i. be responsible for imparting the training on PTW system and upkeep of the training packages.
The training packages must be based on this Standard.
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ii. Conduct internal system audits on PTW at least once two months and report findings to the
management team at site.
6.1.4 Issuer of PTW shall …

i. be responsible for determining the nature and extent of the job to be carried out, possible
hazards and the necessary precautionary measures to be taken prior to issuing the permit
ii. Ensure that necessary isolations are carried out
iii. Provide acceptor with necessary Method Statements / Risk Assessments (where applicable)
iv. Take assistance of maintenance manager/officer in carrying out above responsibilities in
case of an engineering job
v. ensure that necessary precautionary measures are taken prior to authorizing the permit.
For jobs directly under charge of the Issuer, the Issuer of PTW shall …
a) Select competent people for the job
b) Be responsible for explaining the safe Work Method to the persons carrying out the job
provide them with proper tools / PPE
c) Be overall responsible for the job.
6.1.5 Competent person for certifying isolation shall…

i. be responsible for checking and certifying isolations as relevant
ii. Be the electrician for electrical isolation
iii. Be the issuer or operator for process / services isolation.
6.1.6 Acceptor (& The Contractor Supervisor) of the PTW shall …

i. assist the issuer / maintenance officer in hazard identification and developing
Method Statement (if required)
ii. Provide the issuer / maintenance officer the names of all persons carrying out the job
iii. Be responsible for explaining fully to his subordinates the nature of the hazards involved in
carrying out the task and any precautions necessary to protect others who may be in the area
iv. Ensure that the nature and extent of the work does not differ from that described in the
permit
v. and that all persons under his control understand the precautions that they are required to
take
6.2 General Rules

I. Only persons who have been trained and authorized shall issue, authorize or accept PTW
II. Only work, which is specified on the PTW, shall be undertaken.
III. Where preparation for a job includes blanking of pipelines for physical isolation, separate
PTW shall be issued for the isolations, main task and reinstatement of pipe work or equipment.
IV. For jobs of long duration, as far as practicable, the PTW shall cover only a particular phase of
the task at a time, that can be fully specified and to be completed within the duration
mentioned in the Permit.
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V. If work requires isolation across plant boundaries, a separate isolation PTW shall be issued by
one plant as evidence that the task can proceed on the interconnected system in the other
plant.
VI. The hand over from Issuer / Engineering officer (or manager) to Acceptor must include a
visit to the job location.
VII. The period of validity for a PTW in defined areas within a site shall be the estimated time
for the completion of the job, but no more than 8 hours or the period during which the Issuer /
Eng Officer is present at site. Work beyond this period shall be re-authorized by the respective
Reliever(s) after re-assessment of the job location.
VIII. An Acceptor needing to continue with the job into the next shift/period must be asked to
contact the Issuing Plant in the next shift and ensure the validity is extended provided that no
change has taken place in the conditions stipulated in the permit.
IX. The permit issued on a particular day may be extended, if required, only for the shifts on
that particular day. For work extending beyond the day and to continue on the next day(s) a
fresh permit shall be issued.
X. Acceptance of Permit to Work
In accepting a PTW the Acceptor must
i) Understand the scope of work to be carried out, read the permit and understand the
isolations/preparations made
ii) Visit the Site with the issuer/engineering officer if necessary
iii) Sign the permit and retain the first COPY
iv) acceptor has the responsibility to ensure that all the other people doing the work are
familiar with the contents of the Permit to Work, that the specified precautions are observed
and that a new Permit to Work is obtained if the nature of the work changes.
v) Work Completed
The acceptor (i.e. the contractor supervisor or own employees on the job) must detail on the
Permit to Work and describe to the issuer the precise state of the equipment when the task is
finished, and confirm the area has been left clean and tidy. He will confirm this by signing the
permit.
vi) Energization and Permit Closure
The issuer shall then arrange for the de-isolation and restoration of energy as required which
will be recorded in the permit. Permit shall be closed (both original & the copy)
7.0 System Audit

7.1 The Site Safety representative shall conduct formal audit of PTW system covering all defined
areas at site, at least once in a month, to confirm its appropriateness and full compliance to all
provisions of this Standard.
7.2 The audit shall be carried out using a checklist developed based on this Standard
7.3 Formal audit reports shall be prepared and appropriate corrective actions identified
7.4 The Unit Head and Department Head shall personally carry out daily random checks of
Work permits
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8.0 Records
The following documentation / records shall be regularly updated and retained for the times
indicated.
Records Retention Time Location
Closed PTW - 3 month
System Audit Reports & Action Reports of last 2 years.
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Module Twenty Three
HOT WORKS
1.0 Purpose
To ensure adequate protection to people and plant during hot work operations
2.0 Scope
All business locations under the company’s control
3.0 Definitions
Hot Works Grinding, welding, flame cutting or other fire or spark-producing operation
4.1 Site Manager
The Site Manager must:
i. Ensure that this procedure is implemented and adequate controls are in place
ii. Ensure that cutters, welders and their Supervisors are suitably trained in the safe operation
of their equipment and the safe use of the process
iii. Advise all Contractors about flammable materials and/or hazardous conditions of which they
may not be aware

The Site HSE Representative will monitor implementation of this procedure
4.3 Supervisors
Supervisors are responsible for:
i. The safe handling of the cutting or welding equipment and the safe use of the hot work
processes
ii. Determining the combustible materials and hazardous areas present or likely to be present in
the work location
iii. Protecting combustibles from ignition by moving the work, moving or adequately protecting
the combustibles, or seeing that cutting and welding are so scheduled that operations which
might expose combustibles to ignition are not started during cutting or welding
iv. Gaining approval for the cutting or welding operations from the designated management
representative
v. Ensuring that the cutter or welder obtains proper verification that conditions are safe before
proceeding
vi. Ensuring that fire protection and extinguishing equipment are properly located
vii. Ensuring contractors are made aware of existing or potential flammables combustibles in
the areas in which they work
viii. Ensure that this procedure is implemented and adequate controls are carried out.
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5.0 Process
5.1 Key Principles
All sites must implement fire prevention and protection methods specific to hot work
operations as applicable such as:
a) Eliminating/minimizing fire hazards in the vicinity of the hot work process
b) Providing a fire watch when hazards cannot be adequately minimized
c) Completing and approving work permits and associated requirements prior to beginning the
cutting or welding process
d) Prohibiting hot work in designated, high-hazards areas
e) Cutting and welding equipment care and use
f) Training affected personnel
5.2 General Requirements

I. Hot work must only be performed in areas proven by risk assessment to have fire hazards
adequately controlled.
II. All combustibles must be relocated, where practicable, a minimum of 6m from the work site.
Where relocation is impractical, combustibles must be protected with flame proof covers,
guards or curtains.
III. Ducts and conveyor systems that could carry sparks to distant combustibles must be suitably
protected or shut down.
IV. Where hot work is done near combustible walls, partitions, ceilings or roofs, fire resistant
shields or guards must be provided to prevent ignition.
V. If hot work is to be done on non-combustible walls, partitions, ceilings or roofs, precautions
will be taken to prevent ignition of combustibles on the other side, due to conduction or
radiation, preferably by relocating combustibles. Where combustibles are not relocated, a fire
watch on the opposite side from the work must be provided.
VI. Hot work must not be attempted on a metal partition, wall, ceiling or roof having a
combustible covering nor on walls or partitions of combustible sandwich-type panel
construction.
VII. Cutting or welding on pipes or other metals in contact with combustible walls, partitions,
ceilings or roofs must not be undertaken if the work is close enough to cause ignition by
conduction.
VIII. Floors must be swept clean of combustible materials for a radius of a minimum of 6m.
Combustible floors must be kept wet, covered with damp sand, or protected by fire-resistant
shields. Where floors have been wet down, personnel operating arc welding or cutting
equipment will be protected from possible shock e.g. insulated blankets.
5.3 Welding
I. No welding, cutting, or other hot work must be performed on used drums, barrels, tanks or
other containers that were used for holding flammable/ combustible materials until they have
been cleaned. Cleaning must remove all flammable materials present, as well as any substances
such as grease, tar, acids, or other materials that might produce flammable or toxic vapours
when subjected to heat.
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Any pipelines or connections to the drum or vessel must be disconnected or blanked.

II. All hollow spaces, cavities or containers will be vented to permit the escape of air or gases
before preheating, cutting or welding. Purging with inert gas is recommended.
III. Welding cables and oxy-acetylene lines must be clear of passageways, stairways, and ladders
when practical.
IV. All hot work equipment must be inspected before each use.
V. Welding cables with nicks or small cuts in the insulation must be repaired. Cuts or breaks in
the insulation jacket that penetrate to the conductor must be removed from service and
repaired or replaced.
VI. Welding cables and splices within 3m of an electrode must not be used.
VII. Portable welding machines must be thoroughly inspected and documented annually.
VIII. Welding machine terminals must be effectively guarded by the use of a dead front plate or
guard that will prevent inadvertent contact with energized terminals.
IX. When arc welding is suspended and equipment is left unattended, the equipment must be
effectively shut down. Cutting torches will have the cylinder valves shut and lines bled of
pressure. Torches must be removed from confined spaces if left unattended for any length of
time such as over lunch or overnight.
X. Oxy-acetylene torches must be equipped with flashback arrestors
5.4 Handling and Use of Gas Cylinders

5.4.1 Care and Use of Oxygen Cylinders
i. Keep oxygen fittings and lines away from oil or grease products
ii. Oil or grease may ignite violently in the presence of oxygen under pressure
iii. Only use equipment rated and marked for oxygen use only
iv. Never connect an oxygen regulator to a cylinder containing combustible gas
v. Use flashback arrestor of oxygen cylinder
5.4.2 Care and Use of Acetylene Cylinders

i. When storing acetylene cylinders, remember it is a fuel gas
ii. If the valve outlet becomes iced over, thaw in warm, not hot water if needed
iii. Never use a leaking acetylene cylinder
iv. Do not open an acetylene cylinder valve more than 1 1/2 turns. In general, acetylene valves
only need be opened one quarter to one half turn
v. Never use acetylene from a cylinder except through an acetylene regulator
vi. Use acetylene only in an upright position.
vii. Never use acetylene at pressures greater than 1 bar.
viii. Use flashback arrestor of acetylene cylinder
5.5 Hot Work

Hot Work Permit
a. Before hot work may proceed, a work permit must be completed and signed.
b. A designated, qualified person must approve hot work operations identified on the permit.
This person will inspect the area prior to granting authorization for such operations so that
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potential hazards and necessary precautions can be identified on the permit. All such
precautions must be communicated, documented and implemented prior to work proceeding.
Module Twenty Four
DISCHARGE OF WATER
1.0 Purpose
To protect natural waters
2.0 Scope
All business locations under a company’s control, where there is a risk of ecological-harmful
materials entering controlled waters.
3.0 Definitions
Controlled Waters: All surface, estuarial, coastal and ground waters subject to regulatory
control
Discharge Consent: Discharge consents outline the terms and conditions under which industrial
effluent may be discharged into controlled waters.
Storm Water: Water that originates during precipitation events i.e. rain, melting snow etc
Unplanned Discharge: Any release to controlled water or a discharge exceeding the limits of a
consent condition or legal limit, either knowingly or accidentally.
Waste water: Any water that has been adversely affected in quality as a result of BL business
activities
Water Pollution: Causing or knowingly permitting polluting matter (substances or energy) to
enter controlled water or to cause harm to the “Water environment”.
4.1 Site Manager

The Site Manager must ensure that a detailed knowledge of the functioning of the site's storm
water and wastewater drainage systems is gained. This is to ensure that foul and surface waters
are discharged correctly to the right drainage system.

i. Monitor implementation of this procedure
ii. Co-ordination of emergency response in the event of a spillage
iii. Ensure that any environmental incidents are reported
5.0 Process
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5.1 Site Drainage

5.1.1 The locations of any Site water discharge points must be identified before any work is
undertaken. This will involve:
i. Mapping of the wastewater and storm water networks on site, including the sources of all
discharges and the discharge points
ii. Identification of discharge points for these networks
5.1.2 Drains must be identified as to whether they are storm (surface) water drains or foul
(wastewater) drains to aid identification of where a spill will leave the site.
5.2 Consented Discharges to Controlled Waters

5.2.1 For all water discharges to controlled waters, it must be ensured that:
i. No water is discharged without consent.
ii. Discharge is monitored and recorded, taking samples where necessary.
iii. All conditions of the consent are met / none of the conditions are breached.
iv. If conditions are breached, the breach must be reported firstly to the regulatory authority
and secondly, internally using the Accident / Incident reporting procedure
5.2.2 Storm water that is essentially "clean" water can be allowed to enter controlled
watercourses without the need for Consent.
5.3 Planning for Spill Emergencies

I. An emergency plan must exist for the control of spills. This plan will be simulated at least
annually to ensure its effectiveness.
II. An adequate number of personnel will be trained in spill containment. This could be all site
personnel but may be a dedicated emergency response team.
III. Spill kits must be inspected weekly to ensure completeness of the inventory and to ensure
that the location of the spill kit is appropriate to the site activities such as storage, offloading
and use of materials.
IV. Arrangements must also be in place to ensure that spill kits are replenished if items have
been used in the event of a spillage
V. Outfalls and interceptor pits will be inspected daily as part of the daily site as inspection
system.
5.4 Unplanned Discharges and Spillages

5.4.1 Identification of Substance
All unplanned discharges or spillages must be reported to the site HSE Representative, who will
evaluate the spillage or release and determine the required response.
5.4.2 Clean-up Protocol

I. Non-Harmful
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Where the spillage/release is not a harmful substance and has no potential for causing harm to
the environment, a general cleanup operation will be initiated with the source of the
spillage/release being identified and stopped.
II. Harmful
A. Where the spillage/release is a harmful substance and/or has the potential for causing harm
to the environment the following procedure is to be followed:
i. Clear the area of all non-essential personnel.
ii. Inform the company’s Site HSE Representative who will organize assistance and determine
whether the Regulatory Authorities should be informed and asked for assistance if needed.
iii. Obtain and distribute suitable protective clothing (if required) to those dealing with the
spillage (reference must be made to the appropriate Material Safety Data Sheet).
iv. Take appropriate action to localize the spillage if possible and locate the source of the
spillage/release and take appropriate action to stop or minimize the release.
v. Surround the spillage with absorbent booms or convenient, inert material to prevent access
to drains. Use an emergency portable pump to transfer the spillage to a sound storage
receptacle.
vi. Spillage/ releases, which can’t be pumped, should be dealt with by using absorbents.
vii. Where the spillage/release has entered a drain, the outfall of the drain must be identified
and containment of the spillage/ release continued in accordance with this procedure
viii. All spent absorbent materials are to be stored in a waste disposal area for recycling or
disposal in accordance with procedure
B. All spillage’s as identified above will be investigated and reported in line with procedure of
Accident and Incident Reporting.
6.0 Records:
Consent to operate Layout of waste water & storm water.
Records of discharged water parameters.
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Module Twenty Five
AIR EMISSIONS CONTROL
1.0 Purpose
To ensure that air emissions are controlled to legal requirements.
2.0 Scope
This document is the minimum requirement for all sites of a company.
3.0 Definitions
Air Emission: Any channeled air emission i.e. one that is discharged into the atmosphere
through a duct, stack, vent, or other conduit.
4.1 Unit Head
The Unit Head must ensure that arrangements are in place to enable compliance with the
requirements of this procedure.
5.0 Process
5.1 Process Emissions Monitoring
I. The basis for air monitoring may be set by Regulatory authorities in the form of
“Permits or Consents”
i. When planning emissions monitoring, consideration must be given to the following, where
applicable:
ii. The process or material to be monitored (dust, smells or hazardous compounds etc)
iii. The applicable consent, contract clause and/or legislation requirements.
iv. Emission point description and sampling points shared in the Map.
v. Frequency will be at least once a year.
*Note: It is recommended that a list of activities that may generate regulated atmospheric
emissions (dust particles, VOCs, etc.) is compiled and then each of the emission points (e.g.
chimney stacks, vent holes in tanks, ventilation points for air recycling in buildings) identified on
a site map
II. Only suitably trained or experienced personnel will carry out sampling and surveys.
III. Any equipment used for measuring / monitoring purposes must be calibrated to an
approved standard or tested prior to use, as appropriate
5.2 Monitoring Techniques

5.2.1 Dust Emission Sampling
Where no limit has been specified, levels of dust exceeding 200mg/m3 or those giving rise to a
complaint will be cause for evaluation of dust suppression methods.
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5.2.2 Odour and Process fume

Any odour noted which may cause community complaints, will be reported to the HSE
Representative for action. The likelihood of process fume must be assessed during task
preparation and minimized at source.
6.0 Records
Air emission test records
Map showing all locations of discharge.
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Module Twenty Six:
CONSERVATION OF SOIL AND GROUND WATER
1.0 Purpose
To ensure the protection of soil and groundwater from spills of fuels, chemicals and ecologically
toxic materials.
2.0 Scope
The procedure is applicable to a company’s sites to fulfill the general requirement of HSE
Management system and fulfill the legal requirement.
3.1 Unit Head:
Ensure that this procedure is implemented and adequate controls are in place.
3.2 HSE Manager
i. Ensure that adequate controls are maintained and that rapid response is given to any spills
ii. Audit the site against this procedure
4.0 Description
4.1. Above Ground Storage
4.1.1 All fuels, paints or other chemicals must be stored within a bunded area suitably
positioned, or other steps taken, such as the provision of drum trays with integral bunds, so as
to minimize any risk of damage by impact (so far as reasonably practicable) the walls and base
of which must be impermeable to the substance stored and to water. The bund must be
capable of providing containment for 110% of the volume of the largest tank or 25% of the total
capacity of all the containers, whichever is the greater.
4.1.2 Bunded areas must be examined on a regular basis (at least weekly for oil storage
facilities) for any leakage of liquid from the storage vessel, associated pump and pipelines and
any spills or releases cleared up immediately. Bunds must be inspected during or after periods
of heavy rainfall to ensure that they do not overflow. All internal areas will be maintained in a
clean state, free from general litter and debris.
4.1.3 Oil Storage installations, the valves, filters, sight gauge, vent pipe or other equipment
ancillary to the container must be within the bunded area.
4.1.4 Bund Drainage

Under normal operating conditions all bund drain valves must be locked in the closed position.
Valves may only be opened to allow drainage of rainwater when there is no obvious sign of
contamination - particular care must be taken when the stored substance is water-soluble. If
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contamination is suspected a sample must be taken for analysis and the results approved by a
competent person before the bund is drained.
On completion of drainage, the drain valves must be locked in the closed position. Any water
found to be contaminated must be disposed of in accordance with procedure of Waste
Management.
4.1.5 Temporary Storage

When it is necessary to have temporary fuel or chemical storage facility the most appropriate
method of containment must be applied
4.1.6 Prepared Bund

A bund must be fabricated on a level (as far as practicable) base; using materials that will
ensure that the walls and base are impermeable to the substances stored and to water. The
height of the bund must be calculated to hold at least 110% of the volume of the largest
container or 25% of the total capacity of all the containers, whichever is the greater. It is
recommended that the minimum height of the walls be 150mm.
4.2 Underground Storage

4.2.1 The use of underground storage tanks and pipe work is to be avoided wherever possible.
Where such facilities do exist, an action plan must be drawn up for their elimination (unless the
underground storage system incorporates technology capable of providing the same degree of
control as that for above ground storage).
Until such time as they are removed the following precautions must be taken:
i. The locations of the tanks and pipe work must be recorded, as far as is practical, preferably on
a map and by physical markings / signs above ground.
ii. Records must also be kept as to the volume, method of construction (i.e. single or double
skinned, in a pit, pipe work in ducts) and the nature of the product contained (at present or in
the past)
iii. Measures taken to protect tanks and pipe work from physical damage, such as that caused
by excessive surface loading, ground movement or ground disturbance
iv. Some form of monitoring of contents employed to ensure that leaks are readily detected
v. Regulatory testing must be performed
4.2.2 To avoid the risk of pollution, underground tanks that will not be used again must be
removed. All remaining product and residues removed, tanks and pipe work must be disposed
of in accordance with local regulatory requirements.
4.2.3 Once the tank has been removed, samples of soil and groundwater (if present) should be
taken to check for subsurface contamination. The samples must be analyzed for the parameters
appropriate to the type of product stored.
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Module Twenty Seven
WATER SUPPLY & CONSERVATION
1.0 Purpose
To ensure that water resources are conserved.
2.0 Scope
All operation sites.
3.1 Site Manager
Ensure that arrangements are in place for the management, monitoring and reporting of water
consumption in accordance with this procedure
4.0 Process
4.1 Identification of Water Supply
Each Site must:
i. Document the source or sources of its water supply (Corporation Water, pumping from the
water table etc)
ii. Document quantitative data of its water consumption for each of its means of supply and for
each of the major uses of water in the processes
iii. Minimizing water consumption to the lowest practical level
4.2 Reduction of Water Consumption
In the event that water consumption reduction is possible and practical, then this will become
part of the environmental objectives and targets for the site and must be supported by
appropriate action plans for continual improvement.
5.0 Records
Monthly water consumption data
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Module Twenty Seven
WASTE MANAGEMENT
1.0 Purpose
To ensure effective management of waste, movement, storage and disposal of waste produced
by an organization and to minimize harm to human health and to ensure minimum impact on
environment.
2.0 Scope
The procedure is applicable to the company’s sites to fulfill the general and also the legislative
requirement.
3.1 Unit Head
Ensures the waste management is controlled and implemented in accordance with this
procedure
3.2 HSE Representative
I. Obtaining and reviewing information for each waste stream relating to the relevant legislative
requirements and confirming validity with the relevant authorities
II. Ensuring that waste control documentation is completed and retained as per procedural/
legislative requirements.
III. Planning, conducting and reporting of waste audits.
3.3 Stores Officer
I. Control of the waste storage area
II. Responsible for making appropriate arrangements and assessing the waste for classification
III. Responsible for auctioning the wastes and preparation of comparative statement and
disposal
IV. Ensuring that waste carriers and disposal sites are suitably licensed for waste to be disposed.
3.4 Operational Managers / Maintenance Managers
Responsible for segregation of waste at source.
4.0 Description
4.1 Wastes have been categorized as:
1. Bio-degradable waste
2. Non-Biodegradable waste
3. Contaminated waste
4. Hazardous Waste
a. Industrial
b. Biomedical
4.2 Generation and collection

All types of wastes are to be put into designated bins after generation. Those are to be disposed
to identify bins for further handling.
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I. Biodegradable waste like paper, cotton waste, wood will be kept in green bins which will be
transferred to an identified area in Scrap Yard for further disposal.
II. Non-Biodegradable waste include plastic, polythene, rubber, concrete debris, fire bricks,
glass and welding slugs are to be kept at blue bins and to be disposed to identified place at
Scrap Yard for further disposal.
III. Welding slugs are to be collected and used for land filling
IV. Oil Contaminated wastes are to be collected in one red bin which will be transferred to an
identified area in Scrap Yard for further disposal.
V. Industrial hazardous wastes in liquid form (used lubricant and used coolant oils) are to be
collected in empty oil drums and to be kept under shed and lock and key and the floor must be
made of concrete with non permeable membrane below ground. The content must be labeled.
Biomedical wastes are to be sent to Medical Centre for disposing by deep burial method.
4.3 Disposal
I. Biodegradable waste includes paper waste, wood waste, cotton waste, and cardboard
packets can be used for landfill or sold to vendor through auction.
II. Non-Biodegradable wastes include plastic, polythene, rubber, concrete debris; glass cannot
be used for landfill. Those are to be sold through auction for recycling.
III. Contaminated waste include oil/ grease impregnated cotton waste - cannot be used for land
filling and to be incinerated through authorized vendors.
IV. Metallic Waste include off-cuts of steel tubes, plates and turning and borings of tubes and
bars, and also nonferrous metallic scrap like aluminum, copper and bronze coming out of
maintenance. These wastes are to be sold through auction.
V. Old machinery list which is approved are disposed off through open auction.
VI. Hazardous waste include empty paint containers, paint sludge, empty dye penetrate cans,
used lubricants, used cutting oil, used transformer oil ,effluent treatment plant (ETP) sludge &
asbestos waste , generated out of shop floor roof sheets and rain water pipes of roof sheds.
These are to be disposed through approved recyclers or approved disposers of Central/ State
Pollution Control Board. The vendors must be able to provide all legal documents prescribed in
legal register.
5.0 Records: Hazardous waste generation, storage & disposal authorization.

Manifest of disposed hazardous waste.
Annual return to State pollution control boards (SPCB) by not later than June each year.
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1

Module two HSE reporting & monitoring

Module three Identification, evaluation and control of occupational

Module four Procedure for identification, evaluation and control of

Module five Identification and compliance of HSE legal requirements

Module six HSE objectives, targets and improvement agenda

Module seven Reporting of accidents, incidents, corrective and

Module eight Training, awareness and competence for HSE

Module ten Emergency preparedness

Module eleven Generic emergency plan

Module twelve Contract HSE performance management process

Module fourteen: Industrial hygiene

Module fifteen Working at height/fall prevention

Module sixteen Confined space work

Module seventeen Electrical safety

Module eighteen Safe lifting operations

Module nineteen Excavation work

Module twenty Personal protective equipment (PPE)

Module twenty one Energy isolation (LOTO)

Module twenty two Permit to work system

Module twenty three Hot works

Module twenty four Discharge of water

Module twenty five Air emissions control

Module twenty six: Conservation of soil and ground water

Module twenty seven Water supply & conservation

Module twenty seven Waste management

3.0 HSE Organization & Responsibilities

3.2 Directors (Manufacturing, Service Businesses as it applies in the organization)

3.3 Director (HR&CA)

3.4 Director (Finance)

3.5 SBU / Corporate Function Heads

3.6 Unit/Branch/Site Heads

3.7 Corporate HSE Resource

3.8 Unit/Branch/Site HSE Representative

4.0 HSE Governance Structure & Process

4.1.2 The status of HSE implementation in the Unit/SBU/Company should be communicated to

4.2 Documented Management System

HSE REPORTING & MONITORING

1.2 HSE & Sustainability Monthly Information System

SBU : UNIT: Month:

ENV03 HSD consumption in MT

HSE Performance to be reviewed at the beginning of any business review.

HSE PERFORMANCE REVIEW

Man Hours Worked

1 HSE Training(man Days

4 Tool Box Talk

5 Job Safety Analysis

2 Loss Time Injury

3 First Aid Incidents

5 IFR(Injury Frequency Rate

6 ISR( Injury Severity Rate)

IDENTIFICATION, EVALUATION AND CONTROL OF OCCUPATIONAL

4.2 Site Supervisors:

4.3 Site HSE Representative

5.1.2 When to Conduct a Risk Assessment

5.1.3 Who should carry out a Risk Assessment?

5.1.4 Conducting the Assessment

IV. Hazard Analysis

In answering these questions the following “Hierarchy of Control” must be considered: