Management System

1- LICENSEE HSE MANAGEMENT SYSTEM
➢ NPL HSE management system/manual is prepared in guidelines of NFPA, OSHA,

EPA, Govt. laws etc. and is implemented.
➢ NPL takes permission/registration/certification from govt institutes for the operation
of plant and also maintained HSE legal compliance register at site.
➢ In evidence, following documents are attached;
Sr. No Description Page No
1 NPL HSE Manual 1
2 HSE Legal Compliance Register 430
3 Environmental Approval from EPA Punjab 440

Complex Registration Certificate and Annual Inspection Report
4 442
by Punjab Labour Welfare Office
5 Social Security Registration Certificate 445
6 EOBI Registration Certificate 446
7 Petroleum Storage License 447
8 Boiler Inspection Certificate 448
9 Electrical Installations Test Certificate 451
10 Approval for Local Purchase/Consumption of H2SO4 452
NISHAT POWER LIMITED

1 Km off, 66 Km Lahore-Multan Road, On BS Link Canal Near Jambear Kalan, Tehsil Pattoki, District
Kasur, Pakistan.
Health, Safety and Environment Department
Nishat Power Limited
1
Part-I
HSE Administration
2
Document ID NPL-HSE-D001
Issue Date 01-01-2016
Revision No 02
TABLE OF CONTENTS Revision Date 20-01-2022
Last Review 20-01-2022
Next Review 20-01-2025
Plant NPL Author Manager HSE Archive Site Archive Status Finalized
TABLE OF CONTENTS
Document No Description
NPL-HSE- D001 General – Table of Content
Part-I HSE Administration
NPL- HSE- A001 Front Matter

NPL- HSE- A002 Employee Safety Orientation
NPL- HSE- A003 Visitors Guidance
NPL- HSE- A004 HSE Committee
Part-II HSE Procedure
NPL- HSE- A005 Incident Reporting and Investigation

NPL- HSE- A006 Safe Handling of Chemicals
NPL- HSE- A007 Compressed Gas Cylinders
NPL- HSE- A008 Cranes, Chains and Slings (Safe Use of Lifting Equipment)
NPL- HSE- A009 Equipment and Tool Safety (Portable Hand and Power Tools /
Equipment Safety)
NPL- HSE- A010 Personal Protective Equipment’s
NPL- HSE- A011 Fire Protection System Inspection, Testing and Maintenance
NPL- HSE- A012 Forklift Trucks
NPL- HSE- A013 Civil Work Procedure
NPL- HSE- A014 Hot Work Permit Procedure
NPL- HSE- A015 Ladders
NPL- HSE- A016 Permit to work & Lockout/Tagout
NPL- HSE- A017 Materials Handling
NPL- HSE- A018 Office Safety
NPL- HSE- A019 Confined Spaces Entry
NPL- HSE- A020 Emergency Preparedness and Response
NPL- HSE- A021 Impairment of Safety System
NPL- HSE- A022 Hazard Identification & Risk Assessment
NPL- HSE- A023 Occupational Health and Hygiene Procedure
NPL- HSE- A024 Waste Disposal Management
NPL- HSE- A025 Housekeeping
NPL- HSE- A026 Change of Management
NPL- HSE- A027 Work at Height
NPL- HSE- A028 Scaffold Erecting, Altering and Dismantling Procedure
NPL- HSE- A029 Eye and Body Shower Inspection Procedure
NPL- HSE- A030 Mutual Aid Response
NPL- HSE- A031 HSE Document and Record Management
NPL- HSE- A032 First Aid Facilities
NPL- HSE- A033 HSE Audit and Visit
NPL- HSE- A034 Contractor Safety
NPL- HSE- A035 HSE Signs, Pipeline Colour Coding and Barricade
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Revision No 02
NPL- HSE- A036 Training Procedure

NPL- HSE- A037 Vehicle Safety
NPL- HSE- A038 HSE Team
NPL- HSE- A039 Electrical Safety
Part-III HSE Policy and Plan
NPL- HSE- E001 Smoking Policy

NPL- HSE- E002 Environmental Management Plan
Part-IV Formats and Checklist
NPL- HSE- C002/01 Employee Safety Orientation Form

NPL- HSE- C003/01 Visitors Safety Orientation Form
NPL- HSE- C004/01 HSE Committee Meeting MOM
NPL- HSE- C004/02 Monthly Safety Report
NPL- HSE- C004/03 Safety Walk
NPL- HSE- C004/04 Annual Safety Walk Plan
NPL- HSE- C004/05 Annual HSE Committee Meeting Plan
NPL- HSE- C005/01 Incident Report Form
NPL- HSE- C005/02 Nearmiss & Unsafe act/condition Report Form
NPL- HSE- C008/01 Mobil Crane Inspection Form
NPL- HSE- C009/01 Portable Hand and Power Tools / Equipment Inspection Form
NPL- HSE- C010/01 New PPE Issuance Against Damage/Missing PPE Form
NPL- HSE- C011/01 Fire Extinguisher Monthly Inspection Form
NPL- HSE- C011/02 Fire Hydrant and Hose Monthly Inspection Form
NPL- HSE- C011/03 Fire Water Line Valve Inspection Form
NPL- HSE- C011/04 Fire Foam Trolley Monthly Inspection Form
NPL- HSE- C011/05 Fire Hose Hydraulic Test Form
NPL- HSE- C011/06 Fire Pumps Weekly Check and Test Form
NPL- HSE- C011/07 Foam Firefighting System Inspection and Test Form
NPL- HSE- C011/08 Wet Pipe Sprinkler System Inspection and Testing Form
NPL- HSE- C011/09 Fire Detection System Quarterly Inspection, Test and
Maintenance Form
NPL- HSE- C011/10 Fire Foam Proportionate Test Report Form
NPL- HSE- C012/01 Forklift Trucks Inspection Form
NPL- HSE- C013/01 Civil Work Permit Form
NPL- HSE- C014/01 Hot Work Permit Form
NPL- HSE- C014/02 Daily HIRA Checklist form for Hot Work
NPL- HSE- C015/01 Ladder Inspection Checklist
NPL- HSE- C016/01 Permit to Work Form
NPL- HSE- C016/02 Permit to Work Master Log
NPL- HSE- C016/03 LOTO Form
NPL- HSE- C016/04 LOTO Master Log
NPL- HSE- C016/05 PTW Quarterly Inspection Form
NPL- HSE- C016/06 Lock Accountability Form
NPL- HSE- C016/07 TLTR Form
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Revision No 02
NPL- HSE- C016/08 TLTR Master Log

NPL- HSE- C016/09 Permit to Work Audit Form
NPL- HSE- C019/01 Confined Spaces Entry Permit Form
NPL- HSE- C020/01 Mock Drill Form
NPL- HSE- C021/01 Fire Impairment Notice Form
NPL- HSE- C021/02 Fire Watch Log Sheet
NPL- HSE- C021/03 Fire Impairment Record
NPL- HSE- C022/01 Personal Safety Checklist
NPL- HSE- C022/02 Hazard Identification & Risk Assessment Form
NPL- HSE- C023/01 Kitchen Hygiene Inspection Form
NPL- HSE- C023/02 Noise, Illumination and Temperature Measurement Form
NPL- HSE- C025/01 Housekeeping Evaluation Form
NPL- HSE- C026/01 Change of management Form
NPL- HSE- C027/01 Work at Height Permit Form
NPL- HSE- C028/01 Scaffold Erecting, Altering and Dismantling Permit Form
NPL- HSE- C028/02 Scaffold Inspection Form
NPL- HSE- C029/01 Eye and Body Shower Monthly Inspection Form
NPL -HSE- C031/01 HSE Document Control List
NPL- HSE- A032/01 First Aid Box Checklist
NPL- HSE- A032/02 Use of First Aid Box Items
NPL- HSE- A032/03 Ambulance Inspection Form
NPL- HSE- A032/04 Emergency Equipment Cabinet Inspection Form
NPL- HSE- A033/01 HSE Audit/Visit Report
NPL- HSE- A036/01 Annual HSE Training Plan
NPL- HSE- A036/02 HSE Training Attendance Form
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Document ID NPL-HSE-A001
Revision No 01
FRONT MATTER Revision Date 20-10-2019
1. Objective
The purpose of this Environmental, Occupational Health & Safety Manual is to:
A) Establish procedures, methods and guidelines to promote and ensure a health
and safety working environment for plant personnel, visitors, suppliers and
contractors.
B) Identify the equipment necessary to eliminate, control and establish procedures
and methods for hazards and risks.
C) Establish a plan of action in the event of natural disasters and other
emergencies, such as fire, hurricanes and so forth.
D) Conform to the approved EHS policies and procedures of NPL.
2. Scope
This manual is applicable to all plant personnel, including Administration, Finance,
Operation, Maintenance, Logistics, Safety & Environment, Contractor employees and
visitors which can directly affect the quality of operation & management services of NPL.
3. Responsibility
3.1. EHS Committee
Committee shall act as a consultative body with the employees and to provide
feedback to the plant management on EHS related matters.
3.2. HODs
Responsible for the implementation of EHS procedure.
3.3. Employees
All employees are responsible for adhering to the instructions of the procedures in this
manual in their respective work place.
4. General
The personal safety and health of each employee is of primary importance. Prevention of
occupationally induced injuries and illness is of such consequence that it will be given
precedence over operating productivity.
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Revision No 01
FRONT MATTER Revision Date 20-10-2019
To the greatest degree possible, management will provide all mechanical, biological and
physical protection required for personal environment, health and safety, but employees
must bear primary responsibility for working safely. A little common sense and caution
can prevent most accidents from occurring.
Facility Nishat Power Limited.
Location 1Km off 67-km Lahore Multan Road near Jambar Kalan Tehsil
Pattoki, District Kasur.
Operation Date Commercial Operation from 6th June, 2010.
Operation Schedule The plant operates as per demand from NPCC Grid Station;
however, it is scheduled to operate throughout the year with load
variations.
Operation Shift Engineer is the plant coordinator. During any emergency, the plant will be
under his command and he will take appropriate action to cater the emergency.
5. Procedure
For information, method, guidelines and compliance individual procedures to be followed.
This manual includes the procedures under the following headings:
A) Safety Administration
B) Plant Safety
C) Emergency Preparedness Plan
D) Environmental Management System
E) Occupational Health & Safety
6. Records
All records are maintained as per Archive Structure of Health, Safety and Environment.
7. Forms
Mentioned with the procedures where ever applicable.
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EMPLOYEE SAFETY Revision No 01
ORIENTATION Revision Date

Last Review
23-07-2019
20-01-2022
1. Objective
NPL is committed to ensure that new employee will receive a general safety orientation on
first day of his job. It is essential that employees are familiar with potential hazards
associated with their workplace.
2. Scope
This procedure will be followed by new employee.
3. Responsibility
3.1 Employee
Employee will
 Participate in 1st safety orientation process and ongoing safety training sessions
conducted by HSE department.
 Identify the need of extra training sessions if required.
3.2 Head of Department
HOD shall ensure,
 The general safety orientation of new employee and his participation in monthly safety
training session.
 The health and safety of his department employees.
3.3 HSE Manager
HSE Manager shall conduct,
 General safety orientation of new employee and maintains its record.
 Staff training sessions as per annual safety training program and other additional training
session as and when required.
4. Procedure
 New employee safety orientation will be performed on first day of his/her employment.
 General safety orientation will include the following;
 General Safety Rules for site and task
 Personal Protective Equipment (PPEs)
 Eye Protection
 Fall Protection
 Foot Protection
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EMPLOYEE SAFETY Revision No 01
ORIENTATION Revision Date

Last Review
23-07-2019
20-01-2022
 Hand and Head Protection

 Hearing Protection
 Housekeeping
 Slips, Trips & Falls
 Lifting Techniques
 Tools and Equipment Safety
 Welding, Cutting & Grinding Safety
 Electrical Safety
 Fire Prevention & Safety
 PTW & LOTO
 Entry into Confined Spaces
 Vehicle Driving
 Emergency Preparedness Plan
 Environmental Management System (EMS)
 Occupational Health & Safety Management System (OH&SMS)
 In the absence of HSE manager, operation officer will conduct the safety orientation.
 In orientation, safety instructions/procedures will present to new employee for reading.
 The new employee shall read these instructions and raised question if any.
 Engineer or HODs will discuss about safety risks and PPEs that involve in work before
assigning any work to new employee.
 All old employee shall participate in EHS training sessions for refreshing their knowledge
about site safety hazards and risks and safety procedures.
 HSE department will maintain the record of Employee Safety Orientation and HSE
Training Sessions.
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Document ID NPL-HSE- A003
Revision No 01
VISITOR SAFETY GUIDANCE Revision Date 23-07-2019
1. Objective
The purpose of this procedure is to provide awareness in visitors about site health, safety and
environment rules for making their visit safe and secure.
2. Scope
This procedure will be implemented on people those are visiting the site for repairing,
maintenance, training, auditing, inspection, interview etc.
3. General
Other than NPL employee or contractor’s regular staff fall in visitor category.
Visitor safety guidance have been developed in order to implement safety standards in NPL
premises.
4. Procedure
4.1. General Visitor
 Information about visitor will be shared by admin department/main gate office to the
concerned department head before entrance to plant premises.
 Gate office will perform gate entry procedure after approval of host then send the visitor
to host after his/her safety orientation by HSE department.
 Contractor team will be allowed to enter working area for maintenance job after safety
orientation. New joiner of contractor team must be taken safety orientation before joining
the team. For maintenance activity contractor shall arrange all related PPEs for his staff.
 Visitors must wear all PPEs in PPEs compliance area. Wearing of PPEs can be
exempted by the approval of GM plant.
 Provision of necessary PPEs to visitors is responsibility of HSE/Admin department.
Note: Safety orientation is not required for visiting project/admin building area. Safety
orientation is valid for six months.
4.2. Safety Guideline for visitors
 Orientation of visitor covers the following site safety rules;
 Follow marked walking routes and safety signs.
 Avoid touching any equipment.
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Revision No 01
VISITOR SAFETY GUIDANCE Revision Date 23-07-2019
 Keep a safe distance from machinery.

 Do not walk or stand under lifted loads
 Smoking policy
 Speed limits
 PPEs for visitor may include; overalls, safety footwear, protective gloves, Hearing
protection and safety goggles (if required).
 Fire Prevention & Safety information
 PTW and Lockout/Tagout information
 Emergency exit procedure of plant and location of muster points.
 Follow the instruction of host during visit.
4.3. Unescorted visitor
 Whenever an employee notices an unescorted visitor inside a restricted area, the visitor
must be immediately questioned for purpose of his presence in restricted area and take
appropriate action accordingly.
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Revision No 01
HSE COMMITTEE Revision Date 22-12-2019
1. Objective
Health, Safety and Environment committee is a forum of plant that work together to solve
environment, health and safety issues. An effective committee helps to
 Prevent environment, health and safety issues at site.
 Increase awareness about environment.
 Develop strategies to make working environment safe and healthy.
2. HSE Committee Organization
HSE committee establishes as a management tool to recommend improvements in health,
safety and environment at site having authority to take decisions.
2.1. Committee Membership
The committee consists of;
 General Manager (Lead the committee)
 Head of HSE department
 Head of departments (HODs)
2.2. HSE Department Responsibilities
 Prepare the agenda for each meeting.
 Schedule meeting timing and venue.
 Notify committee members for meeting.
 Prepare and share minutes of meeting.
 Prepare and share monthly safety report.
2.3. Committee Responsibilities and Functions
The committee will:
 Establish procedures for employees to report hazards or suggest safety improvements
to the committee without fear of disciplinary action.
 Help to review and upgrade the workplace environment, health and safety program by
evaluating employee injury and accident records, identifying trends and patterns,
accident investigative findings and employee near-miss reports.
 Address health and safety complaints and suggestions from employees.
 Promote safety and health awareness in staff by continuous improvements in HSE
training program.
 Conduct site safety walk as per annual plan to observe health, safety and environment
hazards and suggest necessary measures.
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Revision No 01
HSE COMMITTEE Revision Date 22-12-2019
2.4. Committee Meetings

HSE committee meetings will be conducted on monthly basis as per schedule and as
and when required.
Minutes of meeting will be prepared and shared accordingly with committee members
for necessary actions.
2.5. Committee Procedures
Meeting agenda will be shared with committee members.
Employee’s observations, health and safety risks and near-miss reports will be
discussed in meeting.
Committee recommendations will be shared with action plan to concern department
for implementation.
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Part-II
HSE Procedures
14
INCIDENT REPORTING AND Revision No 02
INVESTIGATION Revision Date 20-12-2021

1- Introduction
Despite all our preventative measures, an accident, incident/near miss or a dangerous
situation may still occur. To avoid such situations, it is essential to have an understanding
about them to know the underlying causes.
This procedure has several objectives, i.e.:
 Find out which (underlying) causes have led to the accident, incident/near miss or
dangerous situation.
 Outline the requirements, methods and outcomes of reporting all occupational injuries
and incidents.
 Where necessary additional measure can be taken to prevent a recurrence and
improve the risk management of the activities.
 File or record creation.
 Creating clarity in staff those are involved or may be involved in the unlikely event that
they are faced with one of the above-mentioned situations and what to expect after
they have completed the form.
 Informing the plant management to ensure that everything is correctly dealt with.
Reporting can provide insight into the remaining dangerous work situations. It can therefore
contribute to improving these situations.
2- Scope
The following types of events and injury and/or illnesses will be reported, regardless of the
nature or severity of the event:
 Fatality
 Critical injury
 Lost-time injury
 Injury for which an employee receives/seeks medical attention
 First aid treatment
 Property damage
 Near-miss
 Fire
 Environmental release
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 Explosions
 Exposures to biological, chemical or physical agents
3- Definitions
3.1. Unsafe Act
Performance of a task or other activity that is conducted in a manner that may threaten the
health and/or safety of workers
For example;
 Lack of or improper use of PPE.
 Failure to tagout/lockout.
 Using defective equipment.
3.2. Unsafe Condition
A condition in the work place that is likely to cause property damage or injury.
For example;
 Poor housekeeping.
 Excessive noise.
 Poor ventilation
 Insufficient light/Lux Level
3.3. Near Miss
A near miss is an unplanned event that did not result in injury, illness, or damage but had the
potential to do so.
3.4. An Accident
Any unplanned & uncontrolled event that led to:
 injury to persons, damage to property/plant/equipment.
 impairment to the environment or some other loss to the company.
3.5. First Aid Injury
First aid refers to medical attention that is usually administered immediately after the injury
occurs and at the location where it occurred. It often consists of a one-time, short-term
treatment and requires little technology or training to administer.
3.6. Lost time injuries (LTI)
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It includes all on the job injuries that require a person to stay away from working site more
than 24 hours, or which result in death or permanent disability.
3.7. Work Restricted Injury
Any work-related injury other than a fatality or lost time injury case which results in a person
being unfit for full performance of the regular job on any day after the occupational injury.
3.8. Immediate Causes
These are aspects of the incident/accident which directly influenced the outcome (damage
or injury) and are often referred to as “direct causes”. They are the features of an
incident/accident which immediately contributed to harm or damage being caused.
Example - if an employee is injured by items falling off from high platform, the items falling
and striking the employee is an immediate cause.
3.9. Underlying Causes
These aspects of the incident/accident are effectively contributory breaches which in
themselves did not cause harm but made a significant contribution to the incident/accident.
They are often referred to as “in-direct causes”
Example - poor maintenance of the high platform could be an underlying cause.
3.10. Root Causes
These are effectively the purpose we are doing Root Cause Analysis to discover the root
cause of our incident/accident.
Generally, these are aspects of our safety management performance which have in some
way failed. You may have identified in Immediate and Underlying causes that there have
been individual, equipment or structural failings which directly or in-directly contributed to
the incident/accident.
Example – the failure to supervise the platform maintenance is a root cause
3.11. Actual/Real Severity Rating
Rate the Actual Severity of the incident in terms of the actual outcome of the event.
Severity Rating Definitions for Actual/Real Severity Rating
0. No Impact Requires no treatment
1. Minor Requires localized (In-house) care with short term effects
2. Moderate Requires ongoing care (In-house or external) with short to medium term
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effects
Requires timely external care (evacuation) with medium to long term

3. Serious
effects.
4. Major Requires urgent emergency assistance with long term effects
Requires urgent emergency assistance with serious ongoing long-term

5. Catastrophic
effects- Fatality
3.9. Potential Severity Rating

Rate the Potential Severity of the incident in terms of the worst possible in the scenario
Severity Rating Definitions for Potential Severity Rating
An incident where the potential outcome has a negligible

0. No Impact
consequence.
1. Minor An incident where the potential outcome to risks has a low consequence.
An incident where the potential outcome to risks can cause moderate injuries
2. Moderate
or illnesses.
An incident where the potential outcome to risks encountered is such that it
3. Serious
may cause major irreversible damage or threaten life.
An incident where the potential outcome to risks encountered is such that it
4. Major
may cause major irreversible damage or threaten life.
5. Catastrophic An incident where the potential outcome to risks encountered is certain death
4- Roles & Responsibilities

4.1. Employee
 An employee who sustains an injury or involved in any accident as a result of workplace
conditions or work activity must verbally report to Shift Engineer immediately (not
necessarily their own).
 If, because of the nature of the injury or damage, an employee is unable to report, it is the
responsibility of any other worker, who happens upon the incapacitated worker, to
promptly report the event to Shift Engineer.
 Report any near-miss after fill the near-miss report form to HSE Officer for further
corrective measures.
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4.2. Shift Engineer

The Shift Engineer upon being notified of the accident (injury, spillage, fire etc.) must:
 Promptly ensure that accident is administered by plant Emergency Response Team.
 Ensure the employee is given subsequent medical treatment, if necessary, provide
emergency transportation for hospital treatment if necessary; and record any such
treatment.
 Additional rescue/response from Electrical, Mechanical or other department teams are
notified as necessary.
 Prepare initial accident report and submit it to HSE Officer within 24 hours after an
accident.
If the following occurs, notify Plant Management immediately;
 Fatalities
 Amputations
 Deep lacerations/cuts requiring medical attention beyond first aid treatment
 Loss of vision in one or both eyes
 Fractures (other than to fingers or toes)
 Burns requiring medical attention beyond first aid treatment
 A loss of consciousness
 Worker admission to a hospital as an in-patient
 Any accidental explosion or exposure to a biological, chemical, or physical agent, whether
or not a person is injured
 Any catastrophic event or equipment failure that results, or could have results in an injury.
 Heavy Spillage of Fuel Oil
 Fire
4.3. HSE Manager
 Discuss the initial accident/incident report with GM.
 Measure the severity of accident and inform to EHS Committee for the investigation of
accident
 Investigate the accident/incident independently or jointly with EHS Committee members/
person (s) designated by the General Manager
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 Prepare final accident/incident report and share it with HODs for necessary corrective
measures.
 Update the HIRA (Hazard Identification and Risk Assessment) if required.
 File in and maintain the record of all Accident/Incident (Injuries, Nearmiss, Fire, spillage
etc.).
 Trainee the staff for basic first aid and share the incident report with staff
 Immediately rush the accident area and assist the Emergency response team
4.4 Manager/HOD
 Participate and give his input in investigation of accident as and when needed.
 Take necessary corrective measures in his department to prevent the such accidents in
future.
5- Reporting of Accidents
 All accidents/incidents, regardless of severity should be immediately reported to Shift
Engineer/HOD – who shall then deal with the accident in the appropriate manner and
record the details in Accident Report Form and sent to HSE Officer within 24 hours. Final
report shall be prepared by HSE Manager within a week after receiving the initial accident
report and complete investigation.
 The analysis of the incident/accident shall take place as soon as possible while details are
still fresh. All issues shall be resolved in a timely fashion. Hazard identification & risk
assessment (HIRA) shall be reviewed after accident/incident if needed.
 After investigation final report is submitted to General Manager.
6- Accident/Incident Investigation
Any accident, incident or work-related injuries/illness that occurs must be properly
investigated by the HSE Manager/EHS Committee / person (s) designated by the General
Manager plant.
All Accident/Incidents including Near misses, minor accidents and property damage must
also be investigated.
6.1. Investigation Techniques or Steps
A successful accident/incident investigation process contains standard investigation
techniques or steps. The accident investigation process involves the following steps;
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 Report the incident to Shift Engineer (Emergency Coordinator).

 Initially provide first aid and medical care to injured person(s) and prevent further
injuries or damage at plant and afterwards if it demands the victim shall be sent to the
Hospital for treatment.
 Control hazards/secure accident site
 Investigate the accident, including interview of participants and witnesses
 Take any photographs or details about the event
 Check on any previous accidents/incidents in the area
 Check on injured persons training records
 Identify the causes
 Report the findings
 Develop a plan for corrective action
 Implement the plan
 Evaluate the effectiveness of the corrective action
 Make changes for continuous improvement
7- Record and Necessary Action
After investigation final report will be shared with HODs for necessary corrective / preventive
measures.
HSE Manager will keep the record of incident reports.

21
Revision No 01
SAFE HANDLING OF CHEMICALS Revision Date 23-07-2019
1. Introduction
A wide range of chemicals are being used at NPL in operation, maintenance and laboratory
activities. The hazards associated with these chemicals are depending on their properties
and mode of handling and usage. Inherent hazards are also associated with the reactions
that are carried out with these chemicals and the equipment being used. The risks involved
in handling includes serious injuries and adverse health effects.
2. Objective
This procedure provides guidelines for the safe handling and usage of chemicals so as to
minimize the risks of injury, adverse health effects and environment pollution.
3. Scope
This procedure applies on chemical handling and its usage at plant.
4. General
 Personnel handling chemicals must be familiar with MSDS’s before handling chemicals.
 Chemicals present several types of hazards. Improper use or lack of understanding of the
personal protective actions can result in employee injury, illness or property damage.
 To properly use chemicals employees, need to understand the physical properties and
health hazard of each chemical. These are found in MSDS.
5. Routes of Entry
The chemicals being handled can adversely affect the health of the person if it finds its way
into the body. This can happen either through the
 respiratory system by inhalation
 skin absorption
 Ingestion
Among these three modes, the respiratory system is the main route of entry of chemicals into
the body.
5.1. Inhalation
Inhalation is the most common route of entry for chemicals into the body. The vapours or
fumes released from chemical containers or during the chemical reaction being carried out
can enter the respiratory system if adequate precautions are not taken. The impact on the
respiratory system will depend upon the type of chemical, its properties, ambient
concentration of the chemical and duration of exposure. The chemical vapours can cause
22
Revision No 01
severe irritation of the respiratory tract or it can be absorbed into the blood stream to be
carried to target organs.
The respiratory system has its own defense mechanism against foreign materials entering it.
The mucous secretion along the nasal cavity and millions of tiny hairs called cilia lining the
respiratory tract help in expelling foreign material. In addition to this, macrophage cells
attack and expel the dust particles reaching the lower respiratory passages. But these
defense mechanisms are often overwhelmed when foreign materials enter the body in
excess amount.
5.2. Skin Absorption
Next to inhalation, absorption through the skin forms the main route of entry of chemicals
into the body. Absorption through the skin can happen when the chemical handled comes in
contact with unprotected body parts. This happens when the person handling the chemicals
is not wearing appropriate clothing or personal protective equipment. Cuts and abrasions on
the skin can be a source of absorption of the chemical into the blood stream. Chemicals can
also be absorbed through the intact skin.
5.3. Gastrointestinal Introduction of Toxins
This route of entry of chemicals into the body is rare when compared to other means of
entry. Ingestion of the chemical can result from the consumption of food items inside the
labs, contamination of food items stored in chemical storage refrigerators, mouth pipetting
and accidental ingestion of chemicals stored in drinking water bottles and poor personnel
hygiene.
6. Types of Chemicals
6.1. Corrosives
 Corrosives are chemicals which cause burns on the skin, mucous membrane and eyes.
 Chemical burns are also caused when tissues come in contact with corrosive solids,
corrosive liquids dispersed in the air as mists.
 It includes mainly acids and alkali.
 Acid mists or fumes can corrode structural materials and equipment.
 Corrosive chemicals have other dangerous properties as well.
 Facilities like emergency eyewash and shower must be available in corrosives handling
and usage areas.
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 Splashing of corrosives into the eyes can result in partial or total loss of vision if not
flushed with sufficient amount of water immediately.
 Caustics can cause serious skin burns as they penetrate deep into the tissue.
 Corrosive chemicals, both solid and liquid, can generate large amounts of heat when
mixed with water. This can cause the solution to boil or even erupt violently.
 When water is added into a container of concentrated sulfuric acid it is converted instantly
to steam which will eject the entire contents into the air. To prevent this always add
corrosives to water, slowly, in small amounts, with frequent stirring.
 Always use personal protective equipment like safety goggles, face shields, chemical
apron/coverall and hand gloves with long sleeves while handling corrosive chemicals.
 Examples of corrosives include,
 Nitric acid
 Sulphuric acid
 Calcium hydroxide
 Hydrocholric acid
 Sodium hydroxide
6.2. Oxidizers
 Oxidizers are a hazard as they support combustion. Fires can burn violently in their
presence.
 Oxidizers must be stored away from flammables, since they can start a fire if they come
in contact with each other.
 Oxidizing materials which start to decompose at temperatures marginally above normal
room temperatures must be stored well below their decomposition temperature.
 Do not use sawdust or other combustible substances to clean up spills of oxidizing
materials.
 Examples of oxidizers include,
 Nitric acid
 Perchloric Acid
 Permanganates
 Nitrates
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 Perchlorates
6.3. Flammables
 Flammable chemicals are a fire hazard. The lower the flashpoint (the lowest temperature
at which a liquid fuel will give off enough vapour to form a momentarily ignitable mixture
with air.) of the chemical, greater the hazard.
 Flammable chemical bottles must not be kept open without caps. They must not be kept
near ignition sources.
 They must not be left on the lab bench after use, but to be stored in safety cabinets after
use.
 A fire in a laboratory can easily get out of control if it involves any flammable solvents.
 Flammable chemicals must not be kept open in beakers or containers as they readily
release vapour. The released vapours can form a flammable vapour air mixture which
can ignite in the presence of a source of ignition.
 Open flames must be prohibited where solvents are handled and stored. The amount of
solvent storage inside the labs must be only those required for immediate use.
 Flammable chemicals must not be stored along with oxidizers.
 Flammable chemical bottles or open containers with flammable chemicals must not be
stored in domestic refrigerators. The vapours released can be ignited by the lighting unit
or the thermostat inside. Intrinsically safe lab-purpose refrigerators must be used for the
purpose of storing flammable chemicals.
 Distillation of solvents must only be done inside a chemical fume hood.
 Flammable chemicals must not be heated with Bunsen burners, use a water bath for the
same.
 Examples of flammable chemicals are
 Acetone
 Toluene
 Methyl alcohol
6.4. Water Reactive
 A violent reaction can occur if water reactive chemicals come in contact with water or
moisture.
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 They must be stored away from wash areas or places where it can come in contact with
water.
 Some chemicals react with water to produce heat and flammable gases.
 The bench must be kept dry in the vicinity of an experiment involving alkali metals.
 The apparatus used must be free of moisture.
 Examples are
 Sodium
 Lithium
 Potassium
6.5. Toxics
 Toxic materials are substances that can cause harm to an individual if it enters the body.
 Effects of toxic chemicals are of two types- acute and chronic.
6.5.1. Acute Effect
The ill effects appear during or immediately after a single exposure to a toxic
chemical. The health effects may be temporary, such as irritation of the skin, sickness,
or they may be permanent: blindness, scars from acid burns, etc. Acute toxicity is
often seen within minutes or hours after a sudden, high exposure to a chemical.
6.5.2. Chronic Effect
The effects become visible after a long period of exposure. This can vary from several
weeks to years. This results from multiple exposures to the toxic chemical in sufficient
concentrations after a long period of time.
6.5.3. Prevention of Toxic Exposures
 Use the minimum quantity wherever possible.
 The release of toxic vapours into the workplace must be prevented.
 This can be achieved by carrying out the handling of toxic chemicals in fume
hoods or using local exhaust ventilation system.
 Personal exposure can be prevented by the use of personal protective equipment.
7. Receipt of Chemicals
 The MSDS/SDS (Material Safety Data Sheets) must be obtained from the manufacturer
or the supplier upon receipt of the chemical.
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 Ensure that the chemicals containers/bottles received are in good condition without
damage.
 The details of the chemicals must be included in the inventory list.
 The dates of receipt and first opening of the bottle must be recorded on the bottle and in
the inventory.
 Emergency information about the chemical must be compiled for quick reference.
8. Material Safety Data Sheets (MSDS/SDS)
Material Safety Data Sheet (MSDS) is a document that contains information on the potential
hazards of a chemical and how to work safely with the chemical product. Material safety data
sheets/Safety data sheets of chemicals are provided by the manufacturer or supplier of the
chemical. It gives the following information about the chemical:
 Physical properties
 Chemical properties
 Fire hazard
 Reactivity hazard
 Health hazard
 First Aid Measures
 Spill control measures
 Type of fire extinguishers to be used in case of fire
 Personal protective equipment required
9. Labelling of Chemicals
 Chemicals when transferred to secondary bottles/cans must be provided with proper
labels.
 Chemical formulae or short forms must not be used for labelling of the containers.
 The label must contain the full name of chemical.
 The label may contain other characteristics along with full name;
 its hazards
 information for safe handling
 the signage/pictogram indicating the hazard class
 Labels of bottles which got deteriorated or worn off must be replaced immediately.
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 Chemical bottles without labels or improper labeling can result in the wrong chemical
usage.
 Further it will also cause difficulty in case of a spill or body contact or at the time of
disposal of the chemical.
Pictograms as per Globally Harmonized System of Classification and Labeling of Chemicals
created by the United Nations are as follows.
- Oxidizers
- Flammables/Emits Flammable
Gas
- Self-Reactive/Self Heating
- Pyrophoric
- Organic Peroxides
- Explosives
- Self-Reactive
- Organic Peroxides
- Acute toxicity (Severe)
- Corrosives
- Carcinogen
- Respiratory Sensitizer
- Reproductive Toxicity
- Target Organ Toxicity
- Mutagenicity
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- Aspiration Toxicity
- Environmental Toxicity
- Irritant
- Dermal Sensitizer
- Acute toxicity (harmful)
- Narcotic Effects
- Respiratory Tract
- Irritation
10. Storage of Chemicals
 Storage must be as per the reactive class of the chemicals. Incompatible chemicals
must not be stored together.
 Inventory of the chemicals must be checked at least annually.
 Chemicals with expired shelf lives and deteriorated or leaking containers must be
disposed of safely. A ‘first in, first out’ system must be used.
 The shelves used for storing the chemicals must be firmly fixed to the wall.
 Rim guards must be fixed to prevent bottles falling from the edge of shelf in lab.
 Chemicals must not be stored sunlight. Certain chemicals can undergo decomposition
upon exposure to heat and it can also increase vapour pressure inside the
bottle/can/drum.
 Chemical bottles or drum must not be kept on the floor along the passage or near
exits, where they could be knocked over.
 Chemicals must not be stored on higher racks of the shelf which are difficult to
access.
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 Secondary containers (chemical resistant trays) must be used for storing and usage of
chemicals. This will help to contain the chemical in case of spill or breakage of
bottle/can/drum.
 Corrosives must not be stored above eye level.
 Keep the container tightly closed after usage.
 Never return unused chemical to the original container, as it may contain traces of
contamination of incompatible chemical which can cause a chemical reaction.
 Do not reuse empty containers as it may contain residues of hazardous chemicals.
11. Incompatible Chemicals
A wide variety of chemicals are used at plant and many of these can be incompatible with
each other. This can lead to serious injuries if they are not handled correctly. Incompatible
materials are a pair of substances which on coming in contact with each other produce a
potentially harmful effect. The mixing can result in a fire or explosion or can result in the
release of toxic gases. Examples include,
 Acids and bases
 Flammables and oxidizers
The mixing of incompatible chemicals can occur due to
 breaking of two chemical containers stored together during handling or fall from
shelves.
 washing of chemical bottles.
 improperly labelled chemical bottles/can.
 transferring spent chemicals.
 Prevention of chemical accidents from mixing of incompatibles can be done by
 First identifying the incompatibles among the chemicals available at plant.
 Segregating them in different cupboards/shelves/containments.
 Secondary containments can be used for storing compatible chemicals.
 Proper labeling of chemical.
 Not to carry out unauthorized experiments.
12. Chemical Hazard Control
Once the hazards involved in the handling and use of chemicals are identified, the next stage
is to put control measures in place. This includes,
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 Elimination- Options which get rid of the hazard altogether.

 Substitution- Replacing a hazardous chemical with a less hazardous one wherever
possible.
 Engineering Controls- Fume Hoods, local exhaust ventilation, etc.
 Administrative control- Standard Operating Procedures (SOP), caution signage’s, etc.
 Personal protective equipment’s- Lab coats, safety glasses, hand gloves, etc.
12.1. Local Exhaust Ventilation
Local exhaust ventilation helps to remove the vapors/gases/dusts from the point of
generation before it reaches the breathing zone of the user. A local exhaust ventilation
system consists of;
 a hood or opening that captures the vapors/dust at the source
 ducts that transfer the contaminant from the hood
 fan/blower that discharges air outdoors
 an exhaust stack from which the contaminated air is discharged outside.
During use of chemicals in labs, exhaust ventilation must be operational.
12.2. Personal Protective Equipment’s
Irrespective of the engineering and administrative controls, personal protective
equipment must be used by all personnel working with chemicals.
 Lab coat/acid suit, apron, safety glasses/goggles and shoes are a minimum
requirement for working with chemicals.
 Open toed footwear must not be used because it will not offer protection in case of a
chemical spill.
 Personal protective equipment in addition to above mention must be used based on
the hazards involved in the task being carried out.
 While selecting the personal protective equipment the following points must be kept in
mind.
 Must be appropriate to the hazards of the job being done.
 Must properly fit the user and be comfortable to use.
 Regularly maintained and replaced as per the manufacturer’s recommendation.
 If reusable must be properly cleaned and disinfected.
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 After use the personal protective equipment must be stored away from the work area
at a designated place to prevent contamination and damage.
 All personal protective equipment must conform to relevant International Safety
Standards.
 Never use damaged personal protective equipment
12.2.1. Hand Gloves
 Hand gloves protect the skin from chemical contacts. Types of hand gloves
available for chemical handling are nitrile, butyl, neoprene, PVC, etc.
 No single glove material is resistant to all chemicals. The glove which is most
appropriate must be selected as per the recommendations given in the MSDS
by the chemical manufacturer.
 The gloves irrespective of the material used, will not remain impervious to a
chemical forever.
 Some chemicals will travel through or permeate gloves within a few minutes
while others may take a few days or weeks. Details of the same must be
obtained from the manufacturer.
 The best type of chemical protective material (e.g., neoprene, butyl rubber) can
be determined by referring to MSDS.
 Handling of certain chemicals requires double gloves for e.g., Hydrochloric acid
(nitrile and neoprene hand gloves to be used).
12.2.2. Eye Protection-Safety Glasses and Safety Goggles
 Chemical handling operations involve the risk of eye injuries due to chemical
contact or from flying fragments in case of failure of apparatus or equipment.
Safety glasses/safety goggles offer protection from above mentioned risks.
 Goggles can be used if there are chances of splashing of chemicals during
handling or from the experimental setup used.
 Goggles provide a tight seal around the eyes.
 A face shield offers protection to the face from chemical splashes. Eye
protection must be worn even when the face shield is used.
Care
 Clean your glasses daily. Follow manufacturer’s instructions.
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 Avoid rough handling that can cause scratches on lens.

 The glasses must fit properly. The frame must be as close as possible to the
face and adequately supported by the bridge of the nose.
 Damaged glasses must not be used.
 Keep them in a case when they are not worn.
12.2.3. Respiratory Protection
 Wherever possible use a fume hood or local exhaust ventilation for protection
from vapours and gases.
 If the task involved is such that the above facility cannot be used, then
inhalation of toxic vapours can be prevented by the use of chemical cartridge
respirators.
 The respirator must be selected on the basis of the type of contaminant present
in the work area.
 The cartridge must be replaced periodically as per the recommendations of the
manufacturer.
The chemical cartridge respirators must NOT be used in an oxygen deficient atmosphere.
12.2.4. Body Protection
 Aprons/coveralls protect the body from chemical contact; the type and material
selected depends upon the properties and hazards of the chemical being
handled.
13. Spill Control
 In case of a chemical spill, ventilation of area will be performed.
 All persons will evacuate from the area except persons that involve in spill cleaning
process.
 The personnel carrying out the cleaning must wear proper personnel protective
equipment. This includes eye/face protection, hand gloves and coveralls as required.
 Never assume that gases or vapours do not exist because of lack of smell.
 Breathing vapours from spilled material must be avoided. Chemical cartridge respirators
(half/full face masks) must be used for protection against fumes/vapours.
 Spill control kits can be used to neutralize or absorb the spilled chemical. Absorbent
pillows/pad/sand can be laid around the spill to prevent the chemical from spreading out.
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 Reduce vapour concentrations by covering the surface of a liquid spill with absorbent or
other suitable material specified in the safety data sheet.
 The absorbed chemical can be collected in polyethylene bags, plastic drum and labelled
and stored for disposal off.
 In case of a major spill involving a flammable or toxic chemical the building/area will
have to be evacuated.
 In case of major spill of toxic chemical, the personnel doing the cleaning must wear self-
contained breathing apparatus (SCBA) in addition to other personnel protective
equipment’s.
 If flammable vapours are involved, do not operate electrical switches in the vicinity.
 Try to turn off open flames, where it is safe to do so.
 While dealing with a flammable chemical spill make sure that there is an exit behind,
which can be used if the chemical ignites.
14. Emergency Measures
Every person at site must be aware of site emergency response plan. This includes-
 The location and use of emergency equipment’s like
 Fire blanket
 Emergency shower and eye wash
 Fire extinguishers
 First aid box.
These equipment’s must be located at an easily accessible location and must not be
obstructed.
 The emergency Exits.
 Emergency contact numbers file must be displayed at area notice boards, preferably
near the telephone
14.1. Splashes on the Skin
 All chemical splashes on the skin must be immediately flushed under running water.
 If the splash has happened on a large area of the body, an emergency shower must
be used.
 Contaminated clothing must be removed while flushing the body. Flushing must be
continued for at least 15 minutes.
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 If the substance is known to be insoluble in water gentle cleaning of the surface with
soap while the drenching continues will help to remove the chemical.
14.2. Splashes in the Eye
 Eyes must be immediately flushed with copious amount of water for at least 15
minutes. Certain chemicals like sodium hydroxide, phenol, aniline, hydrochloric acid,
etc. penetrates deep into the tissues.
 An eye wash and body shower must be used for the same.
 During a chemical splash, a spasm may develop in eye lids and keep them firmly shut.
So, while flushing, the eye lids must be raised with fingers to ensure that no chemical
remains in the space below the eye lid.
 Medical attention must be sought only after thorough flushing of the eyes. Failure to
flush the eyes can result in partial or permanent loss of vision.
14.3. Inhalation of Chemical Vapours
 In case of exposure to toxic fumes or vapours, the person must be immediately shifted
to fresh air area.
 If the person is conscious and breathing his condition must be observed for sometime.
 In case the person is not breathing Cardiopulmonary Resuscitation (CPR) must be
started immediately by a trained person.
 Medical help must be sought immediately.
 In certain cases, the symptoms appear late. For example, dilute hydrofluoric acid and
phosgene gas. so, the person must be provided with medical attention immediately
even if there are no visible symptoms.
14.4. Ingestion of Chemicals

 If the chemical ingested is corrosive, it can result in burns in the mouth. For such
injuries, mouth must be washed repeatedly with water.
 In case the chemical has been swallowed, it must be diluted by drinking water or milk
(one or two glasses). And the person must be shifted to hospital immediately.
 Whenever the injured person is shifted to hospital, the person accompanying him
must carry the material safety data sheet along with him or provide details of the
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chemical. This will help in giving quick information about the chemical to the doctor
treating the injured person and help to avoid delay.
 Emergency eye wash and shower must be checked at least once in a month and the
details of which must be displayed nearby. This will prevent contamination of water
inside and ensure the operability in an emergency.
14.5. Fire on the Cloth
 If a person’s clothes are on fire, the flames must be extinguished by drenching with
water from an emergency shower.
 Never run when the clothes are on fire, as this will fan the fire. Roll on the ground.
15. Personal Hygiene
 Personal cleanliness is a very important way of protecting personnel working with
hazardous chemicals.
 Wash hands before eating and drinking.
 Clean contaminated clothing before wearing it again, or discard it.
 Do not drink or eat in any areas where hazardous chemicals are present.
 Avoid touching yourself with contaminated hands.
16. Electrical Apparatus
 The floor near electrical apparatus must be dry and equipment must not be operated
with wet hands.
 Insulated wire must be used for all electrical connections.
 Electrical apparatus which produces even the slightest shock presents a potential
danger will be checked and disconnected immediately.
 Electrical cables never allowed to come into contact with hot surface, which would
burn the insulation and cause a short circuit.
 Electrical plugs and switches must not be fixed near wash area or where they can
come in contact with water.
 Electrical wires or cables must not be laid along the passage, which can become a trip
hazard and can also cause damage to the wire insulation.
 Electrical fittings must be fixed at a height over the work bench, either against the wall
or on rack so that accidental spillage of water on the bench cannot get to the electric
connections.
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 Electrical equipment must be switched off after use.

 Bare wares must not be used in sockets. Use three pin plugs.
 Go through the safety instructions given in the user/operating manual of the
equipment before using the same.
17. Housekeeping
 Maintaining good housekeeping in lab, chemical storage shed and other chemical
usage areas.
 Good housekeeping helps to prevent damage of equipment, fire and other such
accidents in labs and other chemical usage area.
 A designated place must be assigned for every item and the items must be returned
back to its place after use.
 Maintain cleanliness and order at all times.
 Clean up any spills and buildups of corrosives promptly and safely.
 Chemical bottles/containers must not be placed at locations from which they can fall
or can be struck down.
 Remove empty containers from site periodically.
 Chemical bottles/containers must be returned to the storage areas immediately after
use.
 In case of breakage of glass apparatus, the glass pieces must be removed promptly.
18. Disposal of Chemical
 All chemical used at site are water dissolved.
 The practice of chemical disposal is very rare due to rare chance of chemical expiry
because only required quantity of chemicals are purchased.
 Disposal of chemical in case of spillage, contamination, usage and expiry shall be
made by dilution with water.
 Dilution process is very suitable for disposal of water-soluble chemicals because
dilution does not affect the effluent water parameters limits. In effluent the level of
BOD and COD parameters remain well within the NEOS limits. Hence there is no
need of special disposal method.
 Proper PPEs will be used during disposal of chemical.
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COMPRESSED GAS CYLINDER Revision No 01
02-05-2019
SAFETY Revision Date
20-11-2021
Last Review
1. Purpose
The purpose of this procedure is to provide guidance for the safe handling, storage and use of
compressed gas cylinders.
2. Scope
This procedure applies to all NPL and Contractor staff that are involved in handling, storing
and using compressed gas cylinders.
3. Definitions
3.1. Flammable Gas
A gas having flammable range with air at 20°C (68°F) and at standard pressure of 101.3 kPa
(14.7 psi). Aerosols are not classified as a flammable gas.
3.2. Toxic Gas
A gas which is classified as acutely toxic, mutagenic, carcinogenic or a reproductive toxin.
3.3. Oxidizing Gas
A gas that can cause or contribute to the combustion of other material.
3.4. Corrosive Gas
A gas that come in contact with living tissue, causes destruction of the tissue by chemical
reaction.
4. Responsibilities
4.1. HSE Manager
• Review, maintain, oversee and assist with implementation of this procedure.
• Conduct a hazard analysis of handling, storing and using compressed gas cylinders.
• Provide training in the safe handling, storage and use of compressed gas cylinders.
4.2. Head of Department
• Review and implement this procedure.
• Ensure the implementation of appropriate control measures taken against hazard
analysis.
• Ensure personnel compliance with this procedure.
• Minimize the size and quantity of compressed gas cylinders used and stored at NPL.
4.3. Compressed Gas Cylinder Users
• Make compliance of procedure and also follow the instructions of HOD and HSE
Manager.
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5. Safe Handling Practices

• Ensure cylinders are properly labeled when received. Do not accept cylinders that are
not labeled. Do not add, remove or alter any cylinder markings or labels.
• Wear PPEs during handling of cylinders.
• When a cylinder or valve is corroded or malfunctioning contact the gas supplier for
assistance.
• Do not modify or repair any part of the cylinder including the pressure relief device and
valve.
• Use a gas cylinder hand truck or approved lifting/transporting device to move cylinders
and properly secure cylinders to transport device. Never lift cylinders by the valve cap.
• Valve caps shall be in place and hand tightened when cylinders are in storage or being
transported.
• Cylinders should not be used as rollers, supports or for any purpose other than to
contain and use the contents as received from the supplier.
6. Safe Storage Practices
• Minimize the number of cylinders in use and storage with a just-in-time ordering process.
• Avoid storing cylinders in entrances, near elevators, passages or near exits. Cylinders
must not obstruct exit routes, electrical panels or emergency equipment.
• Cylinders must not be stored where moving objects may strike or fall on them. All
cylinders in service or storage must be secured to prevent falling or rolling. Store in an
upright position and secure with a bracket, chain or low-stretch strap around the upper
third of the cylinder (above the center of gravity) or with equivalent method.
• Store and use cylinders in well ventilated locations and temperature do not exceed
125°F or 52°C.
• Storage areas must be prominently posted with the hazard class or the name of the
gases stored (e.g., Hydrogen-Flammable Gas-No Smoking-No Open Flames).
• Empty cylinders should be segregated from filled cylinders and shall be marked or
tagged EMPTY.
• Cylinders should not be placed where they may become part of an electrical circuit.
7. Safe Use Practices
• Never use a compressed gas cylinder when the contents are unknown.
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Last Review
• Gas delivery lines must be clearly labeled to identify the gas.

• Valves shall be kept closed at all times except when the cylinder is in use. Valve outlets
should be pointed away from personnel when the valve is being opened.
• Use a check valve to prevent reverse flow into cylinder.
• Ensure that the regulator and valve fittings are compatible and free of dust and dirt.
• Do not use Teflon tape or other sealants when attaching regulators.
• Slowly open the valve. If there is difficulty in operating a cylinder valve than discontinue
its use and contact with supplier. Open the valve completely and then close it a quarter
turn back. This will help prevent the valve from being stuck open.
• Never insert an object into valve cap openings. Doing so may damage the valve and
may cause leakage.
• Do not tamper with or modify valves, regulators or safety devices.
• Do not direct compressed gas streams toward any person. This could cause serious
injury to eyes or body.
• Pipes, regulators and other apparatus shall be kept gas tight to prevent leakage. Use a
compatible leak test solution or an appropriate leak detection instrument to test
connections.
• Before a regulator is removed, close the container valve and relieve the regulator gas
pressure. Regulators, gauges, hoses and other apparatus which are provided for use
with a particular gas shall not be used on cylinders having different chemical properties
or service pressure ratings unless information obtained from the gas supplier indicates
that this can be done safely.
8. Precautions for Flammable Gases
• Flammable gases shall be stored in well-ventilated areas away from oxidizers, open
flames, sparks and other heat and ignition sources.
• All lines and equipment associated with flammable gas systems shall be grounded and
bonded.
• Cylinders containing flammable gases (empty or full) that are not in use must be
separated from cylinders containing oxidizers (empty or full) by a minimum distance of
20 feet or by a barrier at least 5 feet high which has a fire-resistance rating of at least
one-half hour. (5/8” rock sheet provides at least a ½ hour fire rating).
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NOTE: Flammable cylinders that are in use (i.e., with regulators and associated piping/hoses
attached) may be adjacent to oxidizers that are in use.
• A maximum of two full-size cylinders of flammable gas are permitted in working area.
• If possible, use flow restrictors or limiters to prevent a sudden flow of gas in the event of
a rupture or leak.
• An open flame must never be used to detect leaks of flammable gases.
• Acetylene cylinders must be stored/handled with valve end up.
9. Precautions for Toxic Gases
• Cylinders larger must be kept in a certified gas cabinet or other equivalent engineered
enclosure that vents directly outside. Small size bottle gas cylinders should be used and
stored in a fume hood or ventilated enclosure.
• Gas detection systems may be required in labs or work areas that use toxic gases.
Contact the HSE department for assistance.
10. Precautions for Oxygen and Oxidizing Gases
• Do not permit oil or grease to come in contact with compressed oxidizing gases,
regulators or fittings.
• Do not store or use near flammable solvents, combustible materials or near unprotected
electrical connections, heat and other sources of ignition.
11. Precautions for Corrosive Gases
• Cylinders should be periodically checked to ensure that the valve has not corroded. If a
cylinder or valve is noticeably corroded, the gas supplier should be contacted for
assistance.
• Use caution if flow does not immediately start when a valve is opened slightly. If the
valve or delivery system could be obstructed, contact the gas supplier for assistance.
12. Precaution for Liquid Nitrogen Gas

12.1 Transportation and Handling
• Liquid nitrogen should be handled in well-ventilated areas.
• Handle it slowly to minimize boiling and splashing. Use tongs to withdraw objects
immersed in a cryogenic liquid - Boiling and splashing always occur when charging or
filling a warm container with cryogenic liquid or when inserting objects into these liquids.
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12.2 Container
• Use only approved and impact resistant containers that can withstand the extremely low
temperatures. Materials such as carbon steel, plastic and rubber become brittle at these
temperatures. Therefore, tanks are double walled with inner stainless steel and outer
carbon steel with annular space with per liter or super insulation and vacuum.
• Only store liquid nitrogen in containers with loose fitting lids (Never seal liquid nitrogen in
a container). A tightly sealed container will build up pressure as the liquid boils and may
explode after a short time.
• Never touch non-insulated vessels containing cryogenic liquids without proper gloves.
Flesh will stick to extremely cold materials and never put your hand into the container.
Even nonmetallic materials are dangerous to touch at low temperatures.
• Never tamper or modify safety devices such as cylinder valve or regulator of the tank
12.3 Storage
• Liquid nitrogen should only be stored in well-ventilated areas (do not store in a confined
space).
• Do not store liquid nitrogen for long periods in an uncovered container.
• Cylinders should not be filled to more than 80% of capacity, since expansion of gases
during warming may cause excessive pressure buildup.
12.4 Personal Protective Clothing
12.4.1 Eye/face protection
• A full-face shield over safety glasses or chemical splash goggles are recommended
during transfer and handling of cryogenic liquids to minimize injuries associated with
splash or explosion.
• Loose-fitting thermal insulated or leather gloves, long sleeve shirts and trousers with
cuffs or boiler suits should be worn while handling liquid nitrogen. Safety shoes are also
recommended while handling containers.
12.4.2 A special note on insulated gloves
• Gloves should be loose-fitting so they are able to be quickly removed if cryogenic liquid
is spilled on them. Insulated gloves are not made to permit the hands to be put into a
cryogenic liquid. They will only provide short-term protection from accidental contact with
the liquid.
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13. Emergency Handling Procedures for Leaky Cylinder

13.1 Toxic gas
If the cylinder is in a fume hood or vented enclosure, evacuate the immediate area. If it is
possible that a toxic gas could enter an enclosed space and expose personnel, warn others,
immediately leave and close the door(s), activate the nearest fire alarm pull station and call-
in control room from a safe location to report the emergency.
13.2 Flammable or oxidizing gas
Follow the same steps as for toxic gas and if it can be done safely, attempt to shut off ignition
sources and/or isolate the leak prior to evacuate the area.
13.3 Inert Gas
Warn others and evacuate the area if you are in an enclosed space without adequate
ventilation as this could create an asphyxiation hazard. If the leak is small and you are in a
well-ventilated location you may attempt to stop the leak.
14. Cylinder Inspection and Testing
All type of gas cylinders shall be inspected on regular basis for paint, rust and wear and
tear in cylinder body. Necessary measure shall be taken as per inspection
recommendations.
All type of gas cylinders shall be tested hydrostatically after every five years and after
cylinder body repair work.
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SAFE USE OF LIFTING Revision No 01
EQUIPMENT Revision Date 06-07-2018

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1. Purpose
The purpose of this procedure is to safeguard the health and safety of users of lifting
equipment and gears.
This procedure will contribute to establishing, maintaining and further developing an
acceptable safety level for personnel, environment and material values in the planning and
execution of lifting operations.
2. Scope
This procedure provides guidelines for the safe use of lifting equipment and gears
associated with lifting operations like fork lift, jacks, manual trolleys, manual chain hoist,
overhead cranes, chains, slings etc.
3. Definitions
3.1 Lifting Operation:
All activities before, during and after a load is moved and until the lifting equipment is
ready for a new load.
3.2 Blind Lift:
Lifting operation where the crane driver is not direct sight of the load, hook attachment or
landing place
3.3 Heavy Lift:
Lifting of heavy loads not to be considered as routine operations.
3.4 Coordinated Lift:
Lift carried out with two or several separate lift appliances.
3.5 Personal Lift:
Lift for employees with a basket or platform suitable for lifting of persons.
3.6 Lifting Appliances / Equipment:
An assembled unit that is used for lifting a load with or without horizontal movement.
 Cranes – all types
 Winches
 Hoists – all types
 Fork lift
 Jacks
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3.7 Crane:
Lifting device where the load in addition to the vertical movement may be led horizontally
in one or more directions
3.8 Lifting Device / Gear:
Components or equipment used between the lifting appliances and the load or on the
load to grip this, but which are not an integrated part of the appliance or load.
 Lifting beams, Shackles,
 Blocks Slings – fiber/chain/wire rope
 Eye bolts / Eye nuts
 Hooks
 Pendants
 Lifting fittings
3.9 Load Container (Lifting Device):
All types of containers, boxes, baskets, freight containers, gas cylinder racks, wheel
barrows, etc. which are fitted with lifting lugs for use/handling with a crane.
3.10 Pulley Block:
A lifting device consisting of at least one disc in a frame, with an attachment point for rope,
steel wire or chain that can be attached to a fixed point on the load
3.11 Safe Working Load (SWL)
 For lifting appliances: SWL is actual hook load that the lifting appliance is designed
to lift in a given operating condition
 For lifting device: SWL is the maximum permitted load that a lifting device can be
subjected to under normal use. For a multipart lifting device this is labelled for a load
angle of 30 degrees.
3.12 Before-and-After Use Check:
Visual check of technical condition without dismantling. For lifting devices, a functionality
test of all movements and safety systems must be carried out before and after use.
3.13 Inspection:
Visual inspection carried out by a competent person to verify that the equipment is free of
faults and complies with requirements.
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4. Risk Assessment of Lifting Operation:

All lifting operations are to be subjected to risk assessment and safe lifting plan. The risk
assessment should take into consideration the:
 Type of lift and the equipment to be used
 Environment (location, ground condition, noisy, etc.)
 Load (weight, center of gravity, stability, lifting points, etc.)
 Visibility (for the entirety of the lifting operation)
 Weather (wind speed and direction, etc.)
 Proximity of other hazards, etc. (e.g., overhead power lines)
 Power failure of lifting equipment during lifting mode.
 inadequacy of inspection regime.
 Training of operators in the use of lifting equipment;
 Other persons in the vicinity of the lifting operation (staff, visitors, etc.) and the need
for exclusion zones.
 Overturning and overloading.
The main consequence of these hazards is being injured by;
 Moving parts of machinery– for example being drawn in, trapped or crushed;
 Dropped or ejected material
 Sharp edges or sharp-pointed parts
 Hot or cold surfaces; or
 Parts of the equipment which may fail and/or loads may drop
5. Use of Electric Over Head Crane
The crane along with lifting gears is use for lifting and moving of engine parts and heavy
materials in main workshop and both engine halls.
Below procedure will provide to reinforce the basic principles of crane operations for all
operators to ensure that equipment is safe for use and remains safe at all times.
5.1 Risk Assessment
Although it is a requirement to conduct risk assessment or job hazard analysis
therefore Craft Person (Operator) will conduct his own personal risk assessment at
the start of each new lifting operation.
 What is the task?
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 Do I understand how to do the task correctly?
 Do I have the right lifting gears, tools and electric overhead crane?
 Have I been trained and authorized to operate electric overhead cranes to be

used?
 Are the correct controls and procedures in place?
 Guards warning devices in place
 Control units
 Personal Protective Equipment
 Inspection records
 Safe working loads (SWL)
 Exclusion zones
If any of the above controls are not in place then stop and inform your immediate team
Leader / Manager and use the crane after rectification of faults or placement of all
controls.
5.2 Pre-Use Precautions / Checks
Before using any crane, it is important to carry out some preliminary checks.
5.2.1 Visual Checks
It is preliminary to check electric overhead crane include lifting machines and lifting
gears.
 Ensure that no warning signs are on the crane which can either be attached to the
control unit or on the main isolation switch. If PTW & LOTO system is in use do not
attempt or ask someone to bypass it.
 Check the crane for:
 Oil leakage.
 Any unusual vibration or sound.
 Check that the crane is in proper working condition, and all motion indicators on
the pendant control correspond with control device marking.
 Always familiarize with the controls as pendant controls can differ from one
another.
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 Ensure all crane limit switches (upper & Lower), travel limit switches (long & cross)
and indicating devices are in good working condition. Below following types of
indicators:
 Load indicator;
 Working space limits;
 Anti-collision device; and
 Motion indicator (Audible and visual).
 Check hook block to make sure it is in good working condition.
 Check that the safety latch is able to spring back.
 There should be no illegal modification to the hook.
 Inspect the hook for nicks, grooves, deformation of the throat opening, wear on
saddle or load bearing point, and twisting.
 Check shackles for any defects and make sure they are in good working condition.
 Check wire ropes for any deformation or damages such as:
 Broken wires;
 Strand distortion;
 Kinks;
 Excessive wear;
 Bird caging;
 Crushing;
 Rusty; and
 Stretching.
 Check chains and chain slings for any defect. Make a link-by-link inspection and
report the defect if the following conditions are:
 Cut, nicked, cracked, gouged, burned, or corrosion pitted;
 Twisted or bent; and
 Stretched (Links tend to close up and get longer).
 Check web slings for any defect. Damage is usually easy to detect. Report to the
immediate Team Leader/Manager and replaced immediately if there are:
 Cuts, holes, tear;
 Frays, broken stitching, worn eyes and worn or distorted fittings; and
 Burns from acid, caustics or heat.
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 Proper housekeeping of working area and walk ways free for walks.
5.2.2 Trail Lift:
Before lifting operation, a trail lift should be made. In trial lift;
 Ensure that load is secure and not fastened in position before trying to lift it.
 Lift the load a couple of inches from the ground or specific location then stop.
 Ensure that the load is stable and secure before continuing with crane travel
checks.
 Never snatch the load as this can cause additional loading on the lifting
attachments and the crane leading to potential failure.
5.3 Operational Safety
5.3.1 Safety Considerations
 Visually check the operating environment to make sure that there are no new
hazards which might affect the safe use of the crane.
 Do not make assumption. Ask if in doubt.
 Do not operate the crane if not feeling well.
 Do not overload crane.
 Do not use the hoist rope/chain as a sling.
 Do not lift a load from the side.
 Centre the crane directly over the load before hoisting to avoid swinging the load.
 Do not ride on the load or allow others to do so.
 Do not lift loads over people.
 Make sure the load is properly secured before lifting.
 Do not multi-task when operating the crane.
 Do not operate the crane in a rushed manner.
 Communicate clearly between lifting team before and during lift.
 Use Tag Lines or Push/Pull Sticks to control the load.
 Do not use crane to pull out a jammed or stucked objects.
 Ensure adequate clearances between cranes and fixed objects.
 Do not leave suspended load overnight or unattended.
5.3.2 Tandem Lifting
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When using more than one crane or with two hoists for tandem lifting operations, a
competent person shall carefully plan out the operation in detail with a thorough lifting
plan and emergency plans. The operation shall be carried out under proper
supervision. The person supervising the operation shall fully understand the details of
the operation and shall ensure that the operators understand the sequence and the
hazards of the operation.
5.3.3 Maintenance
The concern department must maintain a crane and its accessories in a condition that
will not endanger an operator or other employee.
A preventive maintenance program based on the manufacturer’s recommendations
will be made and maintained by concern department.
5.4 After Use Precautions / Checks
 Park the crane in a position of safety at the end or the tracks or in a designated
area where it does not cause a hazard to other equipment, machinery or
personnel.
 When Craft Person finished using any crane it should be switched off and lifting
attachments removed and placed into storage to prevent any unauthorized usage
and left in a safe position.
 The lifting hook should be parked above head height or away from process or
mobile equipment.
 Pendent control should be left in a safe position either in a designated holder or
away from where anyone could walk into it or it could become entangled in mobile
plant or machinery.
6. Manual Chain Hoist:
Manual chain hoists are commonly known as chain hoist that is suspended (usually from
a beam via a trolley) featuring a chain and hook and are designed for heavy duty lifting
and materials handling operations. Chain hoist raise and lower loads by pulling on the
hand chain. Chain hoist with single fall is being used in fuel treatment building, engine
halls auxiliary area, washing shed and decanting area.
6.1 Inspection Before Use:
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Ensure that the chain block and trolley beam identification plate and SWL are clearly
visible and readable.
The pre-use inspection for a chain block should include the following:
6.1.1 Load Chain
 Inspect chain for wear.
 Inspect chain for grooves, nicks, arc burns, twisted & bent links and corrosion.
6.1.2 Lift Wheels & Sheave Wheels
 Inspect lift wheel for foreign material, wear and corrosion.
 Inspect dead end pins for wear, tightness and corrosion.
6.1.3 Hooks
 Inspect hooks for signs of opening, cracking, bending, arc burns and corrosion.
 Hooks should swivel freely.
 Inspect safety latches for condition & operation.
 Measure the hook throats for allowable service openings.
6.1.4 Hand chain
 Inspect chain for wear.
 Inspect chain for twisted or scratched links and corrosion.
 Inspect connecting link for signs of opening.
6.1.5 Miscellaneous
 Inspect frame and covers for distortion, cracks, grooves, corrosion & other
damage.
 Inspect hangers for cracks, grooves, corrosion & other damage.
 Inspect unit for clear SWL identity.
6.2 Care In Use:
 The load chain must always mesh correctly with the load sheave.
 Regularly lubricate the whole length of the load chain with machine or gear oil but be
careful not to over lubricate as oil or grease on the brake discs can cause the brake to
malfunction and slip.
 Confirm that the brake is functioning properly by hoisting the load 100mm and check
the brake when lowering the load.
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 Non-vertical (sideways pulling) of the hand chain is not recommended on Rig-Mate

chain blocks.
 The hand chain is equipped with a safety link. When the safety link opens or deforms,
stop at once and inspect for the cause.
 Confirm that the monorail beam or structure supporting the chain block is of sufficient
strength to support the load to be lifted.
 Never lift loads in excess of the SWL of the chain block.
 Never walk or work under a hoisted load and never lift, support or transport people.
 Use chain blocks manually only.
 Do not permit more than one operator to pull on the hand chain at one time.
 Lift loads correctly with proper slings and attachments. Never lift with the point of the
hook and never use the load chain as a sling by back hooking.
 Lifting a load with two chain blocks is not recommended. If the operation is
unavoidable, hoist the load with utmost care, keeping the load balanced.
 Never run the load chain out too far. When operated beyond the range of lift, an
excessive load that can cause damage will be imposed on the chain block.
 Chain blocks are designed for lifting loads vertically and should not be used for
horizontal or angle hoisting.
 Extreme temperatures will reduce the durability of the hoist. Loads should be hoisted
or lowered very slowly and carefully in extreme temperatures.
 Never leave a load hanging on the hoist.
 Never use the chain or hook as a ground for welding.
 Use only genuine parts and chains for repairing.
The hooks and load chains are made of special alloy steels and are precisely heat-
treated. Never weld or heat-treat them. Load chains are exceptionally long wearing, but
wear is unavoidable and certain conditions will cause wear and corrosion that will lower
the strength. Load chains worn beyond the permissible limits must be replaced.
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6.3 Hooks
The opening will elongate with overloads and incorrect hooking. When the hook opening
is elongated beyond permissible limits it is dangerously deformed and must be replaced
immediately.
Never galvanize or subject the chain, or other load bearing parts to any other plating
process.
7. Mobile Crane
7.1 Selection of Crane
The cranes should always be selected to handle the maximum anticipated load with
capacity to spare. Other consideration for the selection of the cranes is the nature of lift,
ground condition, site constraints, etc.
7.2 The Crane Operator
The crane shall only be operated by a trained and competent operator. The operator
must have competency certificate with him and also use proper PPEs (safety shoes,
helmet, coverall, etc.).
7.3 Documents for the Crane
When the crane arrives on site, the following documents should come along with the
crane for inspection and review when requested by HSE Officer and recorded in
inspection document:
 A valid certificate of test / thorough visual examination of lifting equipment for the
mobile crane.
 A valid certificate of test / thorough visual examination of all lifting gears that comes
with the crane.
If the operator is unable to produce the above documents, the crane supplier should be
contacted and the documents obtained before the machine is put into use. It is
advisable to state that the production of these documents will be required when the
crane is hired. Inspection
7.4 Setting of Crane
The stability of the crane depends heavily on the proper siting and setting of the crane.
Unless stated by the manufacturer, the crane should have its outriggers fully extended
with the wheels off the ground. The ground should be level and capable of supporting
the full weight of the crane and its load.
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In addition, sufficient and suitable packing in the form of steel plates or timber mats
should be placed under the outriggers to evenly distribute the weight.
The crane should also be positioned so that:
 The operator has a clear view of the operation as far as practicable.
 There is sufficient operating space.
 It is well away from edges of excavation and fixed structures which people may be
trapped by the moving parts such as counterweights, etc.
7.5 Planning and Supervision
All lifting operation should be properly planned by a competent person before the actual
execution and not left solely to the crane operator.
Investigation into crane accidents revealed that one of the root causes of these
accidents was due to lack of proper planning and supervision. This is particularly so for
simple routine lifts.
Hence, all contractors are advised not to be self-satisfied during any lifting operation,
and to plan and supervise the operation carefully.
Site constraints that would have an impact on the safe operation of the lifting should be
considered before the execution of the lift. Examples of such constraints are:
 Lifting next to or over an excavation pit;
 Materials or machines placed along the access way thereby reducing the available
space to extend the outriggers;
 Site is located nearby busy traffic, or existing building or structures
Careful planning is especially critical for difficult lifts such as pick and carry operations,
tandem lifting and tilt-up operation.
7.6 Personnel
The appointment of the following personnel for all mobile crane operation;
 Trained lifting supervisor
 Trained riggers
 Trained signalman
All contractors are advised to familiarize themselves with the duties of these appointees
as spelt out in the regulation and ensure that the only trained and competent personnel
are appointed.
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In the case where the lifting operation is out of the view of the operator (such as lifting a
load from the rooftop of a building), the occupier is obligated to appoint sufficient
number of signalmen for the operation.
7.7 The Load
The weight of the load should always be known from specifications or through
calculations. It is important to note that the safe working loads (SWL) indicated in most
load capacity charts are gross SWL. This means that the weight of the hook block, and
all lifting gears used must be deducted from this gross SWL to obtain the net SWL that
the crane is able to lift at that configuration.
7.8 Load Radius Indicator

The mandatory load radius indicator gives the safe working load at the configuration
that the crane has been set, and gives a warning signal when the radius is unsafe. The
indicator:
 must be calibrated regularly.
 must be configured for both main and auxiliary hooks (when both hooks are used).
 The operator must be trained to use / set the indicator correctly to tally with the
actual configuration adopted;
It is important to note that the load radius indicator served primarily as an operational
aid.
7.9 Checks and Maintenance
The crane should be in good working condition when it arrives on site and before the
start of the work shift. The manufacturer’s recommendation on the inspection and
maintenance regime should also be followed closely.
7.10 Hand Signals
For direction of lifting operations, the following hand signals will be used:
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8. Pallet Jack Safety

A pallet jack may not appear to be the most dangerous piece of equipment; however,
there are numerous opportunities for personal injury or property damage.
Simple procedures must be followed to avoid crushed toes, trip hazards, scraped knuckles
and pulled backs.
8.1 Personal Protective Equipment
Only trained and authorized person will operate a Pallet Jack. Person who works with
pallet jacks need to wear appropriate personal protective equipment, including:
 Protective eye wear to prevent injuries from material strapping and hazardous
chemicals being moved.
 Safety-toed footwear to prevent foot injuries caused by run over by the wheels,
being hit by materials falling from the jack or stubbing a toe on the jack;
 Gloves to reduce the risk of cuts, bruises, blisters, smashed fingers and to protect
hands in general.
8.2 Pallet Jack Maintenance
Keeping your pallet jack in good condition is imperative.
Using a damaged or defective pallet jack can have serious consequences. For example,
it can cause a load to shift and fall, resulting in injury. It's important to inspect pallet jacks
before using them.
Periodic maintenance of pallet jacks will enable workers to operate the devices with the
minimum amount of hand, arm and finger force.
8.3 Safe Handling Guidelines
 Only trained and authorized person will operate a Pallet Jack.
 Always check the Pallet Jack to see that it is in good working order before use.
 Confirm load being lifted is within the capacity limit of Pallet Jack.
 If observe in fault than notify the HOD immediately.
 Always inspect the load before move it. Determine that load is secured, evenly
distributed and proper height to clear doorways.
 When pulling loads, always be observant for any overhead obstructions.
 Ensure the jack is centered and straight in the pallet.
 Never attempt to lift a load with one fork.
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 To prevent muscle strains, use both hands to jack up a manual Pallet Jack.
 Obtain assistance when pulling heavy loads, pulling on wet floor, or on grating.
 Swing wide on corners to avoid hitting with objects.
 Use Extra caution when operating jack on a grate. Never turn sharp on a grate.
 Always let the Jack down when the Jack is left unattended.
 During parking do not bump or hit with walls because hitting may cause damage to
pallets.
 Make sure the Pallet Jack is at a complete stop and in down position before
releasing handle.
 Keep all body parts (hands, arms, feet, etc.) from getting underneath a pallet when
it is in a raised position.
 Pallet Jacks are for work only. Horseplay, including riding the jacks, is strictly
prohibited.
8.4 Proper Storage
When not in use, store pallet jacks where they will not create tripping hazards. Ensure
that the devices do not block exits or emergency equipment, such as fire extinguishers.
9. Jacks
All personnel working with Jacks will ensure that a job hazard analysis is performed and
that PPE is available and worn to protect against the identified hazard.
9.1 General Requirements for Critical Lifting Operations
Only high-quality OEM type equipment will be used if it is maintained, designed and
operated to the requirements.
Critical lifts are lifts where failure/loss of control could result in loss of life, loss of or
damage to flight hardware.
All personnel involved in critical lifting operations shall:
 Follow specific written procedures.
 Ensure one qualified person is officially designated as responsible for the safety of
the operations. That person may be an engineer or a task leader.
 Ensure that jacks used to lift or support flight hardware are labeled and tagged.
 Ensure that jacks are operated or used as per OEM instructions.
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 Identify all hazards to include operations, maintenance, equipment, facility,

anticipated loads, and human factors.
9.2 Labeling or Marking Requirements
Personnel working with Jacks shall ensure that Jacks clearly indicate the items below
which can be painted on the Jack or listed;
 The rated load capacity or SWL.
 Hydraulic or air pressure force.
 Type of hydraulic fluid to be used.
10. Use of Lifting gear
Users of lifting gear must be trained. This means that the NPL must provide specific
training in all lifting gear that the personnel will use in their work.
10.1 Procedures Before Use, After Use and Storage of Lifting Gear
In order to ensure a good overview of loose /damage lifting gear that is not in service, the
maintenance department has been established a procedure for storage including the
storage of gear in set places and no mix-ups and incorrect equipment is not chosen.
 Lifting gear must be protected against the weather and other damaging effects
during storage.
 Large pieces of equipment such as spreaders, beam spreaders, control pendants,
load carriers and so on must if it is practicably possible be protected against
damaging effects during storage.
 Lifting gear must be inspected before and after use in respect of correct marking,
possible overloading, wear and tear or damage.
 The user must bring loose /damage lifting gear back to the storage place after use.
 Defective and damaged lifting gear must be marked or made unusable and should
be collected at a definite place.
 A collection place for defective and damaged gear must be clearly marked.
 A qualified person must carry out these checks.
10.2 General Instructions About the Use of Lifting Gear
 The load must always be connected to the crane hook using suitable lifting gear.
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 When using lifting gear made of chain, steel rope or fiber, the lifting capacity will be
calculated in relation to the number of legs, load angle, slinger method and other
factors that change the gear’s capacity
 When the lift is calculated in accordance with a table for symmetrical lifts, the load
is divided almost equally between the parts.
 Use of more than two individual parts in the crane hook makes poor load division
between the parts. Use two shackles in the crane hook as a lifting head in order to
split the load better between the parts.
 A lift is defined as asymmetrical when the load angles are unequal and have a
difference of more than 15° out from the vertical line.
 The strap must be tightened/force applied with care and not jerked.
 Always try to use lifting gear and a slinger method which you are sure prevents the
load or parts of the load from falling down.
 U-lifting should normally be avoided as the load will be loose in the straps and may
slip out in contact with obstacles.
 Lashing/ securing is considered to be a good method for attaching the load to the
hook, but lifting capacity is reduced by 20%.
 When lashing/securing loads consisting of several units, the strap is put “twice
around” the load, alternatively cargo lashings may be used to ensure that parts do
not slip out.
 Place lashing from the same side of the load when lashing pipes, steel
reinforcement bars, materials etc. This means the load is kept together better and
twisting is avoided.
 Individual items can be lashed from each side, if the load can withstand rotation
forces.
 All loads must be placed on grit/surface so that the load doesn’t rest on the lifting
gear when landed. This is to make it easy to pull them out and avoid them getting
squeezed or damaged.
 The surface must be able to hold the weight of the load and the load must be
stable when the crane is offloaded.
10.3 Lifting Gear Made of Fiber
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 Consider the fiber strap’s adverse properties with respect to chemicals, heat,
cutting damages, etc.
 Protection must be used between the straps and any sharp edges of the load.
 The fiber strap’s contact radius must comply with the manufacturer’s instructions.
A sleeve can be placed on the shackle pin to increase the diameter.
 When fiber straps or slings used in the same loop or hook, they must not be on top
of each other.
 When shorting smaller fiber straps only recognized shortening hitches must be
used and it must be ensured that any unused parts of straps cannot get caught on
obstacles during lifting.
 When shortening and joining fiber straps the lifting capacity should be reduced, as
for lashing, by 20%.
 Using knots that are hard to loosen are not allowed for joining and shortening.
 When using fiber straps connected to steel components only component intended
for that use should be used. Refer to the manufacturer’s recommended.
10.4 Chain Sling
 When using a chain sling the parts should be gathered up when driving the crane
without a load. This is to avoid the slinger getting injured by swinging chains when
gripping the sling without a load. Tie a half hitch with one of the chains around the
other. Avoid joins that can get caught on obstructions.
 Avoid twisting of the master link and the chain legs during use.
 Avoid sideways forces on the hook when lashing. This is when the hook is laying
on an edge or when lashing around small diameters.
 Hooks must always take the load at the bottom, not on the tip. Use hooks of a size
that fits the lifting point.
 When lashing a sling with large load angle, the opening of the hook should face
away from the sling’s vertical line.
 Ensure that the shortening hooks/ claws/ mechanisms and lashing hooks with
sliding loops are used in accordance with the manufacturer’s user instructions.
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 When chains are joined by mechanical joining devices, the pre-use inspection
must also focus on corrosion and mobility in the join. Mechanical joining devices
must be lubricated.
10.5 Wire Rope Clamps
 Clamps for steel wire ropes shall normally not be used in lifting gear.
 For other use the manufacturer’s user instructions must be followed.
10.6 Shackles
 When using shackles, it is preferable to use shackles with rotating pin/nut bolt with
cotter pin.
 The shackle’s SWL is estimated from the load between the shackle loop and the
pin.
 Shackles have reduced capacity sideways and some also are reduced in the case
of point load on the pin, refer to the user instructions.
 The load angle between several parts gathered in one shackle can cause
reduction in the lifting capacity, see user instructions.
 Shackles with rotating pin should always be used in permanent suspension and
when coupling equipment and the nut must be secured with a split pin of steel.
 In a simple lift with shackle, locking pins that are easier to operate can be used for
extra security, such as linchpins. Hairpin cotter pins should not be used as they
can be pushed out in contact with obstacles.
 If using a shackle with an eyebolt or a track bolt in the lifting setup, the bolt must
be adequately secured to withstand rotating forces transferred to the shackle pin.
 When the risk of rotating forces on the shackle pin is small, other types of shackles
can be used, but should only be used for “simple lifting operations”, i.e. that the
shackle is opened and closed fully between each lifting operation.
 Shackles where the pin is only locked with a split pin (no threaded design) are not
allowed.
10.7 Eyebolts, Eye Nuts and Swivel Pins
 Check that eye bolts/nuts are of a recognized type and correctly labelled.
 Check that the eye bolt/nut is not modified or damaged.
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 Check that threaded bolt that the eye bolt or nut is to connect to is of similar
quality, thread type and dimensions, and is free of damage.
 Correct fitting is when the eye bolts or the nut’s contact face is fastened against
the surface.
 Ensure that the pull direction after installation is in accordance to the user
instructions and SWL. Feel free to use eyebolts in the joint/swivel finish.
 The goods thickness of the material into which the eyebolt is screwed in must at
least be the same as the bolt diameter.
10.8 Lifting Beams/Spreaders
 Get to know and adhere to the lifting beam’s user instructions.
 Check the marking of the lifting beam and any lifting instructions.
 Check that the top attachment (suspension device) of the spreader bar has the
right dimensions in relation to the weight of the load and the load angle.
 Check that the spreader is correctly assembled and that all screws, bolts and pins
are fitted.
 Ensure that spreader frames are not loaded so that they become warped.
 Avoid load angles between the spreader and the load, since this can cause
adverse torsional forces in the spreader.
 Ensure that shackles and hooks are connected and loaded correctly.
11. Inspection and Maintenance of Lifting Equipment
All lifting equipment must be inspected before and after use and repair/discard the
damage equipment.
Quarterly inspections of lifting equipment is also made during colour coding of tools.
All lifting equipment must be thoroughly examined by competent person after every 12
months. Records of such examinations should be kept for a period of five years. Any
recommendations or repairs identified must be actioned in line with any recommended
time scales as soon as possible.
All lifting equipment must be maintained by a competent person in line with manufactures’
instructions and records kept for 5 years.
63
PORTABLE HAND AND POWER Revision No 01
TOOLS / EQUIPMENT SAFETY Revision Date 13-10-2018

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1- Purpose
This procedure will ensure the safety of employees working with portable hand and power
tools/equipment.
2- Scope
This procedure applies to all NPL and Contractor staff who may use portable hand and
power tools/equipment during work. Staff must be able to use portable hand and power
tool/equipment safely and shall comply with manufacturer guidelines.
3- Definitions
3.1 Hand Tools - Tools that are manually operated and powered by human force such as
screw drivers, pliers, wrenches, and cutting shears, etc.
3.2 Portable Power Tools - Power tools that are hand held, manually operated, and
powered by electricity, air, gasoline, diesel, or explosion, such as circular saws, sanders,
drills, reciprocating saws, air wrenches, air grinders, air fasteners, chainsaws, etc.
4- Responsibility
4.1 HOD HSE:
HOD HSE is responsible for;
 Periodically evaluating the procedure implementation that portable hand and power
tools safety measures are in place.
 Reviewing hazards associated with hand and portable power tools during workplace
inspections.
 Reviewing and updating the hand and portable power tools procedure.
 Ensuring the proper use of PPEs.
 Training of employees about the safety hazards involved in hand and power tool
operation.
 Ensure regular tool inspection and calibration process and follow-up of repairing of
damaged or unhealthy tools.
 Maintain inspection, maintenance and repairing record of portable hand and power tools.
4.2 Head of Department:
HODs are responsible for:
 Ensuring that all portable hand and power tools and other hand-held equipment used
at NPL are maintained properly, healthy and free from defects.
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 Ensuring that all tools are being used in accordance with OEM’s recommendations
and prudent engineering practices.
 Ensuring that all users are trained and in applying this procedure.
 Ensuring the proper use of PPEs.
 Establishing a procedure for control of tools such as a check-out system at tool store.
 Providing proper storage facilities in tool store and on job site.
 Determine the need for special tools for more safe work by identifying the hazards
associated with the job or recommended in technical bulletin/ service letters.
4.3 Tool Store Handler
Designated person is responsible for:
 Ensuring that safety guards and switches on portable power tools are healthy and
functioning properly.
 Ensuring unsafe, faulty, damaged portable hand and power tools are not issued for
working.
 Tagging off defective/damage tools and compliance for non-issuance immediately.
 Performing quarterly inspection and colour coding of tools.
 Maintaining the record of repaired, damaged and missing tools.
4.4 Employees:
Employees are responsible for:
 Attending required training of procedure
 Inspecting portable hand and power tools and equipment for defects or hazards
prior to use.
 Report any defects in tools to Tool Store Handler immediately.
 Anticipating all work hazards.
 Use appropriate PPEs.
 Following all safety guidelines for the use of portable hand and power tools according
to manufacturer’s instructions.
5- General Safety Requirements
The following will help to prevent hazards associated with the use of portable hand and
power tools:
 Keep all tools in good condition with regular inspection and maintenance.
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 Use the right tool for the job.

 Inspect each tool for healthiness before use.
 Never use damaged tools - take damaged tools out of service immediately.
 Operate tools according to the manufacturers’ instructions.
 Use the proper personal protective equipment (PPEs).
5.1 Safety Guards
The exposed moving parts of power tools shall be guarded. Safety guards never be
removed when a tool is being used. Belts, gears, shafts, pulleys, sprockets, spindles,
drums, flywheels, chains, or other reciprocating, rotating, or moving parts of equipment
must be guarded.
Machine guards must be provided to protect the operator and others from the following:
 Point of operation
 In-running nip points
 Rotating parts
 Flying chips and sparks
5.2 Personal Protective Equipment (PPE)
Employees who use hand and power tools and are exposed to the hazards of noise,
vibration, falling, flying, abrasive, and splashing objects, or to harmful dusts, fumes, mists,
vapors, or gases must be provided with the appropriate personal protective equipment.
The following considerations should be evaluated at a minimum in the selection and use
of PPE when using hand and portable powered tools:
 Safety glasses or goggles must be worn at all times when using hand and powered
tools;
 A face-shield may be used in addition to safety glasses or goggles to protect the
face and neck;
 Composite-toe leather shoes should be worn while working with power tools to
prevent injury from dropped tools; and
 Hearing protection is recommended when using power tools.
Before working with hand and power tools consult the hazard evaluation for the job you
will be conducting to determine if additional PPE will be needed.
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6- Hand Tools
Hand tools are tools that are powered manually. Some examples of hand tools include
anvils, axes, chisels, files, hammers, hand boring tools, planes, pliers, punches, saws,
scissors, screw drivers, tin snips, wrenches etc.
The primary hazards encountered when using hand tools include striking or contacting parts
of the body with the hand tool or the work piece flying off the tool. The most common injuries
from the use of hand tools are:
 Laceration or cut
 Contusion or bruise; and
 Eye injury
These injuries are generally caused by:
 Not wearing appropriate PPEs
 Using the wrong tool for the job
 Improper use of the tool
 Failure to inspect the tool
 Improper storage and transportation of the tool
 Defective tools.
To prevent injury, follow the guidelines listed below:
 Hand tools shall be used for their intended purpose. For example, if a screwdriver is
used as a chisel, the tip of the screwdriver may break and fly off, hitting the user or
other employee.
 Inspect tools for damage prior to use.
 Hand tools shall be maintained in good condition. For example, wooden handles on
tools, such as a hammer or an axe, shall be tight and free from splinters or cracks.
 Bent screwdrivers or screwdrivers with chipped edges to be avoided for use.
 Always secure tools such as knives, saw blades, etc. from aisle areas and other
employees working in close proximity.
 Knives, cutters and scissors must be sharped; dull tools can cause more hazards than
sharp ones.
 Cracked saw blades must be removed from service.
 Wrenches must not be used when jaws are sprung to the point that slippage occurs.
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 Impact tools such as drift pins, wedges, and chisels must be kept free of mushroomed
heads.
 Iron or steel hand tools may produce sparks that can be an ignition source around
flammable substance. Spark-resistant tools made of non-ferrous materials should be
used where flammable gases, highly volatile liquids, and other explosive substances
are stored or used.
 Keep the work area and tools clean. Dirty, greasy tools and floor may cause
accidents.
 Tools shall be stored in a dry secure location.
 Carry and store tools properly. All sharp tools shall be carried and stored securing the
sharp edges.
 Do not carry sharp tools in pocket.
 Wear the proper personal protective equipment (PPEs).
7- Power Tools
Power tools must be equipped with guards and safety switches. They can be hazardous
when used improperly. Types of power tools are determined by their power source: electric,
pneumatic, liquid fuel, hydraulic, and powder-actuated.
To prevent hazards associated with the use of power tools, workers should observe the
following general precautions:
 Read the OEM manual to understand the tool’s proper applications, limitations,
operation and hazards.
 Never carry a tool by the cord or hose.
 Never yank the cord or the hose to disconnect it from the receptacle.
 Keep cords and hoses away from heat, oil, and sharp edges.
 Ensure tools are properly grounded; use Ground Fault Circuit Interrupter (GFCI) for
corded tools.
 Disconnect tools when not in use, before servicing and cleaning and when changing
accessories such as blades, bits and cutters.
 Keep all people not involved with the work at a safe distance from the work area.
 Secure work with clamps or a vise, freeing both hands to operate the tool.
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 Avoid accidental starting. Do not hold fingers on the switch button while carrying a
plugged-in tool.
 Maintain tools sharpness and cleanliness.
 Be sure to keep good footing and maintain good balance when operating power tools.
 Wear proper PPE. Loose clothing, ties, or jewelry can be caught in moving parts.
 Inspect tools for damage before each use. Remove all damaged portable electric tools
from use and tag them: “Do Not Use.”
7.1 Electric Tools
The main hazard of electrical tools is electrocution. Electricity can cause burns, shocks
and death. The factors that increase the risk of electrocution while using electrical
portable power tools are:
 Faulty power cords

 Misuse of power cords
 Failure to use GFCI.
 Improper grounding;
 Improperly insulated tools
 Working around wet surfaces etc.
To prevent the user from electrocution, electric tools shall have a three-wire cord with a
ground and be plugged into a grounded receptacle, be double insulated, or be powered
by a low voltage isolation transformer to protect from burns and shocks.
Three-wire cords contain two current carrying conductors and a grounding conductor.
When an adapter is used to accommodate a two-hole receptacle, the adapter wire must
be attached to a known ground. If such practice cannot be avoided than double-insulated
tools will be used to provide protection against electrical shock without third-wire
grounding.
The following general practices shall be followed when using electric tools:
Do Not:
 Energize the tool before use.

 Contact with running/moving parts of an electrical tool.
 Lay electrical cords over sharp edges or through doorways or holes in walls.
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 Use an electric tool in an area where flammable gases or vapors may be present
unless the tool is designed for that application.
 Use any tool that is sparking or appears to be unhealthy.
 Use any tool with a damaged cord or exposed wiring.
 Use electric abrasive tools if the grinding wheel, buffer, or wire brush wobbles or
vibrates excessively
 Use excessive force on saws or drills to cut through hard materials
 Use any tool unless the blade or bit is securely tightened.
 Use any tool with the blade guard removed or rendered unworkable.
7.2 Pneumatic Tools
Pneumatic tools are powered by compressed air and include chippers, drills, hammers,
and sanders. Some hazards associated with pneumatic tools include noise, vibration,
fatigue, and strains. Additional hazards are described below:
 The greatest hazard is being hit by one of the tool’s attachments or by a fastener used
with the tool. Eye protection must be worn for employees working with pneumatic
tools.
 Pneumatic tools must be checked to ensure that they are fastened securely to the air
hose to prevent them from becoming disconnected. A short wire or positive locking
device attaching the air hose to the tool must also be used and will serve as an
additional safeguard.
 Screens must be set up to protect nearby workers from being struck by flying
fragments around chippers, riveting guns, staplers, or air drills.
 Compressed air guns should never be pointed toward anyone. Workers should never
“dead-end” them against themselves or anyone else.
 Don’t horseplay with air operated tools.
7.3 Liquid Fuel Powered Tools
Some tools are fuel powered and are dangerous because of the potential for burns,
explosion, and fire. The most serious hazard with fuel powered tools comes from fuel
vapors that can burn or explode and exhaust emissions that can create a hazardous
atmospheric condition.
Observe the following when working with gasoline, diesel and other mixed fuel tools:
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 Fuel shall be stored and transported in approved flammable liquid containers,

according to proper procedures for flammable liquids.
 Before filling the tank for a fuel powered tool, turn off the engine and allow it to cool to
prevent accidental ignition of vapors.
 Effectively ventilate an enclosed area or don the appropriate PPE to avoid inhalation
of carbon monoxide; and
 Ensure access to fire extinguishers.
When using these tools, inspect them for:
 A constant pressure throttle/control that will shut off the power when the pressure is
released.
 A handle or trigger guard or lock to prevent accidental activation of the tool
 Fuel leaks.
 Muffler condition.
 Spark plug and wire connection condition.
Gasoline/diesel powered tools may not be used:
 In confined spaces.
 In tunnels/trenches
Gasoline powered tools may be used inside buildings only after ensuring proper
ventilation
7.4 Hydraulic Power Tools
The fluid used in hydraulic power tools must be an approved fire-resistant fluid and must
retain its operating characteristics at the most extreme temperatures to which it will be
exposed.
 The manufacturer’s recommended safe operating pressure for hoses, valves, pipes,
filters, and other fittings must not be exceeded.
 All jacks—including lever and ratchet jacks, screw jacks and hydraulic jacks—must
have a stop indicator, and the stop limit must not be exceeded. Also, the
manufacturer’s load limit must be permanently marked in a prominent place on the
jack, and the load limit must not be exceeded.
 A jack should never be used to support a lifted load. Once the load has been lifted, it
must immediately be blocked up. Place a block under the base of the jack when the
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foundation is not firm, and place a block between the jack cap and load if the cap
might slip.
To set up a jack:
 The base of the jack shall rest on a firm, level surface;
 The jack must be correctly centered;
 The jack head must bear against a level surface; and
 The lift force must be applied evenly.
 All jacks must be lubricated regularly.
 Each jack must be inspected according to the following schedule:
 for jacks used continuously or intermittently at one site—inspected at least
once every 6 months,
 for jacks subjected to abnormal loads or shock— inspected before use and
immediately thereafter.
7.5 Operating Controls and Switches
The following hand-held power tools must be equipped with a constant-pressure switch or
control that shuts off the power when pressure is released:
 Drills
 Tappers
 Fastener drivers
 Horizontal, vertical, and angle grinders with wheels more than 2 inches in diameter
 Other similar tools.
These tools also may be equipped with a “lock-on” control, if it allows the worker to also
shut off the control in a single motion using the same finger or fingers.
The constant-pressure control switch should be regarded as the preferred device.
7.6 Powder-Actuated Tools
Powder-Actuated Tools must be operated only by specially trained operators. Both
types of powder-actuated tools, e.g., low-velocity and high-velocity, use explosives to
drive studs, pins, or fasteners into a work surface.
Operators shall take the following precautions;
 These tools shall not be used in an explosive or flammable atmosphere.
 The tool shall not be loaded until ready for use.
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 A loaded tool shall not be left unattended.

 Hands shall be kept clear of the barrel end.
 Suitable PPE will be used.
 Powder-actuated tools must be designed for varying powder charges so that the
operator can select a powder level necessary to do the work without excessive
force.
 If the tool develops a defect during use, it shall be tagged and taken out of service
immediately until it is properly repaired.
 Powder-actuated tools shall not be pointed at other people.
 Driving into materials that are easily penetrated must be avoided, unless such
material is backed by a substance that will prevent the pin or fastener from passing
completely through and create a flying-missile hazard on the other side.
 Fasteners must not be driven directly into materials such as brick or concrete
closer than 3 inches from the unsupported edge or corner, or into steel surfaces
closer than 1/2 inch from the unsupported edge or corner, unless a special guard,
fixture, or jig is used.
 Fasteners must not be driven through an existing hole unless a positive guide is
used to secure accurate alignment.
 No fastener must be driven into uneven surface caused by an unsatisfactory
fastening.
 All tools must be used with the correct shield, guard, or attachment recommended
by the manufacturer.
 The tool must be inspected and repaired in accordance with the manufacturer’s
specifications.
8- Transporting
When transporting portable hand and power tools at and from job site, observe the following
safety guidelines:
 Do not carry portable power tools by their electric cord, airline or hydraulic hose.
 Transport the tool in it carrying case if provided.
 Do not carry sharp or pointed tools with the edge or point upward and toward the
body.
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 Place all tools in a tool box if available.

 Never carry tools in a manner that obstructs vision.
 Never give sharp or pointed tools to another person with the sharp end toward the
receiver.
 Never hand another person a portable power tool that is in motion or operation.
 Never throw any tools at or towards another person.
9- Storage
Tools will be stored properly when they are not in use or will not be used within a short period
of time. Below guidelines will be followed for storing the tools/equipment.
 Store sharp tools in a specially designated cabinet or cupboard, with a blade guard in
place.
 Prior to storage, de-energize tools such as removing air pressure, removing loads and
de-pressurizing hydraulics.
 For Power-Actuated and Pneumatic tools, make sure there are no loaded fasteners in
place while changing the load, disconnecting/connecting an air-line, or storing.
 Hydraulic fluid must not be added to jacks or other support tools while they are in use
and under stress.
 Keep batteries and battery chargers away from heat sources and potentially wet
areas. Never throw a battery into a fire. Follow equipment OEM’s safety tips when
handling batteries.
10- Inspections
10.1 User Inspections:
The user will visually inspect all hand and portable power tools before use to ensure
that the tools are in safe and usable condition. All damaged and/or defective tools will
be immediately reported to the Tool Store Handler.
10.2 New and Rented Equipment Inspections:
Prior to use, all new or newly arrived tools will be inspected to ensure its safe working
condition. For any newly purchased or rental tool, make sure the proper PPE is
available for use.
10.3 Inspection Cycle:
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Inspection will be performed on regular/annual basis for verifying the proper operation
as per OEM operating guidelines and remove unsafe tools/equipment from use.
Tools will be used after repair. Repairing and maintenance of tools will be performed
by competent person.
11- Trainings
All employees shall be trained for proper use of hand and power tools and other hand-held
equipment prior to application in field. Employees shall be trained in the following:
 Selecting the right tool for the job
 Hazards and their controls
 Common causes of injury
 Safety precautions
 Personal Protective Equipment
 Inspection/Maintenance
 Safe operation.
Employees shall be retrained as necessary to maintain their understanding and knowledge
on the safe use of hand and power tools and other hand-held equipment.
75
PERSONAL PROTECTIVE Revision No 02
21-06-2022
EQUIPMENT Revision Date
21-06-2022
Last Review
1. Purpose
The Personal Protective Equipment (PPE) Program is designed to protect NPL people from the
risk of injury by creating a barrier against workplace hazards. The PPE Program is intended to
be used in conjunction with good engineering, administrative controls and work practices, and
should not be viewed as a replacement.
2. Scope
The Personal Protective Equipment Procedure is applicable to Nishat Power Limited and all people
(including contractors) conducting work for NPL.
3. Definitions
For the purpose of defining the words or phrases in this section, the following definitions shall be
used:
3.1. Plant
Any and all areas, locations, sites, buildings associated with the operation of the Nishat Power
Limited and surrounded by the boundary wall of Nishat Power Limited.
3.2. Personal Protective Equipment (PPEs):
Personal protective equipment is worn to reasonably protect a person from injury and lose of
any body part.
PPEs shall include (but not be limited to):
a. Hard Hat with chin strap
b. Safety footwear
c. Hearing protection
d. Safety Glasses or Safety Goggles (as per requirement of work permit or as & when required)
3.3. PPE free areas:
Those areas of the plant where there is no requirement for the use of PPE.
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3.4. Hard Hat Free Areas:
Those areas of the plant where there is no requirement for the use of a Hard Hat
3.5. Safety Glasses Free Zone:
Those areas of the plant where there is no requirement for the use of Safety Glasses.
3.6. Designated Hearing Protection Area:
Those areas of the plant where hearing protection (Ear plug or Ear Muff) are required. Hearing
protection shall be used in equal or greater than 85 dB sound level area.
3.7. Specialized Personal Protective Equipment (SPPE):
Personal equipment worn to reasonably protect a person when there is a potential for splashes,
fumes, burns, flash fires, exposure to high dust levels, chemical vapors or other dangers. SPPE
will include (but not be limited to):
(a) Respiratory Protection
i. Dust Masks
ii. Full Face Respirators (with cartridges)
iii. Self-contained Breathing Apparatus (SCBA)
(b) Chemical Protection
i. Full face shield
ii. Chemical resistant suit
iii. Chemical resistant apron
iv. Chemical resistant gloves
(c) Flame Retardant Clothing
(d) Welding Protection
i. Welding hood/helmet
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ii. Welding gloves
iii. Welding apron
(e) Full face shields
(f) Safety Goggles
(g) Full body harness with shock observer land yard.
4. Use of PPE
The Personal Protective Equipment is to be supplied and used at work wherever there are risks
to health and safety that cannot be adequately controlled in other ways. Follow the Risk
Assessment Procedure for identification and evaluation of hazards in the workplace for which
PPE is an appropriate control measure.
5. Selection of PPE
To allow the right type of PPE to be chosen, the different hazards in the workplace need to be
considered carefully. This will enable an assessment to be made of which types of PPE are
suitable to protect against the hazard and for the job to be done. The following factors should be
considered when assessing the suitability of PPE:
i. All protective devices used should be of an APPROVED type and should be upgraded to be
consistent with new technology, as appropriate.
ii. Is it appropriate for the risks involved and the conditions at the place where exposure to the
risk may occur?
iii. Does it prevent or adequately control the risks involved without increasing the overall level of
risk?
iv. Can it be adjusted to fit the wearer correctly?
v. Has the state of health of those who will be wearing it been taken into account?
vi. What are the needs of the job and the demands it places on the wearer?
vii. If more than one item of PPE is being worn, are they compatible?
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6. Issuance/Distribution of PPE
PPE is to be issued to those employees who are required to wear. Number of PPE shall be
issued to each employee is following;
• One pair of safety shoes per year

• 2 Nos of boiler suites per six months
• One no of ear muff per year
• Safety Glasses, hard hat and SPPE (as & when required).
1. If for any reason additional PPE are needed, He can get required PPE from HSE department
after his Manager approval.
2. If PPE is inadvertently destroyed as the result of assigned duties, other than through the
employee’s negligence, the PPE may be replaced at the company’s expense, at his Manager
and HSE officer’s discretion.
3. Employees reporting for work without PPE shall not be permitted to work and disciplinary
action will be taken as per HR guideline, which will be decided by the line manager/plant
management.
4. SPPE shall be issued on demand as per requirement of department.
7. Maintenance of PPE
Personal protective equipment must be maintained in good working condition. Proper care and
storage, along with routine inspections, will ensure that PPE is in good working condition.
Damaged or defective PPE must be properly discarded. Employees should be trained on how to
properly maintain and inspect PPE for defects and damage. Keeping the PPE cleaned and well
maintained is generally the employee’s responsibility. Without proper maintenance the
effectiveness of PPE cannot be assured. Protective devices must be properly cleaned,
maintained, stored and inspected on a regular basis. Proper PPE maintenance includes –
a. Cleaning.
b. Routine inspections.
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c. Repair. (if possible)
d. Proper storage.
8. Clothing
i.It is the responsibility of all NPL persons to wear the correct safety garments/boiler suits to
enable them to carry out their work.
ii.Loose fitting clothes (examples: Shalwar Qamees, oversize coats, scarves, or other clothing
that may be caught in rotating or moving equipment) are not to be worn in the plant PPE area.
iii.Shirts without sleeves, tank tops, shorts, open weave mesh shirts, etc. are not acceptable for
working inside the plant.
9. PPE Free Areas
The following areas of the plant have been declared as PPE free areas:
a) Gate Office
b) Administration Building
c) Project Building
d) Prayer Room/Area
e) Offices
f) Open area beside/behind the project building
g) Control Room and associated Kitchen and dining hall.
h) Break/Rest rooms
i) Kitchens
j) Toilets/Wash Room
k) Decanting staff and tanker lorry drivers rest area
l) Chang Rooms
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m) The Passage marked in engine hall “B”
n) The passage leading to decanting staff rooms from main road (marking area).
o) Grassy lawns/ground includes”
I.Plants nursery Area

II.Beside day tank storage yard
III.Open areas behind new warehouse
p) he Roads (Yellow Highlighted)
I.Leading from security gate to Workshop

II.Between 132kv Grid Station and Engine Halls (A & B).
III.West south road up to cooling tower Engine hall “A” corner.
NOTE: When performing any maintenance work in the above PPE Free areas, PPE must
be worn.
10. Hard Hats (Safety Helmet)
Hard hats must be worn at all times in the plant to avoid the head injury from falling objects and
electrical shock unless designated as a Hard Hat Free area.
Hard Hat Free Areas:
i. PPE Free areas
ii. Maintenance Rest Room (fuel shop).
iii. I&E shop,
iv. Labs
v. Ware house
vi. Workshop and washing shed
vii. The area marked in fuel treatment building (Aisle marking).
viii. MV Room (excluding cable trench area)
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ix. Other areas designated as Hard Hat Free Areas (as advised by the HSE Committee and
approved by the Plant Manager).
NOTE: when performing work at height and overhead crane operation in the above hard
hat free areas, hard hat must be worn.
11. Safety Glasses
Protective equipment for the eyes is required as the employees are exposed to various hazards
which may cause eyes injuries.
Some operational hazards and their sources are given below;
• Injurious gases, vapors and liquids – Workers handling chemicals and doing welding.
• Dusts or powders, fumes and mists – Some sources are scaling, light grinding, spot welding
and wood working; they can also include very small particles.
• Flying objects or particles – Some sources include caulking, chiseling and grinding,
hammering and metal working.
• Thermal and radiation hazards such as heat, glare, ultraviolet and infrared rays – Sample
sources are welding, metal cutting and furnace tending.
• Electrical hazards – Sample sources are arcing and spark
Note: Safety goggles may be worn in place of safety glasses. Staff (NPL & Contractor)
performing any chipping, grinding, drilling, polishing, milling, lathe-turning work, soot pit
cleaning, water washing, chemical handling, and cleaning of C/A filters with oil spray or any
other job work permit should demand shall wear eye protection.
Do not wear contact lenses while electric arc welding.
12. Safety Footwear
Foot protection shall be used by the employees who are working in areas that have the potential
for injury from:
a. Falling or rolling objects
b. Objects that could pierce the sole of a shoe
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c. Potential electrical hazards
i. The minimum requirement for NPL people and contractors to enter PPE area is a full-toed
shoe having an “upper” of complete leather construction (no nylon or canvas is allowed
anywhere on the shoe).
ii. Maintenance staff is required to wear steel-toed shoes (or equivalent). I&E staff must wear
safety shoes with insulated soles. It is recommended that those people working inside the
plant operational area wear a steel-toed safety shoe (or equivalent) as a minimum.
iii. For safety reasons, the following types of shoes are not acceptable for NPL people in the
plant: tennis or jogging shoes with canvas or nylon tops, chappals, thongs, sandals, or high
heels.
13. Hearing Protection
Hearing protection devices are required in designated hearing protection areas and for
operations involving individual exposure to elevated noise levels.
14. Hand Protection
i. Personnel are required to wear hand protection (gloves) when exposed to potential hand
injuries. Employees will be required to use appropriate hand protection to minimize exposure
to hazards such as chemical absorption through the skin, severe lacerations or cuts,
punctures and chemical or thermal burns.
ii. Personnel must use protective leather gloves for welding and cutting work.
iii. Personnel handling chemicals or other potentially hazardous materials are required to use
the rubber or acid handling gloves.
iv. Personnel working with rigging wire and chains are required to use cotton gloves.
I.Personnel working on live electrical system are required to use Electrical gloves
according to potential hazard.
II.The company will maintain gloves in stock for use by employees. Gloves will be issued
as necessary.
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III.Personnel are required to take care of gloves to maximize their useful life.
IV.The company will provide suitable hand cleaners to personnel.
V.Personnel are required to maintain their hands and nails in a clean condition. Oil, fuel,
grease, and other solvents can cause dermatitis or other skin problems.
15. Specialized Personal Protective Equipment (SPPE)
Specialized Personal Protective Equipment must be worn as required in designated areas or in

the performance of work where there is a potential for splashes, fumes, burns, flash fires,
exposure to high dust levels, chemical vapors or other dangers.
16. Respiratory Protection
Respiratory protection is required in designated areas and for operating conditions involving
individual exposure to high dust levels or potentially harmful vapors.
17. Training
Training must be given to any employee who is required to use PPE. Training can be done in
group presentations; training is a good idea to refresh employees’ knowledge and awareness of
the importance of using protective equipment. Training must be conducted for new employees
required to wear PPE or current employees who may be reassigned to a new job function that
requires different PPE.
Prior to introducing a new type of PPE:
Train employees when you change the type of PPE in use. This training must be done before
the employees use the new PPE.
Evaluate the program annually to determine its effectiveness in preventing injury or illness.
All people associated with the use of PPE (including supervisors of people using PPE should be
trained on its use, care, limitations, evaluation, and maintenance on a regular basis.
Written records should be kept of the names of persons trained, the type of training provided,
and the dates when training occurred. Training records should be maintained for at least 3
years.
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References:
• OSHA Standard 29 CFR 1910.132-1910.138 – Personal Protective Equipment
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86
FIRE PROTECTION SYSTEM Issue Date 01-01-2016

Revision No 03
INSPECTION, TESTING AND Revision Date 21-06-2022
MAINTENANCE Last Review 21-06-2022

1. Objective
This procedure provides guidance to ensure that the main firefighting and detection
systems are operational and fully tested in order to minimize the risk of fire and fire
related hazards at the plant.
2. Scope
This procedure applies to inspection, testing and maintenance of fire prevention and
extinguishing equipment at the plant which may directly affect the quality of operation
and maintenance services of NPL.
3. Definitions
3.1. Hose Nozzle. A device intended for discharging water for manual suppression or
extinguishment of a fire
3.2. Hydrostatic Test. A test of a closed piping system and its attached appurtenances
consisting of subjecting the piping to an increased internal pressure for a specified
period of duration to verify system integrity and leak rate.
3.3. Inspection. A visual examination of a system or portion thereof to verify that it appears
to be in operating condition and is free of physical damage.
3.4. Recharging means replacement of the extinguishing agent including the expellant for
certain types of extinguishers.
3.5. Repair Restore to sound working condition or to fix damage.
3.6. Sprinkler System. A system that consists of an integrated network of piping designed
in accordance with fire protection engineering standards that includes a water supply
source, a water control valve, a water flow alarm, and a drain and is commonly
activated by heat from a fire, discharging water over the fire area.to determine if it
meets requirements.
3.7. Test. The operation of a device to verify that it is functioning correctly as per OEM
guidelines.
3.8. Foam Fire Extinguishing System: A system consisting of water supply, foam supply,
proportionating equipment, foam makers, discharge devices and other allied
equipment for the purpose of adequately distributing foam over a hazard is called a
Foam Fire Extinguishing System.
4. Responsibility
4.1. Mechanical Department
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Maintenance department will perform;

• repair / maintenance of fire system devices (valve, pipelines, etc.) that are not
working properly.
• routine maintenance of fire pumps and diesel engine as per OEM recommendations.
4.2. EHS Department
EHS department will;
• perform general oversight of this program.
• perform routine inspection / testing and verify proper operation of fire equipment and
will keep its record.
• contact with operation, maintenance and electrical teams for repair / maintenance if
any equipment is not functioning properly.
4.3. Operation Department
Operation department (ERT) will;
• perform general oversight of fire protection equipment / device.
• note the abnormalities in fire systems and inform to maintenance departments for
repair / maintenance.
• perform routine operation / inspection of fire pumps and maintain its record.
• Coordinate with HSE officer in inspection, testing and repairing of fire system.
4.4. Electrical Department
Electrical department will;
• perform routine inspections of fire detection system.
• note the abnormalities in fire systems and inform to maintenance departments for
repair / maintenance.
• perform routine inspection of electrical appliances and instruments installed at fire
prevention and extinguishing system.
• Coordinate with HSE officer in inspection, testing and repairing of fire system.
4.5. NPL Staff
• Fire prevention is part of the job of everyone therefore NPL staff will perform the
following;
• knows the location of the firefighting and detection units in the building and ensure
that the emergency units / equipment is clear of obstructions.
• ensure that appropriate signage for the stations is visible.
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• maintain the proper housekeeping.

• Everyone must help to keep the work area clutter-free and safe from other fire
hazards, such as improperly used or stored chemicals.
• do not use any firefighting equipment / services except in firefighting or fire
prevention.
• Do not tamper the fixed or portable fire extinguishers, devices or the fire warning
system.
5. Fire Protection System (Suppression and Detection)
For prevention and detection of fire below equipment / systems are available;
5.1. Fire Suppression System
1. Portable Fire Extinguisher
2. Fire Hydrant / Standpipe / Water Monitor
3. Fire Hose and Hose Box
4. Fire Nozzle
5. Fire water lines / valves
6. Fire Pumps
7. Water Sprinkler System
8. Foam Firefighting System
5.2. Fire Detection System
1. Optical heat / smoke detectors & Panels
2. Manual call point / break glass unit
3. Vigilon panel
6. Portable Fire Extinguisher
6.1. General Requirements
Based on the combustible materials involved and the kind of extinguisher needed to
put them out, fire is classified in four classes. The four classifications are A, B, C and
D.
Class A This type of fire is the most common. The combustible materials are wood,
cloth, paper, rubber and plastics. The common extinguishing agent is water,
but dry chemicals are also effective. Do not use carbon dioxide extinguishers
and those using sodium or potassium bicarbonate chemicals on these fires.
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Class B Flammable liquids, hydrocarbons, gases and greases create class B fires.
The most common extinguisher to use is dry chemical. Also foam and carbon
dioxide extinguishers are used.
Class C Because Class C fires are electrical fires, use a non-conducting agent to put
them out, for example, carbon dioxide and dry chemical extinguishers. Never
use foam or water type extinguishers on these fires.
Class D Fires arising from combustible metals, such as magnesium, titanium,
zirconium and sodium are categorized as class D fires.
These fires require specialized techniques to extinguish them. None of the common
extinguishers should be used since they can increase the intensity of the fire by adding
an additional chemical reaction.
Use dry powder extinguishers specific for the metal hazard present on these fires.
6.2. Types of Fire Extinguisher
Based on the nature of fire and combustible materials, NPL has maintained three types
of fire extinguishers; Dry Chemical Powder (DCP), Carbon Dioxide (CO2) and AFFF
Foam. Approximately 125 Nos of fire extinguishers are placed throughout the plant
premises and hazard of fire in particular area. (Appendix A, Fire Extinguisher
Installation Plan).
6.3. Inspection
Portable Fire Extinguishers will be inspected on monthly basis.
The following items will be checked on all fire extinguishers at the facility and
documented. If there is a fire extinguisher on site that does not pass the monthly
inspection, remove from its site and will send for recharging, maintenance of its parts.
Fresh/refilled fire extinguisher will be placed at empty location from safety stack.
Following will be checked during monthly inspection;
• Discharge hose/nozzle is in good shape and not clogged, cracked, or broken.
• Mounted in an easily accessible place, no debris or material stacked in front of it.
• Safety pin is in place and intact. Nothing else should be used in place of the pin.
• Label is clear, fire extinguisher type and operational instructions can be read easily.
• Handle is intact and not bent or broken.
• Fire extinguisher is clean, paint intact and its body is without rust. Rusty fire
extinguisher shall be repaint.
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• Pressure gauge is in the green and is not damaged. If gauge is in the red it shows
fire extinguisher need to be recharged.
• Extinguisher was turned upside down at least three times (shaken)
• The location of the extinguisher is easily identifiable. (signs)
• Operation instructions are placed and clearly readable.
At least monthly, the date the inspection was performed and the initials of the person
performing the inspection will be recorded on a tag attached to the fire extinguisher,
on an inspection checklist maintained on file, or in an electronic method that provides
a permanent record.
6.4. Maintenance
Fire extinguishers will be subjected to maintenance as and when required, at the time
of hydrostatic test, or when specifically indicated by an inspection.
In maintenance a thorough examination of the three basic elements of a fire
extinguisher will be done:
• Mechanical parts
• Extinguisher agent
• Expelling means
At the time of the maintenance, the tamper seal of rechargeable fire extinguishers will
be removed by operating the pull pin or locking device. After the applicable
maintenance procedures are completed, a new tamper seal will be installed.
Each fire extinguisher maintenance record will be maintained.
6.5. Recharging
All rechargeable-type fire extinguishers will be recharged after any use or as indicated
by inspection or when performing maintenance.
After recharging, a leak test will be performed.
• Water type fire extinguisher will be recharged after every 12 months.

• AFFF (aqueous film-forming foam) fire extinguishers will be recharged at least once
every three (3) years.
• Carbon Dioxide (CO2) fire extinguishers will be recharged at least once every five
(5) years.
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• Dry Chemical Powder (DCP) fire extinguishers will be recharged at least once every
five (5) years.
6.6. Hydrostatic Testing
• Hydrostatic testing will be performed by a competent person of company.
• A hydrostatic test will always include both an internal and external visual
examination of the cylinder.
• Test activity will be performed inhouse or by third party those have all these facilities
as stated above.
• Hydrostatic testing of gas fire extinguishers shall be performed after every five years
and after any body repair.
• Hydrostatic testing of Dry Chemical Powder fire extinguishers shall be performed
after every twelve years and after any body repair.
7. Fire Hydrant / Standpipe / Water Monitor
The inspection of fire hydrants is critical to determine the readiness of the hydrants to
provide water at fire emergencies. The inspection will verify the location, accessibility,
proper mechanical operation, and water flow from the hydrant. In NPL regarding to the
fire water requirement of area, “46 No’s” of fire hydrants/ standpipe/water monitor/
hose reel are installed for cater fire.
7.1. Inspection
Each fire hydrant / monitor will be inspected on monthly basis. In inspection following
parameters will be checked and documented;
• Easily accessibility, no material stacked in front of it therefore front and sides should
be clear at least a 3-feet.
• Remove all caps and inspect valve coupling and seal for damage or any obstruction.
Replace valve gasket if necessary.
• Check leaks in outlets or at top and cracks in hydrant barrel / pipeline / valve
spindle.
• Paint should be in good condition. Hydrants with chips or rust showing should be
coated with aerosol paint.
7.2. Operational Test and Maintenance
In operation test following activities will be performed and rectified the problem if any
abnormality is observed;
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• Place fire nozzle at valve opening and then slowly open and close valve until it
operates properly.
• During flushing test of hydrant valve seat and water pipeline, slowly open the valve
to discharge the water until clean water is passing through the valve.
• Close valve, turn on hydrant to verify valve shuts tight.
7.3. Hydrant Flow Test:
The purpose of this test is;
• To determine the rate of flow available at certain residual pressure at various
hydrants for firefighting purposes.
• To determine the obstacles, extra-ordinary resistance or loss of pressure in the
system.
• This test will be conducted after every 5 years.
8. Fire Hose and Hose Box
In NPL hose boxes are installed along with each fire hydrant/monitors. The number of
fire hoses in boxes is made according to area that will be covered by this particular fire
hydrant.
8.1. Inspection:
Hose box will be inspected on monthly basis and following will be observed;
• Overall condition for corroded or damaged parts.
• Difficulty in opening the cabinet door.
• Door lock.
• Cracks / Broken door glazing.
• All stored items (hose. nozzles, “F” Key etc.) are present in healthy condition.
• Cleaning of box and existing fire hoses.
• Physical obstructions in front of hose box.
In service or stored fire hoses will be physically inspected on annually basis.
In inspection of fire hose following shall be checked;
• Decay, cuts, abrasions and deterioration evidence.
• Condition of male and female coupling.
• Female coupling gaskets either it’s missing or deteriorated.
• Hose is not connected to the nearby hydrant valve.
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The interior of the hose from each end will be visually inspected for any physical signs
of liner delamination. If the liner shows signs of delamination, the hose will be
condemned.
Repairing or replacement of damage hoses will be made after each inspection. Record
of each inspection should be maintained.
8.2. Fire Hose Cleaning and Drying
• After each use hose will be cleaned. If dirt cannot be removed with cloth, then brush
will be used for hose cleaning.
• If the hose is contaminated with harmful/hazardous materials then contaminated
hose will be washed out.
• Wet hose will be wiped for dryness.
• Hose will not be dried on hot pavement or under intense sunlight.
8.3. Fire Hose Storage
• Hose will be kept out of direct sunlight and place in well-ventilated location.
• All hose will be drained and thoroughly dried before being placed in storage.
• Hose will be stored only after it has been inspected.
• Hose that is out of service for repair will be tagged as specified and kept separated
from any hose in storage that is ready for service.
8.4. Fire Hose Test
• Hose that is in service will be service tested at least annually at in-house facility
service pressure.
• In service hose will be hydrostatically tested at intervals not exceeding 5 years after
the date of manufacture and every 3 years thereafter.
8.5. Fire Hose Test Procedure
• All air in the hose should be expelled before pressure is applied. When conducting
hose testing, remember that under normal conditions air is compressible and water
is generally not. Should a hose burst under pressure, the sudden release of
expanding air can cause serious injury.
• A modified gate valve, with a ¼” hole drilled in the gate valve is provided for your
safety and must be used at all times. The modification to the gate valve allows
application of full test pressure (250 psi) with diminished volume. Using the modified
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valve negates the effects of hose or coupling failure during testing. Because the
modified valve has a special application, it will not be carried or stored on apparatus.
8.6. Materials needed for hose testing
• One 2 1/2" Gate Valve, modified with 1/4" hole drilled in the gate.
• Marking pens.
• Paint / pens for color coding.
• Test results/recording sheets.
• Assorted hose gaskets (found on apparatus).
• Tags for marking hose which fails testing.
8.7. Conducting the test:
• Connect hose to a source of water.
• Lay out all hose to be tested in lines not more than 300 feet long. Record identifying
numbers and the length of each section of hose to be tested. Mark the end of the
coupling shank to check for slippage of the coupling during the test.
• Connect the modified 2½” gated valve to pump discharge.
• Attach a shut-off type nozzle to the end of each hose line.
• Fill each hose line with water and make sure that each nozzle is open and elevated
during the filling process. Exhaust all air from each line by permitting normal water
flow.
• After all air has been expelled, leave each nozzle open. Gradually raise the pressure
at the nozzle to approximately “50” psi for solid streams or 100 psi for fog streams.
This procedure can identify defective hose lining, which is more likely to pull loose
during a flow of water under pressure than under static pressure.
• Reduce the pump pressure, close each nozzle slowly, and place each nozzle on an
elevated block or on the ground. Check and tighten all hose couplings.
• Close the gated 2 ½” valve. Gradually raise pump pressure to appropriate pressure
and maintain for “5” minutes (200 psi for “4” inch hose and “250” psi for smaller
diameter double-jacketed hose).
• After “5” minutes reduce pressure slowly, close discharges, disengage pump and
open each nozzle.
• Observe all marks on the hose behind the coupling shanks. If any of the couplings
have moved (slight movement is normal), or if any section develops leaks, record
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and tag as failed. If a section bursts during the test, all other sections in the line
must be tested again. Record results on the Hose Test Report Worksheet.
• Drain all water from the hose to prevent formation of sulfuric acid, which is
particularly corrosive to cotton and Dacron surfaces. Damage from sulfuric acid
accounts for a large number of test failures.
• When putting hose away, be sure it does not come into contact with oil, grease or
solvents, which can cause damage and result in test failures. Wash the hose with
soap and water if contact occurs. Before putting hose away, check threads for
damage. Bent or mashed threads can be straightened with a small piece of
triangular file. Inspect all rubber gaskets and replace if necessary. Use silicone
spray to lubricate all swivels as necessary.
• All new hose must be engraved with a date and number.
• All hose is to be color coded so that the hose is tied to the unit. Color code the
female coupling of each section of hose. Each color should be 1” Length x ½” Width.
• When hose testing is completed, log the records in the computer system.
9. Fire Nozzles
Fire nozzles are placed in each fire hose box as per requirement. One nozzle with
opening bore diameter 12mm is placed in each hose box. In viewing fire intensity and
extra requirement of water, ten extra fire nozzles having opening bore diameter 16mm
with curtain spray characteristic are placed in cluster form.
9.1. Care and use of Nozzles
• Nozzles valves attached to in-service hose will be kept in the closed position.
• If during use there is an obstruction that cannot be removed by flushing the nozzle,
the nozzle will be taken from the hose line and the obstruction removed through the
connection end as soon as in practicable, since any further attempt to force the
obstruction out through the tip can damage the nozzle.
• Care will be taken to avoid dents or nicks in nozzle tips, because they can seriously
affect the reach of the stream.
• To prevent mechanical damage, nozzle will not be dropped or thrown.
• Nozzle control valves will be opened and closed slowly to eliminate unnecessary
strain on the hose and couplings and reduce pressure surges.
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• After each use, all nozzles will be thoroughly washed and inspected before being
placed back in service.
• All nozzles will be maintained in accordance with the nozzle manufacturer/s
instructions.
9.2. Inspection:
All nozzles will be inspected after each use and at least annually. The nozzles
inspection will verify the following:
• The waterway is clear of obstructions.
• There is no damage to the tip.
• All controls and adjustments operate as designed.
• The shutoff valve, if so equipped, operates as designed and closes off the
flow completely.
• There are no missing or broken parts.
• The thread gasket is in good condition.
If a nozzle fails the inspection for any reason, it will be removed from service,
repaired and service tested, or replaced.
9.3. Service Testing
• Each nozzle will be tested at least as frequently as the hose with which it is used.
• Each Nozzle with shutoff mechanism will be hydrostatically tested.
• All air will be bled from the system.
• The gauge pressure will be increased by 50psi (3.5bar) increments, held for 30
seconds at each pressure up to the maximum pressure for which the nozzle is being
tested, and then held for 1 minute without leakage.
• There will be no sign of leakage through the valve or the shutoff.
10. Fire Water Storage Tank
Raw and Fire water tank having capacity of 1000 m3 is installed for protection of fire for
a period of 2 hours. The Inspections, testing, and maintenance of water storage tanks
will be performed in accordance with the manufacturer's instructions or NFPA 25.
11. Fire Pumps
The minimum requirements for the routine inspection, testing, and maintenance of fire
pump assemblies. Below table will be used to determine the minimum required
frequencies for inspection, testing, and maintenance.
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Summary of Fire Pump Inspection, Testing, and Maintenance

Item Activity Frequency
Pump house, heating ventilating Inspection Weekly
louvers
Fire pump system Inspection Weekly
Hydraulic Maintenance Annually / OEM Guidelines
Mechanical transmission Maintenance Annually/OEM Guidelines
Electrical system Maintenance Varies/OEM Guidelines
Controller, various components Maintenance Varies/OEM Guidelines
Motor Maintenance Annually/OEM Guidelines
Diesel engine system, various Maintenance Varies/OEM Guidelines
components
Pump operation
No-flow condition Test Weekly
Flow condition Test Annually
11.1. Inspection
The purpose of inspection will be to verify that the pump assembly appears to be
in operating condition and is free from physical damage.
The pertinent visual observations specified in the following checklists will be
performed weekly:
(1) Pump house conditions:
(a) Heat is adequate, not less than 4.4°C (40°F) for pump room with diesel
pumps without engine heaters.
(b) Ventilating louvers are free to operate.
(2) Pump system conditions:
(a) Pump suction and discharge and bypass valves are fully open.
(b) Piping is free of leaks.
(c) Suction line pressure gauge reading is normal.
(d) Suction reservoir (Fire and Raw Water Tank) is full.
11.1.1. Weekly Inspection Procedure
In weekly inspection of fire pump following will be checked;
• power indicating light on the controller to verify that there is power to the
pump.
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• adequate heat in the fire pump room (not less than 4oC and 21oC for diesel
pumps without engine heaters) during winter session.
• ventilating louvers are free to operate.
• ensure the pump suction, discharge and bypass valves are open.
• Examine fire unit piping, fitting, and connections for any physical damage or
leakage.
• the suction and discharge gauge pressure reading is normal.
• system pressure gauge to ensure the system pressure reading is normal.
11.1.1.1. Electric Fire Pump
• the transfer switch pilot light is illuminated.
• the selector switch is in the automatic position.
• drip pockets under packing gland for proper drainage.
• packing adjustment – approximately one drop per second is necessary to
keep packing lubricated.
11.1.1.2. Diesel Fire Pump
• Diesel fuel tank level is sufficient i.e., > 75%.
• the “start selector switch” is on auto mode.
• both battery banks voltage is normal and electrolyte levels in batteries are
proper.
• battery terminals are free of corrosion and connections are tight
• battery charger and charging current is normal.
• Engine crankcase oil level is normal.
• Water level in radiator is normal.
• pump drip pockets under packing gland for proper drainage.
• Check gland packing adjustment – approximately one drop per second is
necessary to keep packing lubricated.
11.2. Testing:
• A weekly test of fire pump assemblies will be conducted without flowing
water. A weekly test should be conducted at no flow (shut off) condition.
Electric motor driven pump will be tested for 10 minutes while diesel engine
driven pump will be tested for 30 minutes after every seven days.
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• An annual test of each pump assembly will be conducted under minimum,

rated, and peak flows of the fire pump by controlling the flow of water passing
through test devices. If available suction supplies do not allow flowing of
150% of the rated pump capacity, the fire pump will be operated at maximum
allowable discharge. The annual test data to be compared with pump design
curves.
11.2.1. Weekly Test Procedure
11.2.1.1. Electric Fire Pump
• Verify start and stop pressure settings of jockey pump.
• After completion of all inspection procedures, start the pump automatically by
dropping the pressure. Test duration is 10 minutes.
• Pump auto cut in pressure to be recorded.
• Record the pump suction and discharge pressures.
• Check the pump shaft bearings, packing gland stuffing box, and casing for
any signs of overheating.
• Check for any unusual noise or vibration.
• If the pump is equipped with a main relief valve, check to ensure proper
operation.
• Verify operation of all supervisory signals (i.e., pump running, loss of power,
phase reversal, etc.)
• Verify that pump is left in the automatic start mode upon completion of the
test.
11.2.1.2. Diesel Fire Pump
• Verify start and stop pressure settings of jockey pump.
• After completion of all inspection procedures, start the pump automatically by
dropping the pressure. Test duration is 30 minutes.
• Pump auto cut in pressure to be recorded.
• Record the pump suction and discharge pressures.
• Check for any unusual noise or vibration.
• Check the pump shaft bearings, packing gland stuffing box, and casing for
any signs of overheating.
• Record radiator water flow and temperature.
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• Record engine speed (rpm).

• Record oil pressure.
• Verify that engine will start off at both sets of batteries.
• Verify operation of all supervisory signals (i.e., pump running, pump off, etc.)
• Verify that pump is left in the automatic start mode upon completion of the
test.
Note: If any abnormal operation or condition is noted during the test, the pumps
should be shut down and left in the automatic start position until repairs are made.
Repairs should be completed as soon as possible and the pump retested.
11.3. Maintenance:
Maintenance of fire pumps will be performed by as per OEM guidelines.
12. Water Sprinkler System
At NPL water sprinkler system is installed in MV cable room and tranches. Periodic
inspection and testing will be performed as below;
12.1. Inspection and Testing
12.1.1. Sprinkler, Pipeline & Gauges:
Sprinkler system inspection will be done on annually basis during each
scheduled switch yard shutdown from floor level.
During inspection following items will be observed in pipeline, joints, sprinkler
and take necessary corrective measures accordingly;
• Leakage
• Corrosion
• Physical / Mechanical damage
• Loss of fluid in the glass bulb / heat-responsive element of sprinkler.
• Loading (external loads by materials either resting on the pipe or hung
from the pipe)
• Paint condition
In service sprinklers will be tested on the basis of cluster sampling after an
interval of every 5 years.
Inspection and calibration of sprinkler system gauges will be done on
annually or as & when required.
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Summary of Water Sprinkler System Inspection and Testing

ITEM ACTIVITY Frequency
Sprinkler head Inspection Annually (When possible)
Spare sprinkler head Inspection Annually
Sprinkler System Piping Inspection Annually
Gauges Inspection Annually
Sprinkler Head Testing Every 5 years
Sprinkler System Operation Testing Quarterly-As & When Possible
Gauges Test During inspection or system test.
12.1.2. Operational Testing

System will be operationally test on quarterly basis by opening the test
connection valve for observing the following;
• To evaluate the function of water flow alarm and supervisory signal
initiating devices.
• Blockage and leakage in pipelines, joints etc.
• Running of fresh water throughout the lines
13. Foam Firefighting System:
In NPL foam firefighting system is installed on fuel tanks. This system is comprising on;
• Pipelines and Supports
• Fixed Foam Discharge Devices (Foam chamber, rim seal pourer)
• Fixed Proportionating system (Pressure & line proportioner)
• Valves (OS & Y gate valve, test and drain valve)
• Y Strainers
• Foam concentrate pump
• Foam concentrate tank
13.1. Inspection and Testing
• In monthly inspection, the position (open or closed) of valves will be verified in
accordance with specified operating conditions. It will also ensure that all valves
are operating freely. Concentrate tank will be inspected to verify that the
quantity of foam concentrate is sufficient as per original design and external
body condition of concentrate tank is free from rust.
• In Quarterly inspection, all type of strainers will be inspected for cleaning and
verifying its condition.
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• In annual Inspection, pipelines, fittings and supports will be inspected. During

inspection following will be observed;
• mechanical damage (e.g., broken piping or cracked fittings),
• external conditions (e.g., missing or damage paint or coatings, rust, and
corrosion),
• misalignment or trapped sections
• rubber-gas kit fittings condition will be observed.
• Foam-water discharge devices will be inspected visually and maintained to
ensure that they are in place, continue to be aimed or pointed in the direction
intended in the system design, and are free from external loading and corrosion.
• Misaligned discharge devices will be adjusted (aimed) by visual means, and the
discharge patterns will be inspected in scheduled flow test.
• The components of the various proportioning systems will be inspected in
accordance with the frequency specified in below table.
Summary of Foam Firefighting System Inspection, Testing, and Maintenance
System/Component Activity Frequency

Proportioning system(s) — all Inspection Monthly
Control valve(s) Inspection monthly
Foam concentrates strainer(s) Inspection Quarterly
Drainage in system area Inspection Quarterly
Water flow devices Inspection Quarterly
Pipe & Fitting (corrosion, damage) Inspection Annually
Hangers/supports Inspection Annually
Discharge device obstruction Test Annually
Complete foam-water system(s) Test Annually
Foam-water solution Test Annually
Backflow preventer(s) Test Annually
Water supply flow test Test 5 years
Foam concentrates Test Annually
Foam concentrates pump operation Maintenance Monthly
Foam concentrates pump(s) Maintenance 5 years
Foam concentrates strainer(s) if required Maintenance Quarterly
Foam concentrate tank — drain and flush Maintenance 10 years
Foam concentrate tank — hydrostatic test Maintenance 10 years
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13.2. Foam Concentrate Inspection and Test:

Foam concentrate will inspect and test on annually basis and following
parameters will be checked;
• Visual Appearance & Sediment
• pH
• Specific Gravity
• Foam Properties
• Petrol tolerance test
• Foam spreading coefficient
13.3. Mobile Foam Unit:
At NPL “10” no of mobile foam units is present which are located at below
locations of plant;
• Fuel unloading area
• Fuel day tank yard
• Fuel Treatment Building
• Engine Hall “A”
• Engine Hall “B”
• Outside grid station
In monthly inspection cleaning and visual inspection of variable foam line
inducer, foam branch pipe, trolley, venture tube, hoses, foam can will be carried
out.
14. Fire Water Line Valves:
At fire water lines various type of valves are fixed. These valves include screw and
yoke valve, butterfly valve etc.
14.1. Inspection, Testing and Maintenance
Inspection of each valve will be done on monthly basis.
In inspection it will verify that the valves are in the following condition:
• In the normal open or closed position
• Accessible
• Screw and yoke valves are provided with valve opening Key
• Free from external leaks
• Provided with applicable identification
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Each valve will be operated quarterly through its full range and returned to its
normal position.
The operating stems of outside screw and yoke valves will be lubricated
quarterly. The valve then will be completely closed and reopened to test its
operation and distribute the lubricant.
15. Fire Detection System
Fire alarm systems are used to warn employees about emergency conditions and
orderly evacuation of the building.
At NPL automatic fire detection system including manual call points are installed.
Break glass unit/manual call point must be activated by person from his nearest
location during an emergency situation while smoke and heat detectors detect local
condition and activate the alarm system automatically.
15.1. Inspection and Testing.
Inspection, testing and maintenance of fire detection system will be performed by
electrical department.
In quarterly inspection,
• Make a visual inspection of all of manual call points and sounders. Check
their condition and they are unobstructed and firmly attached.
• Perform cleaning and replacement of faulty sensor, analogue value, alert
level, alarm level of smoke detectors, heat detectors, break glass units,
manual call points.
• Perform cleaning of all detection panels (BLN901, 902 and Vigilon) and make
sure that their batteries are in good serviceable condition.
• Make a visual inspection of all cables, fittings and equipment and ensure that
all are secure, undamaged and adequately protected.
15.2. Testing the detectors.
In addition to quarterly inspection, annual testing (flame / heat test) of each
detector will be carried out and take necessary corrective actions in accordingly.
15.3. Changing the batteries.
Fire detection panels batteries should be changed as and when required or after
every three years.
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Revision No 01
FORK LIFTER SAFETY Revision Date 20-12-2019
1. Objective
This procedure provides guidelines for the safe operation of Fork Lifter at plant.
2. Scope
This procedure shall apply to all type of Fork Lifter operation inside the NPL
premises.
3. Responsibilities
3.1. Work Shop Supervisor / Contractor Supervisor
 Ensure that all employees under their direction who are designated to operate
a Fork Lifter are trained, evaluated and certified prior to independent operation.
 Ensure that certification is kept current (e.g., re-evaluation/driving test and
refresher training, as applicable) and notify EHS department of employees
who’s assigned to operate a forklift truck on job as part of their duties.
 Notify EHS department when new Fork Lifter equipment or attachments are put
into service or retired.
 Notify EHS department about accidents and near-misses involving in Fork Lifter
operation.
 Ensure that Fork Lifter and its attachments are appropriate for the use
conditions and maintained in safe operating condition. Immediately remove
defective equipment from service until repaired or replaced.
 To the extent feasible, reduce operational hazards presented by use location
and loads.
 Conduct, document, and maintain Fork Lifter inspection and maintenances
records.
3.2. Employees
 Complete hands-on training and competency in operation of Fork Lifter.
 Read the manufacturer’s operator’s manual. Observe all precautions discussed
in training and the recommendations of the manufacturer of the Fork Lifter.
 Conduct pre-operational inspection and do not operate a Fork Lifter that does
not successfully pass the pre-operational requirements.
 Immediately stop operation if any defect occur in Fork Lifter and to be reported
to workshop supervisor.
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3.3. EHS Department

 Administer and maintain Fork Lifter training program and associated
procedures.
 Conduct monitoring of Fork Lifter to verify its working condition.
4. Procedure
4.1. Pre-Operational Safety Checks
 Locate and ensure you are familiar with Fork Lifter operation and controls.
 Check brakes, lights and horn before use.
 Ensure reversing beeper and warning lights are operational.
 Ensure seat belt/safety restraint is in good condition.
 Know the capacity of the Fork Lifter before using it. Do not use a Fork Lifter
without a load rating plate.
 Ensure the lifting forks are in good condition and centered either side of the
mast.
 Check tyre pressures. Never drive with a flat or under-inflated tyre.
4.2. Operational Safety Checks
 Watch out for pedestrians.
 Ensure the lifting tines are secure into the pallet and the load is stable before
lifting or driving off.
 Be careful of ceiling clearance or overhead obstructions when raising the mast.
 Always remember that the safe working load of a Fork Lifter reduces as the
mast is tilted forward.
 Always put the heavy end of the load against the load backrest.
 When approaching a blind corner, use horn and drive slowly.
 When traveling on slopes, keep the heavy end uphill. On a downgrade, the
Fork Lifter should be driven in reverse and the forks raised only enough to clear
the surface.
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 If operating on ramps or loading docks, verify that the dockboard is secure and
of adequate capacity, proceed slowly when approaching or leaving; do not turn
or park on a ramp or dockboard and keep the forks downgrade.
 Use extra care when handling long lengths of bar stock, pipe or other materials.
 Compressed gas cylinders must be moved only with special pallets designed
for this purpose.
 Always have someone guide you if a load restricts your vision.
 Slow down when changing direction or on wet or greasy surfaces.
 Avoid harsh braking especially when carrying a load.
4.3. Lifting People with Fork Lifter
 A Fork Lifter may not be used to elevate a platform or pallet with persons on it,
except work platforms specifically designed and marked for this purpose.
 Work platforms must have standard guard rails and toe boards and must be
securely fastened to the forks. Personal fall protection (e.g., full body harness,
self-retracting lifeline (SRL), etc.) is required.
 The Fork Lifter may be used only to raise and lower a person- it shall not travel
with a person on the platform.
4.4. Ending Operation and Cleaning Up
When stopping the Fork Lifter:
 Park on even ground and lower the forks to the ground.
 Shift the gear selector to park position and apply the parking brake.
 Turn off the ignition and remove the keys.
4.5. DON’T
 Do not use faulty equipment. Report any faults immediately.
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 Do not use engine-powered forklifts in poorly ventilated areas.

 Do not allow anyone to ride on the forks.
 Do not lift a load with the mast tilted forward.
 Do not travel with forks raised or reach mechanism extended.
 Never travel with the load elevated.
 Do not attempt to turn on an incline or sloping surface.
 Do not dismount from a Fork Lifter while the engine is running unless the
vehicle has completely stopped, transmission is in park position and the
parking brake is effectively engaged.
 Do not leave forks elevated when forklift is unattended.
 Do not refuel an engine-powered Fork Lifter unless the motor is stopped and
ignition turned off.
5. Record
Inspection records to be maintained by maintenance department in Fork Lifter
inspection form.
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HOT WORK PROCEDURE Revision Date 28-10-2020
1. Purpose
This procedure prescribes the management controls to protect personnel, equipment,
and the environment whenever potentially hazardous work is to be performed at the
plant. The formal document through which these controls are implemented is the Hot
Work Permit. A particular form of work permit, called a “Hot Work Permit,” is required
for welding, torch-cutting or other types of work where flame, high temperatures or
sparks are present and create an inherent risk of fire, damage or injury.
2. Scope
This procedure applies to the activities related to Hot Work and Permit thereof at the
plant, which may have adverse effect on quality of Operation and Maintenance
services of Nishat Power Limited.
3. Definitions
3.1. Hot Work: Any work that produces an ignition source such as but not limited to
open flames, molten metal, sparks, slag, and heated work surfaces. Hot work can
lead to serious burn injuries, property damage, and can also produce radiation in the
form of visible and non-visible light that can injure eyes and burn the skin.
3.2. Explosimeter / Gas Detector: A device used to check areas for the presence of
flammable vapors and gases.
3.3. Flammable/Combustible: Any flammable or Combustible materials like solids,
liquids, gases, vapors, dust etc.
3.4. Craft Person: The person(s) who performs the Hot Work.
3.5. Non-Permit Hot Work Area: The area designated for Hot Work but does not
require a Hot Work Permit.
Note: In non-Permit Hot Work area, the craft person shall be responsible for the
safety of himself, other coworkers working in surrounding area and equipment’s.
3.6. Hot Work Area: The whole plant, other than the areas designated as “Non-Permit
Hot Work Area”
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3.7. Requiring a “Hot Work” Permit: A Hot Work Permit is required when any work
that produces a spark or flame that may cause ignition of flammable substances in
the vicinity of that activity.
3.8. Fire Watcher: An individual assigned to observe the vicinity of the hot work area
and trained to prevent or control a fire.
3.9. Lower Explosive Limit (LEL): The minimum concentration of gas/fumes/vapors in
air below which propagation of a flame does not occur in the presence of an ignition
source like flame or heat.
3.10. Welding/Soldering: It includes processes such as arc welding, oxy-fuel gas
welding, open-flame soldering, brazing, thermal spraying, oxygen cutting, and arc
cutting.
4. General Requirements
4.1. Craft Person and Shift Engineer shall identify hot work conditions before the use
the Hot Work Permit and equipment’s required to perform the Hot Work in a safe
manner.
4.2. All work requiring a hot work permit must be carefully reviewed to ensure the
safety and health of the workers during the designated work period.
4.3. Craft Person will write and submit to Shift Engineer for approval of hot work permit
in all areas of the plant where a Hot Work Permit is required. An original copy of
the hot work permit must be submitted to Shift Engineer and cross reference
should be established with relevant tag out order (where applicable).
4.4. Hot work permit must not be written and approved without physically inspecting
the place of work and without conducting atmosphere testing (where required) by
the Shift Engineer or his designee.
4.5. Hot Work Permit will be issued for a specific job in a specific area and will not be
applicable for any other hot work outside specific area.
4.6. The permit shall remain valid for 24 hours for routine jobs. However, a project or a
repair work which cannot be completed within 24 hours, then permit shall remain
valid till completion of job. The work area must be inspected daily before starting
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of job by Asst. Manager HSE and / or Shift Engineer on the request of relevant
Craft Person. If such work is stopped temporarily due to any reason including
weekly rests and holidays, then permit will be closed and new permit will be issued
on resumption of the work.
4.7. Atmospheric test will be performed for all hot works which carry out in close
building / area and also for open areas where flammable gases or fumes may be
present.
5. Responsibility
5.1. Shift Engineer shall be responsible to;
• Implement and maintain the Hot Work procedure.
• Approve the Hot Work Permit and ensure the issuance and removing of
isolation as per PTW and LOTO procedure.
• Restore the equipment to service after completion of HOT Work.
• Atmosphere testing (where required and applicable)
• Recheck the atmosphere and renew permits after a plant emergency situation
or condition changes.
5.2. Maintenance Manager/Engineer shall be responsible to;
• Ensure the competency of welder/fabricator.
• Ensure that contractor’s workers have been informed of and comply with the
procedure when performing work that requires a HOT Work Permit.
• Randomly inspect work sites where a Hot Work Permit is in effect to ensure
that the Hot Work Permit holder and Co-workers are following the requirements
specified in the permit for that work activity
• Ensure routine inspection and calibration of Hot Work Equipment’s.
5.3. Craft Person shall be responsible to;
• Initiate the Hot Work Permit.
• Inspect the hot work equipment’s before use.
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• Accept the Hot Work Permit form after verifying the PTW and LOTO procedure
which includes environmental testing (where applicable) and other
requirements associated with the particular Hot Work task.
• Ensure that all the safety requirements and precautions for Hot Work Permit
are met prior to, during and upon completion of work.
5.4. NPL staff has the responsibility and authority to stop a hot work job any time if
there is a failure to comply with the requirements of this procedure.
5.5. The HSE Manager shall be responsible for;
• Ensuring that all employees are involved in performing or monitoring of Hot
Work is properly trained in this procedure.
• Randomly inspect work sites where a Hot Work Permit is in effect to ensure
that the Hot Work Permit holder and other personnel in adjacent area are
following Hot Work procedure requirements.
6. Procedural Elements
6.1. Risk Assessment
A risk assessment is to be undertaken for hot work activities.
• For routine hot work tasks undertaken in a hot work area, a generic risk
assessment may be prepared, shard with craft person and also attached with
work permit.
• For hot work undertaken in special hazard (i.e. confined space, etc.) area, a
risk assessment is to be undertaken before each hot work task commences.
• The EHS Committee should form a team to undertake the risk assessment.
This team should consist of a competent person from concern department,
HSE officer and workers who are involved in the hot work activity.
• Risk Assessments must consider matters, including but not limited to the:
a. Type of hot work to be undertaken.
b. The location in which it is to be done.
c. The equipment to be used.
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d. The potential for fire and explosion, radiation burns, electric shock and
eye injury caused by exposure to radiation and foreign matter, inhalation of
toxic fumes or gases and other hazards as identified on the risk
assessment and Hot Work Permit.
6.2. Work Permit Initiation:
The Craft Person initiates the Hot Work Permit by filling the following on Hot Work
Permit form;
• The job details of work.
• The location of the work to be performed.
• Special preparations, requirements, precautions required to make the work
safe will be fulfilled by shift engineer.
6.3. Fire Prevention/Combustibles:
• If the object upon which Hot Work is to be performed cannot be moved to Non-
Permit Hot Work area than all movable objects having fire hazard and located
near to hot work shall be moved to a safe location at least 35 feet (10.7m) from
the work location.
• If immovable (fixed) fire hazards objects located near to hot work then these
objects shall be guarded by the placement of barriers that will contain the heat,
sparks and slag and protect these immovable fire hazards objects.
• Flame retardant tarps (fire blanket) may be needed to protect machinery and
other workers from sparks, hot metal spatter and welding flash.
• Pipe and vessels that contained a hydrocarbon or other flammable material must
be cleaned thoroughly prior to performing any Hot Work if proper cleaning
cannot possible then it shall be filled with water or under nitrogen purge (never
use air as purge) prior to welding and/or burning.
Note: Welding or heating of closed systems is prohibited due to potential for
overpressure of liquids within containment. If the fire hazards cannot be moved or
guarded, Hot Work will not be performed.
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6.4. Hot Work Permit:

Below find the activities and location where Hot Work Permit is required or not
required;
6.4.1. Where Hot Work Permit is required:
A Hot Work Permit is required when any work/activity that produces a spark or
flame and may cause ignition of flammable substances in the vicinity of that
activity. These activities are including, but are not limited to:
• Welding and cutting.
• Torches or other open flames.
• Operation of internal combustion engines and pumps inside flammable gas
storage areas.
• Grinding, chipping, chiseling, sandblasting, drilling, or using power hand
tools or non-intrinsically safe electrical equipment (i.e. cameras, electronic
equipment) in areas or on equipment where flammable vapors may be
present.
Hot Work Permit shall be issued for all hot works performed in whole plant
areas other than the areas designated as “Non-Permit Hot Work Area.
6.4.2. Where Hot Work Permit is not required:
A Hot Work Permit is not required in below given areas;
• Work Shop.
• Mechanical washing shed.
• Any other areas may be declared Non-Hot Work Permit area for a short
period of time after the approval of GM plant.
6.5. Fire Extinguishers:
• Based on the nature and quantity of combustible materials that could be
exposed to ignition source, appropriate fire extinguishing equipment shall be
kept ready for immediate use.
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• If sprinklers are provided to protect the area where Hot Work is being
performed, make sure they are in working order.
• Pressurized/charged fire hose and foam system may be required for certain
jobs located on or near fuel oil systems.
• One charged portable fire extinguisher shall be issued to craft person along
with Hot Work Permit. A stock of two or more charged fire extinguishers must
available in control room for Hot Work activities. Craft Person will return the fire
extinguisher to shift engineer in healthy form at the time of work permit closing.
6.6. Fire Watcher:
A fire watch is necessary when a Hot Work Permit is issued in areas where the
potential for ignition of flammable/combustible exists and cannot be removed.
Firewatcher shall be trained in the use of appropriate fire extinguishing
equipment’s and the hazards of industrial fires.
Fire watcher shall be responsible to;
• Notify the person who is doing the hot work in case of fire.
• Call for help and also notify the control room immediately.
• Sounded the alarm if the he is unable to handle the fire alone and also
familiar with the fire alerting system.
• Stay at hot work area for half an hour after hot work is finished.
• Maintain visual or voice contact with the person conducting the hot work.
• Maintain immediate access to an operational fire extinguisher and be
familiar with the proper use of the extinguisher.
• Know how to seek additional help, i.e., contact the control room, sound
the plant fire alarm.
NOTE: Depending on where sparks are landing, additional Fire Watches may
be needed on different levels to manage the area.
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6.7. Fire Safe Work Area:

The area located a minimum of 35 feet (10.7 m) in any direction from a hot work
location. This area will be maintained fire safe throughout the duration of hot
work activities and for a minimum of 30 minutes after the hot work is completed
(If required by Shift Engineer in hot work permit)
WARNING: The personnel performing the Hot Work and the Fire Watch must
confirm that heat transmission through steel members or pipe does not cause a
fire hazard
6.8. Special Hazards:
Special hazards or hazardous locations (i.e. confined spaces, fuel and chemical
pipelines, etc.) are where special precautionary work procedures shall be
adopted after evaluating the inherent risk.
6.9. Ventilation:
When Hot Work is performed in a confined space or other areas with limited
ventilation, forced ventilation is required to reduce to safe levels the
concentration of any potentially hazardous fumes or gases that are present
during the Hot Work process.
6.10.Personal Protective Equipment (PPE):
Following PPE shall be used during performing hot work
6.10.1. Eye Protection: Appropriate eye protection is required based on the type
of Hot Work to be performed. Welding helmets or hand shields shall be used
for arc welding or cutting, goggles for gas welding or oxygen cutting, face
shields or goggles for resistance welding or brazing. The shade number of the
welding helmet and hand shield lenses must be appropriate for the type of Hot
Work to be performed and compliant with the most current version of ANSI
Z87.1.
6.10.2. Protective Clothing: Craft person performing Hot Work and others
coworkers in the area shall wear appropriate clothing (including leather aprons
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CIVIL WORK PROCEDURE Revision Date 0
1. Purpose
The purpose of this procedure is to ensure all risks associated with civil works
(excavation and destruction/ construction) within NPL are identified and managed.
2. Scope
This procedure applies to all civil activities performed.
3. Definitions
3.1. Limited Access Zone An area alongside a masonry work, which is under
construction, and is clearly demarcated to limit access by employees
3.2. Benching (Benching system) means a method of protecting employees from
cave-ins by excavating the sides of an excavation to form one or a series of horizontal
levels or steps, usually with vertical or near-vertical surfaces between levels.
3.3. Cave-in means the separation of a mass of soil or rock material from the side of an
excavation, or the loss of soil from under a trench shield or support system, and its
sudden movement into the excavation, either by falling or sliding, in sufficient quantity
so that it could entrap, bury, or otherwise injure and immobilize a person.
3.4. Competent Person means one who is capable of identifying existing and
predictable hazards in the surroundings, or working conditions which are unsanitary,
hazardous, or dangerous to employees, and who has authorization to take prompt
corrective measures to eliminate them.
3.5. Excavation means any man-made cut, cavity, trench, or depression in an earth
surface, formed by earth removal.
3.6. Hazardous Atmosphere means an atmosphere which by reason of being
explosive, flammable, poisonous, corrosive, oxidizing, irritating, oxygen deficient, toxic,
or otherwise harmful, may cause death, illness, or injury.
3.7. Protection of employees in excavation” Each employee in an excavation shall
be protected from cave-ins by an adequate protective system designed in accordance
with design of sloping and benching system except when:
• Excavations are made entirely in stable rock; or
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• Excavations are less than 5 feet (1.52 m) in depth and examination of the
ground by a competent person provides no indication of a potential cave-in.
3.8. Ramp means an inclined walking or working surface that is used to gain access to
one point from another, and is constructed from earth or from structural materials such
as steel or wood.
3.9. Shield (Shield System) means a structure that is able to withstand the forces
imposed on it by a cave-in and thereby protect employees within the structure. Shields
can be permanent structures or can be designed to be portable and moved along as
work progresses. Shields used in trenches are usually referred to as "trench boxes" or
"trench shields."
3.10. Shoring (Shoring System)" means a structure such as a metal hydraulic,
mechanical or timber shoring system that supports the sides of an excavation and which
is designed to prevent cave-ins.
3.11. Sloping (Sloping System)" means a method of protecting employees from cave-
ins by excavating to form sides of an excavation that are inclined away from the
excavation so as to prevent cave-ins. The angle of incline required to prevent a cave-in
varies with differences in such factors as the soil type, environmental conditions of
exposure, and application of surcharge loads.
4. Procedural Element
4.1. Excavation
NPL/Contractor staff performing excavation work on site must have a properly trained
and designated competent person. Contractors shall maintain on site all requirements of
excavation in accordance with the NPL rule and regulations.
A. General Requirements
1. Departments (civil, mechanical and electrical) shall be contacted and asked to
establish the location of the utility underground installations prior to the start of actual
excavation.
2. Do not permit employees underneath loads handled by lifting or digging equipment.
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3. Employees shall be required to stand away from any vehicle being loaded or
unloaded to avoid being struck by any spillage or falling materials.
4. Gas testing shall be performed if Hazardous Atmosphere present.
5. If excavation/construction fall under definition of Confined Space than confined space
entry permit shall be issued.
B. Protection/Barricade
1. Excavations must be barricaded to alert pedestrians and vehicle traffic.
2. Spoil dirt may be used to barricade one side of an excavation.
3. The spoil pile must be at least three (3) feet high and also must be piled at least three
(3) feet from the edge of the excavation.
C. Access/Egress
1. Provide access and egress for all excavations. Provide ladders at intervals no greater
than 25 feet. Ladders must extend at least three (3) feet above the top of the excavation
and must be secured at top and bottom.
D. Fall Protection
1. Provide walkways where employees or equipment are required or permitted to cross
over excavations. Provide guardrails where walkways are 6 feet (1.8 m) or more above
lower levels.
2. Provide adequate barrier physical protection at all remote excavations. Barricade or
cover all wells, pits, shafts, etc.
3. Upon completion of tasks, excavation must be back-filled.
E. Sloping/Shoring
1. Excavations must be sloped or shored when deeper than five (5) feet.
2. A competent person must check all sloping prior to anyone entering the excavation.
3. Sloping or benching for excavations greater than 20 feet shall be designed by a
registered professional engineer. The approved contract drawing must be kept on site.
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F. Inspections
1. The competent person shall conduct an inspection prior to the start of work and as
needed throughout the work.
2. Daily inspections of excavations, the adjacent areas, and protective systems shall be
made by a competent person for evidence of a situation that could result in possible
cave-ins, failure of protective systems, hazardous atmospheres, or other hazardous
conditions.
3. Conduct inspections after every rainstorm or other hazard-increasing occurrence.
These inspections are only required when employee exposure can be reasonably
anticipated.
4. Where the competent person finds evidence of a situation that could result in a
possible cave-in, indications of failure of protective systems, hazardous atmospheres, or
other hazardous conditions, remove exposed employees from the hazardous area until
the necessary precautions have been taken to ensure their safety.
G. Water Accumulation
1. Employees shall not work in excavations in which there is accumulated water, or in
excavations in which water is accumulating, unless adequate precautions have been
taken to protect employees against the hazards posed by water accumulation.
2. If water is controlled or prevented from accumulating by the use of water removal
equipment, a competent person shall monitor the water removal equipment and
operations to ensure proper operation.
4.2. Construction and Demolition Work.
A. General Requirements
1. Do not place construction loads on a concrete structure or portion of a concrete
structure unless the employer determines, based on information received from a person
who is qualified in structural design, that the structure or portion of the structure is
capable of supporting the loads.
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2. Guard all protruding reinforcing steel, onto and into which employees could fall, to
eliminate the hazard of impalement.
3. Do not permit any employees (except those essential to the post-tensioning
operations) to be behind the jack during tensioning operations.
4. Erect signs and barriers to limit employee access to the post-tensioning area during
tensioning operations.
5. Do not permit employees to ride concrete/brick buckets.
6. Do not permit employees to work under concrete/brick buckets while buckets are
being elevated or lowered into position.
7. To the extent practical, route elevated concrete buckets so that no employee, or the
fewest number of employees, are exposed to the hazards associated with falling
concrete buckets.
8. Do not permit any employee to apply a cement, sand, and water unless the employee
is wearing protective equipment.
9. Do not permit any employee to place or tie reinforcing steel more than six feet above
any adjacent working surface unless the employee is protected by the use of a safety
belt or equivalent fall protection.
10. Inspection of tools, equipment, machinery shall be made by competent person and
remove the unhealthy tools from working area.
11. Access equipment (ladder & scaffold) shall be placed according to NPL ladder and
scaffold procedure.
B. Demolition:
Demolition is the highest risk activity in the construction sector.
The essence of safe demolition lies in efficient risk control, environmental management
and careful planning.
Buildings handed over for demolition generally contain hazardous waste, rubbish for
landfill and recyclable material. Best practice use of site waste disposal management
plans for all demolition projects which assist for properly disposal of waste material.
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NPL can assist by handing over empty buildings and finding new uses for all furniture
and equipment in a building before handing it to the contractor for demolition.
1- Demolition Procedure:
General demolition procedures include:
• Effective building security and maintenance prior to demolition.
• Isolation of utilities and removal of other appliances.
• Intrusive pre-demolition surveys (such as; asbestos survey for demolition,
structural survey, hazardous materials surveys etc).
• Disconnection of utilities.
• Site compound set-up.
• Asbestos removal (in accordance with the Control of Asbestos Regulations).
• Soft strip (taking the structure back to construction materials including the removal
of windows and door frames).
• Superstructure demolition with special measures as constraints demand, such as
de-build or protection of adjacent structures.
• Processing of superstructure arising.
• Slab and foundation demolition.
• Processing of arising.
• Site finishes as required including provision for the future security of the site.
2- Demolition Methods:
Demolition methods include:
• Hand demolition. These methods are required when demolition has to be carried
out in a more sensitive manner due to site constraints such as; proximity to
uncapped mineshafts, overhead utilities, pedestrian access or adjacent structures,
or structural instability.
• Machine demolition. This is by far the most frequently used method and reduces
the need for people to work at height, for manual handling and is an
effective risk control for the demolition industry.
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C. Masonry Construction
Masonry consists of building structures by laying individual masonry units (brick,
concrete block, stone, etc.). Normally the masonry units are laid with cement mortar,
which binds them together to create a structure. Masonry construction can provide
beautiful walls and floors at economical prices.
Establish a limited access zone whenever a masonry wall is being constructed. The
limited access zone shall conform to the following:
1. Establish the limited access zone prior to the start of construction of the wall.
2. The limited access zone shall be equal to the height of the wall to be constructed plus
four feet, and shall run the entire length of the wall.
3. Establish the limited access zone on the side of the wall which will be scaffolded.
4. Restrict the limited access zone to entry by employees actively engaged constructing
the wall. Do not permit any other employees to enter the zone.
5. Maintain the limited access zone in place until the wall is adequately supported to
prevent overturning and to prevent collapse unless the height of wall is over eight feet,
in which case, the limited access zone shall remain in place.
6. Adequately brace all masonry walls over eight feet in height to prevent overturning
and to prevent collapse unless the wall is adequately supported so that it will not
overturn or collapse. Maintain the bracing in place until permanent supporting elements
of the structure are in place.
1- Personal Protective Equipment (PPE):
NPL and Contractors are required to utilize appropriate engineering and administrative
controls to protect their employees from all recognizable hazards on civil project.
When implementation of these controls is not feasible, NPL/Contractors shall issue
appropriate personal protective equipment for their employees.
PPE shall include (but not be limited to):
• Hard Hat (not bump cap)
• Safety Footwear
• Full fitting clothing
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• Ear Muff/plug
Special Personal Protective Equipment-SPPE (As & when required):
• Safety Glasses/Goggles
• Full body harness with shock absorber land yard during working at height (more
than 2 meter)
• Respiratory Protection (dust, chemical mask etc.)
• Chemical Protection (Face shield, Gloves, apron, suit etc.)
• Flame Retardant Clothing
• Welding Protection
4.3. Permit to Work

Permit to work shall initiate, verify, accept and release by NPL Craft Person and Shift
Engineer shall give approval and authorization. If hot work, confined space entry and
work at height need to be performed then civil department will take their work permit in
cross reference of Civil Work Permit. Detail of underground utilities and their safety
measures shall be mentioned in Permit Form.
4.4. Auditing and Inspection
The entire Procedure shall be audited at least once a year. NPL staff involved in Civil
Work shall be trained and qualified.
Inspection would involve:
Civil Team leaders shall perform a random audit of the in progress Civil Work Permits to
ensure effective implementation of the procedure.
HSE Team will conduct an annual inspection of Civil Work paperwork.
4.5. Enforcement
✓ Enforcement is divided into two areas, administrative and physical harm.
i. Administrative pertains to any Team Members not adhering to the
application of Civil Work Procedure.
ii. Physical harm pertains to an individual’s failure to follow procedure, which is
the cause of physical harm to another individual.
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✓ Each incident will be considered individually and may involve an independent

investigative group to provide determination of fault.
✓ All safety occurrences will be discussed at the next HSE Committee meeting and
appropriate actions taken.
✓ Failure to adhere to any and all aspects of this procedure may result in disciplinary
actions.
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and gauntlets) to ensure protection from the potential hazards presented by the
Hot Work.
6.10.3. Respiratory Protection: If mechanical ventilation is not adequate to
maintain fumes or gases at levels below the occupational exposure limits for
recognized health hazards such as fumes, gases, arsenic, hexavalent chromium,
and lead, an appropriate respirator must be used to reduce exposure to within
accepted exposure limits.
6.10.4. Hand and Feet Protection: Craft person performing Hot Work shall wear
appropriate Hot Work gloves and safety shoes to protect his hand and feet
from burn by hot flame, open spark, hot chipping and chiseling particles.
6.11.Hot Work Equipment:
• Inspect all hot work equipment to ensure their condition, suitability and prior
to commencing any hot work.
• Whenever possible, do not take compressed gas cylinders or welding
machines into a hot work area. It is better to take oxy/acetylene hose or
welding leads only into a hot work area.
• Once the work area has been permitted (Atmosphere test completed), craft
person may bring in compressed gas cylinders or welding machines in Hot
Work when it is not possible to leave outside. Confirm that normally running
vent fans are “ON” to ventilate smoke fumes from hot work.
• Only inspected and healthy equipment shall be used while damage/unhealthy
equipment should be placed separately and sent for further repairing and
discard.
• Welding machine and gas cylinder valves should be shut down while relocating
them.
6.12.Securing and Storage of Cylinders and Machines:
When Hot Work is performed in a confined space, the gas cylinders or
machines will be secured outside of the space. Cylinders must be secured
from accidental movement or tipping during all operations. When not in use,
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cylinder valves must be shut off and capped and the cylinders stored so as to
prevent tipping. Flammable gas cylinders must be stored separate (at least 20
feet) from oxygen and other cylinders in a well-ventilated area.
6.13.Atmospheric Testing:
• In areas where flammable gases or vapors may be present, an explosimeter
reading shall be taken when a permit is to be issued, and at least twice per
shift.
• Continuous LEL air monitoring is required in areas where petrol, diesel oil or
hydrogen may be present to check sudden increase in flammable gases or
vapors concentration in atmosphere.
• Hot Work shall not be started if there is any indication of flammable gases or
vapors.
• Hot Work will be prohibited where the atmosphere is tested at levels equal to
or greater than 10% of the Lower Explosive Limit (LEL).
• Only trained staff (use atmospheric testing equipment) shall test the Hot Work
Permit area.
• Readings are to be taken with the explosimeter at points where combustibles
may be present (i.e. inside disconnected piping, at bleeds, piping connection
points, sewers, etc.).
• In confined space;
• Atmospheric test all three levels - top, middle, and bottom.
• If the reading indicates combustibles are present, further cleaning, purging,
or isolation is required prior to allowing hot work to proceed.
• Explosimeters must be calibrated/checked as per manufacturer’s
recommendations. Written records must be maintained of this activity.
• Atmosphere record shall be written on Hot Work permit.
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7. Program Administration
7.1. Auditing:
• HODs/EHS Committee shall conduct periodic inspections of the application of
the Hot Work procedures to ensure that the requirements are being effectively
implemented.
• Inspection records shall be maintained that indicate the date of the inspection,
the employees included in the inspection, and the person performing the
inspection. The inspection records shall identify any deviations or
inadequacies and the corrective actions taken.
7.2. Training:
All personnel must receive initial training as it relates to their duties for hot work.
Refresher training for all affected employees will be conducted in accordance
with the NPL training matrix or when there is a significant change in the
procedure. All training must be documented.
Staff member performing Hot Work must be trained on following topic:
• Type and hazards of Fumes and gases and their control
• Welding, grinding and cutting techniques
• Proper use of Hot Work equipment
• Radiation hazards and their control
• Use of PPE
• Understanding and usage of firefighting equipment.
Staff performing atmospheric testing must be trained on the following topics:
• Proper use, care and field calibration of the gas analyzer.
• Technique for conducting the hot work area atmospheric testing
• Individuals acting as a fire watch must be trained on the following topics:
• Basic site overview of where the hot work is being conducted
• Proper techniques for monitoring for any changes affecting permit
conditions; or for any signs of small or smoldering fires,
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• Proper activation and use of fire protection equipment

• Proper operation of gas analyzer.
• Proper use of communication system/equipment
All training shall be documented and kept on file in HSE and maintenance
department.
7.3. Contractors:
Contract personnel performing hot work within NPL shall be familiar with the
company’s policies and procedures for such work and must either comply with
those procedures or implement procedures that are at least as effective and
approved by the HSE Committee and GM Plant.
7.4. Permit Retention/Filing
After completion of the hot work operations, the permit should be returned to the
control room. Permits should be retained for a period of not less than one (1) year
in control room.
7.5. Enforcement:
• Enforcement is divided into two areas, administrative and physical harm.
• Administrative pertains to any Team Members not adhering to the application of
Hot work Procedure.
• Physical harm pertains to an individual’s failure to follow procedure, which is the
cause of physical harm to another individual.
• Each incident will be considered individually and may involve an independent
• Safety inadequacies/deviations shall be discussed in the next HSE Committee
meeting and appropriate actions taken.
• Failure to adhere to any and all aspects of this procedure may result in disciplinary
actions.
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LADDER Revision Date 23-07-2019
1. Objective
This procedure provides guidelines for the safe use of ladders to minimize the risk of
personnel injury at the plant.
2. Scope
This procedure applies to all activities related to use of ladders at the plant which may
affect the quality of Operation and Management services of NPL.
3. Definitions
N/A
4. General
a) Select the proper ladder for the job
b) Inspect all ladders prior to use. Do not use any that is defective. Check for the
following unsafe conditions:
a. Worn, frayed or missing rivets
b. Bowed or distorted steps
c) Never place the feet of a ladder on top of another object. Feet of ladder must be set
on level surface and secured by tying the top and bottom rungs to a fixed structure.
d) Position ladders so work can be done without leaning to either side of the ladder.
Reposition the ladder as work progresses, rather than leaning to the side.
e) Never place ladders in front of doors opening toward the ladder unless the door is
locked open, locked shut or guarded by another employee.
f) Do not leave unattended step or straight ladders standing. Close and lower them to
the ground.
g) Always face a ladder while ascending or descending.
h) Do not carry materials while climbing or descending a ladder. Raise or lower the
materials using a line or line and bucket.
i) Ensure that shoes are free of mud, oil or grease before climbing or descending a
ladder.
5. PROCEDURES
Lean straight ladders against the object being climbed so that the distance from the
ladder’s feet to the object on the ground is one-fourth the distance along the ladder’s
length to its upper contact point with the object.
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Straight ladders should extend at least 3 feet above their upper point of contact with
the object being climbed.
Never work on a straight ladder by standing above the third rung from the top.
a) Long, straight ladders or heavy extension ladders should be raised into place
by two people:
b) One person holds the ladder feet to the ground, while the second person walks
under the ladder from the opposite end until it is vertical.
c) After an extension ladder is in the vertical or near vertical position, raise the
extension if needed.
d) Reverse the preceding two steps for lowering the ladder.
Stationary ladders should be securely attached to an immovable structure.
Never slide down a ladder by holding onto the sides and letting your feet slide down.
Engine Room and Power House Ladders.
Fixed-installation ladders in the power house in the engine room are fitted with non-
slip treads and hand rails.
Never slide down a ladder or run up or run the ladder.
A non- slip rubber seal should be placed at the bottom of each ladder.
Inspections
Ladders must be kept in good condition at all times.
They need care and cleaning, especially when used in oily or greasy areas or left
outside.
Regular inspection will help ensure ladders are safe.
Check for broken or missing steps or rungs, broken or split side rails and others
defects. Check fallen or misused ladders for excessive dents or damage.
Be sure the connections between the rungs and side rails are not loose.
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1. Objective/Purpose:
The control of all Energy Sources/Hazardous Energy, Permit To Work and Lockout and
Tagout procedure is established to provide administrative guidance and minimum
requirements for the control of hazardous energy sources to ensure the safety of
people, protection of equipment, and continuity of service by clearly defining the
responsibilities and a system to ensure that before any person performs construction
and/or maintenance work on a machine or equipment where the unexpected
energization, start-up or release of stored hazardous energy could cause injury, the
machine or equipment is secured from all Energy Sources.
2. Scope:
This safety procedure applies to NPL staff and contractor staff that work inside the
plant boundary. It covers the process involved in ensuring that a machine or piece of
equipment or area under work is properly isolated from all sources of hazardous
energy, all isolating devices are locked (if applicable) and tagged and all safety
measures has been in place before job commence.
3. Definitions:
3.1. Area Engineer (CRO, Sr. ERO, ERO, Assistant ERO, Boiler Engineer,
Assistant Boiler Engineer and Boiler Operator): An Area engineer/operator
qualified in the specific area (declared by HOD). The Area Engineer is declared
Permit To Work and LOTO qualified by the Safety department after passing a
Permit To Work and LOTO procedure test.
3.2. Acceptance: When a Craft Person signs on Permit To Work to confirm that all
isolations provided as described on LOTO are adequate and system / equipment is
safe in all respect to carry out the job by the Craft person / Craft Group.
3.3. Approval: The confirmation of the Shift Engineer that LOTO and Permit To Work
has been prepared correctly and the procedures for LOTO and Permit To Work
have been carried out, safety precautions quoted have been applied and is ready
for craft person’s acceptance.
3.4. Authorize: Permission to NPL person for accepting and performing specified duties
under the Permit To Work procedure.
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3.5. Shift Engineer: Person having immediate charge and control of the power plant.
Shift Engineer is responsible for ensuring that all procedures are followed prior to,
during and on subsequent release of Permit To Work. Shift Engineer should know
the Isolating Devices and Permanent / Fixed Earthing Devices for the plant
equipments.
3.6. Craft Person: NPL person involved in repairing, testing or performing other work
on equipment. The craft person is declared Permit To Work and LOTO qualified by
the Safety Officer after passing a Permit To Work and LOTO procedure test.
3.7. Craft Group: A group or crew of more than one craft person working on same
equipment or system having the presence of hazardous energy.
3.8. Craft Group Leader: The person responsible for the acceptance and release
responsibilities on behalf of a Craft Group for the Permit To Work that the Craft
Group are to work under. A Craft Group Leader shall be a direct employee of NPL.
3.9. Contractor: A person or group of persons hired from third parties, on a time to time
basis, to perform a specific job / activity to work under the supervision of NPL
People. However, they cannot accept any Permit To Work. Contractor personnel
working with NPL are subject to LOTO and Permit To Work Procedure
requirements. Contractors will be briefed about the procedure. All NPL persons
must never assume that a contractor fully understands the LOTO and Permit To
Work Procedure. NPL people are responsible for contractor’s personnel safety as
well as their own and the safety of other people who may be affected by their work.
3.10. Completion: The confirmation by the area engineer that all work performed
under the Permit To Work and LOTO or under any others Work Permit has been
completed; all the locks and tags have been removed from the isolating
equipment’s and returned to the Shift Engineer.
3.11. Caution Tag: When any NPL person wants to pass on information about any
abnormal condition of equipment to the other people, he will use pre-printed yellow
Tag stating “CAUTION TAG” with all information. Caution tag should never be
confused with the Isolation (danger) tag.
3.12. Craft lock: The lock used by a Craft person who is involved in repairing, testing
or performing work on equipment which has been Tagged out and locked out. This
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lock is to be uniquely identifiable. The lock shall be applied to the lock box by the
craft person before acceptance Permit To Work.
3.13. Danger Tag: A pre-printed tag stating “Danger-Do Not Operate” to be used when
plant equipment has been isolated by issuing Permit To Work and LOTO by the
Shift Engineer prohibiting energy sources from being placed in an operational mode
(tags are to be used in conjunction with the Lock).
3.14. De-Energized: Where no electric or any other Hazardous Energy exists, has
been verified by testing and all sources of energy have been isolated by their
Isolating Devices having been secured in a Safe position.
3.15. Earthing: To provide a connection between an electrical conductor and earth.
3.16. Earthing Device: An approved means of providing a connection between an
electrical conductor and earth.
3.17. Electrically Competent Person: NPL person fully trained, familiar with hazards
associated with electrical equipment’s and authorized by Electrical Manager.
3.18. Energized: Machines and equipment’s are said to be energized when they are
connected to an energy source or they contain residual or stored energy.
3.19. Energy Source: Any source of electrical, mechanical, hydraulic, pneumatic,
chemical, thermal or other energy, in which the machines/equipment are
connected.
3.20. Equipment Restoration: The readiness of machine/equipment to perform its
intended functions.
3.21. Hazardous Energy: Any chemical, electrical, stored mechanical, thermal,
kinetic, radioactive or any potential energy or substance that could harm people, or
equipment or environment.
3.22. Isolating Device: A device which prevents the release and/or accumulation of
Hazardous Energy to equipment, such as breaker, a valve, a switch, a removable
fuse, locking pin or physical separation etc.
3.23. Restoration: The confirmation by the Shift Engineer that all activities performed
under the Permit To Work and LOTO or under any others Work Permit which is
under consideration have been completed and equipment has been restored for
operational use.
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3.24. Lock Box: A Lock Box located in the control room having specified number
which contains all keys of the Tag out Locks applied on isolated equipment.
3.25. Lock Out: Refers to the placement of a lockout device on an energy isolating
device such that the equipment being controlled cannot be operated until the device
is removed. A lockout device (i.e. locks, blank flange, bolted slip blind, etc.) is any
device that uses a positive mechanical means to hold an energy isolating device in
a safe position.
3.26. Lockout and Tagout (LOTO): The placement of a locking device along with a
“Do Not Operate” tag (card) on an energy-isolating device or the placement of a “Do
Not Operate” tag where the device is not lockable.
3.27. Permit To Work (PTW) Request Form: A document that a Craft Person uses to
requests for a Permit To Work document in order to perform work. The Craft Person
shall describe on this form the equipment to be worked upon, the nature of work to
be performed, intended date and time of commencement of the work and any
special requirements, the Shift Engineer prepares the Permit To Work and LOTO
Document(s) as per the request made on this document.
3.28. Operational Lock ((Color Red): The lock used for locking out the equipment
(Locks are to be used in conjunction with the Danger Tag) and the lock used by
Shift Engineer on the appropriate Lock Box.
3.29. Multi-tag out device: A mechanism that provides for the use of multiple locks
either on the equipment or the Lock Box, to be used when more than one group or
person is working on the equipment.
3.30. Observer: An additional person (if required) not participating in the work, present
at the work place to monitor the safety of person(s) and equipment’s.
3.31. Point of Isolation: An Isolating Device secured in its Safe Position with a
Danger Tag attached. All Points of Isolation shall, whenever possible, be locked in
its Safe Position using a Tag Out Lock.
3.32. Release: The confirmation of a Craft Person or Craft Group Leader that all work
on the equipment quoted on the Permit To Work and LOTO or other Work Permit
has been completed. This signifies that the Craft Person, the Craft Group Leader or
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any member of Craft Group are no longer authorized to work on the equipment
covered by this Work Permit.
3.33. Safe Position: The position in which an Isolating Device or Earthing Device has
been placed to prevent the release of Hazardous Energy.
3.34. Safety from the System: The precautions taken to safeguard persons working
on or near to systems / equipment from the Hazardous Energy inherent in the
systems or equipment.
3.35. Servicing and/or Maintenance: The workplace activities such as construction,
installation, and setting up, adjustments, inspection, modification, maintenance
and/or servicing of machines/equipment. These activities include, but are not limited
to, lubrication, cleaning or unjamming of machines/equipment and making
adjustments or tool changes, where people may be exposed to the unexpected
energizing of the equipment or release of stored energy.
3.36. Shift Electrical Person; (Electrical Engineer/Assistance Electrical Engineer/and
Sr. Electrician/Electrician): A member of shift crew having adequate knowledge of
plant electrical system. Electrical Engineer/ Assistance Electrical Engineer/Sr.
Electrician/Electrician and qualified (declared by manager electrical). He should also
declare Permit To Work and LOTO qualified by the Safety Officer after passing a
Permit To Work and LOTO procedure test.
3.37. Suspension: The temporary invalidation of a Permit To Work for a period during
which the subject work has ceased.
3.38. Switching Order Verification: The process to check the sequence of isolation
devices listed in the LOTO / TLTR are correct and complete.
3.39. Switching Order: The sequence of isolation and de-isolation of isolating devices
for a machine or equipment.
3.40. Tag Out: The placement of a prominent warning device, such as a tag and a
means of attachment, which is securely fastened to the energy isolating device to
indicate and ensure that the energy isolating device and the equipment being
controlled cannot be operated.
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3.41. Lockout and Tagout (LOTO): The document which specifies the Points of
Isolation and Points of Earthing for achievement of the safety from the system. This
document to be used to authorize people to work on the equipment specified.
3.42. Temporary LOTO Release (TLTR): A Document which specifies the Isolation
Devices and / or Earthing Devices that are released from a specified LOTO so that
specified work, mentioned in the TLTR, can take place on the equipment quoted on
the Permit To Work and LOTO.
3.43. Verification Check: An independent check made by a Craft Person or Craft
Group leader, to ensure that all tags and locks are hung in accordance with the
LOTO. This check is to be carried out independently after ensuring that all locks
and tags have been hung and hazardous energy has been controlled / released.
4. General Rules and Responsibilities
Shift Engineer is ultimately responsible for ensuring that all procedures are followed
prior to, during and on subsequent release of the Permit To Work and LOTO.
All persons involved in a Permit To Work and LOTO system shall know all hazards
associated with each particular LOTO and Permit To Work system.
The person(s) mentioned below are responsible for the following actions and
activities:
4.1. Shift Engineer:
Ensuring that each step of the Permit To Work and LOTO procedure is followed.
Notifying all the relevant persons associated with the equipment of its operating
status.
Identifying and specifying all Points of Isolation, Points of Earthing and all other
precautions to work safely on the system / equipment, in consultation with Area
Engineer, Shift Electrical Engineer, Assistance Shift Electrical Engineer and Shift
Electrician to eliminate residual Hazardous Energy, which includes but is not limited
to, de-pressurizing, de-energizing, draining, venting, purging, cooling, washing
down, discharging springs, etc.
To ensure that proper Permit To Work and LOTO procedure has been
implemented. That individual must be particularly aware about the interlocks
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associated with the system / equipment to ensure it is locked out and not
temporarily inoperative because of an interlock.
4.2. Area Engineer:
Area Engineer must Lockout, Tag out and test out the equipment in right Switching
Order (process part of the LOTO) to ensure proper Permit To Work and LOTO has
been implemented. That individual must be particularly aware about the interlocks
associated with the system / equipment to ensure it is locked out and not
temporarily inoperative because of an interlock.
Area Engineer who hangs the tags must ensure that the Isolation Devices listed on
the Switching Order are correct and complete (no errors and/or omissions in the
switching order) and all kind of residual energies are released.
After completing the job and Releasing the Permit To Work by craft person and
getting permission from SE, Area Engineer shall remove the isolation (Process Part
of LOTO) in right switching order that was provided under LOTO to restore the
equipment(s)/System.
Ensuring that all tools and debris have been removed from the equipment worked
on under the Permit To Work and LOTO and the equipment and the area is cleaned
prior to close the Permit To Work.
4.3. Shift Electrical Person; (Shift Electrical Engineer, Assistance Shift Electrical
Engineer and Shift Electrician):
Shift Electrical Engineer, Assistance Shift Electrical Engineer and Shift Electrician
must Lockout and Tag out the equipment in right Switching Order (Electrical part of
the LOTO) to ensure proper Permit To Work and LOTO has been implemented.
That individual must be particularly aware about the interlocks associated with the
system / equipment to ensure it is locked out and not temporarily inoperative
because of an interlock.
Shift Electrical and Assistance Shift Electrical Engineer who hangs the tags must
ensure that the Isolation Devices listed on the Switching Order are correct and
complete (no errors and/or omissions in the switching order).
After completing the job and Releasing the Permit To Work by craft person and
getting permission from Shift Engineer, Shift Electrical and Assistance Shift
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Electrical Engineer: shall remove the isolation (Electrical Part of LOTO) in right
switching order that was provided under LOTO to restore the equipment(s)/System.
4.4. Craft Person:
Craft Person shall not do anything that could reactivate, energize, pressurize or
otherwise introduce Hazardous Energy to the equipment or system or possibly
bypass Isolating Devices or Earthing Devices by installing new piping or wiring.
Upon being informed, the Craft Person or a Craft Group Leader will independently
verify the PTW and LOTO and sign off the respective verification column.
In the event that a Craft Person or a Craft Group Leader does not accept a Permit
To Work on the grounds that he is not satisfied that it will provide him or his Craft
Group with safety from the system, the Craft Person or Craft Group Leader shall
explain the objection to the Shift Engineer. The objection shall be dealt with to the
satisfaction of the Craft Person or Craft Group Leader by the Shift Engineer.
It is the responsibility of the Craft Person(s) and Craft Group Leader that they are
aware of the boundaries offered by the LOTO, and that they work only inside these
boundaries. Any work outside the boundaries that is not covered by the LOTO is
strictly prohibited and may lead to a disciplinary action.
After Permit To Work is approved by the Shift Engineer, the craft person will accept
the Permit To Work and sign off the respective acceptance column (print name and
signature). If the scope of the work extends beyond the existing Permit To Work, a
new tag out order must be issued.
It is the responsibility of the Craft Person(s) that all tools and debris have been
removed from the equipment worked on under the Permit To Work and that people
are clear of the area prior to release the Permit To Work.
Craft person(s) will accept the Permit To Work after ensuring that equipment has
been isolated and hazardous energy has been released.Each person working in a
craft group on equipment or systems containing hazardous energy will be given the
same amount of protection as one individual working on the equipment or system.
In a craft group situation, one person will be designated by the group members to
assume Permit To Work responsibilities for the group.
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This person will ensure that all hazardous energy is controlled by use of the LOTO
Procedure for the group, place a craft lock on the lock box and sign off the Tag out
Order as the representative of that group.
4.5. Contractor:
Contractor person or contractor crew leader shall counter sign the WP Acceptance
column after NPL Craft Person or Craft Person(s) group Leader Acceptance.
Contractor person or contractor crew leader shall also counter sign the release
column of WP after NPL Craft Person or Craft Person(s) group Leader releasing the
WP.
5. Permit To Work and LOTO Procedure:
Craft person will make Permit To Work Request in writing at least one day (24
hours) in advance for all planned jobs to provide sufficient time to the operations
team to make necessary preparation of the required equipment. For annual outage /
planned outages, the outage schedule will be considered as Permit To Work
Request. However, for emergency jobs, Permit To Work Request can be served
before job execution.
Risk Assessment and Job Hazard Analysis will be discussed/ prepared (or reviewed
if JHAS exists) prior to commencing the job which cover a complete evaluation of all
hazards related to the specific job. After assessment, the hazards control measures
would be implemented to contain the hazards.
Job briefing shall be conducted by Craft Person or Craft Group Leader to rest of the
crew member(s) to discuss the risk/hazard associated with this job and precautions
to taken to avoid any incident.
5.1. Preparation of a LOTO, Switching Order and Shutdown
The LOTO and Switching Order is prepared by Shift Engineer in the following order;
Related diagrams must be consulted to accurately determine the isolation devices
after consultation with Area Engineer/Craft Person.
The switching order identifies what locks and tags are placed on isolation devices.
The points of isolation and Earthing with its proper identification numbers and safe
position are identified.
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Equipment requiring a Permit To Work must be physically inspected by the Area

Engineer or the Shift Engineer before initiating the LOTO. It requires knowledge of
the following:
 Availability of the equipment for shut down and its impact on plant availability
and reliability.
 The types and all sources of Hazardous Energy present in the equipment
including electrical, hydraulic, pneumatic, mechanical, stored energy, etc.
 The types and quantities of fluids or chemicals associated with the equipment;
 The presence and location of existing control interlocks.
 People who must be notified before removing equipment from service.
 The presence of any secondary (backup) energy sources.
 The existence of any stored energy that must be blocked and drained.
The Shift Engineer and the Area Engineer must be particularly alert with equipment
that features interlocks, emergency stop devices or remotely controlled mechanism.
Such equipment shall be made safe to work on by following the Permit To Work
and LOTO Procedure and shall not be worked on when it is temporarily inoperative
because of an interlock, emergency stop device or remote control.
5.2. Preparing for Equipment Shutdown;
Equipment and/or system requiring a Permit To Work must be looked over before
initiating the Permit To Work and LOTO Procedure. It is essential that the Shift
Engineer and Area Engineer have an accurate and complete knowledge of the
intended job and system to be worked upon. It requires knowledge of the following:
 The types and amounts of energy powering the equipment.
 Fluids or hazardous chemicals associated with the equipment or system.
 The presence and location of control interlocks.
 People who must be notified before removing equipment from service.
 The presence of any secondary (backup) energy sources.
 The existence of any stored energy that must be blocked and drained.
5.3. Equipment Shutdown;
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Make sure equipment is available for shutdown. Verify that the equipment can be
removed from service without operational loss or impacting plant availability for a
specific time period.
Notify all necessary people that the equipment or system is being taken out of
service,
Verify that normal operating controls can be used to shut down the equipment.
5.4. Step # 1 – Initiating Permit To Work
Shift Engineer responsible to obtain a Permit To Work and LOTO number from the
Permit To Work and LOTO Log register till Maximo EHS module is in place. After
that Permit To Work and LOTO numbers will be computer generator and Permit To
Work and LOTO master log will be maintained in computer. Write Permit To Work
number and date on all tags associated with the Permit To Work.
Shift Engineer should obtain Work Order number from Permit To Work Request that
is initiated by Craft Person(s).
5.5. Step # 2 – Equipment and Job Description
Equipment description should be given by the Shift Engineer. Unique equipment
number should be included and the area where the equipment is located should
also be mentioned.
Proper and sufficient job description must also be given. In case if job description
space of Tag out order is not sufficient to include each job, then Job Description
detail form shall also be used along with Permit To Work, craft person will put down
the job in writing with his name and signature and shall get the signature of Shift
Engineer If the scope of the job changes along the way, the Permit To Work must
be reviewed to ensure that proper isolation is maintained.
5.6. Step # 3 – LOTO Preparation and its application
Shift Engineer, Area Engineer and Shift Electrical person shall decide the isolation
boundary in consultation with the craft person. Complete all information on LOTO
form including equipment code, equipment description, it’s safe Position,
Operational Lock No. and Tag considering the steps to control hazardous energy.
Complete “DANGER-DO NOT OPERATE” tag(s) for all isolating devices and fill in
both the WTP number and Operational Lock number.
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The Shift Engineer will allow to Area Engineer and Shift Electrical Person for
isolation and application of all Operational Lock(s) and Tag(s) after ensuring that
the conditions in section 5.2 - “Preparation for Equipment Shutdown, and in section
5.3 “Equipment Shutdown” have been adhered to.
Area Engineer and Shift Electrical Person shall place all isolating devices in the
safe position as noted on the LOTO Form and apply tag out lock with “DANGER-
DO NOT OPERATE” tags or only “DANGER-DO NOT OPERATE” tags if tag out
lock is not applicable by taking the following steps.
 Ensure all possible alternative energy sources are correctly isolated.
Note: Never open isolators under load and never pull fuses under load as an
isolating device.
 Area Engineer and Shift Electrical Person shall put name and signature
against each line item of LOTO Form, whatever he carried out.
 Shift Engineer / Asst. Shift Engineer shall verify the correct placement of tags
/locks and position of isolating device as mentioned on LOTO Form.
Note: NPL uses a Tag out procedure in which both locks and tags are hung on
the isolating device. There may be times when tags can be used separately
without locks, however, a lock must always be used wherever possible and will
always be accompanied by a tag.
Control of Stored Energy: Take steps to drain, remove solids, vacuum out,
wash down or cool off the equipment or system to control the stored energy.
Any of the following precautions (individually or in combination) may be
necessary to guard against residual energy left in the equipment after it has
been isolated.
 Make sure all parts have stopped moving.
 Install ground wires at the specified location, if required.
 Relieve trapped pressure (low point bleed).
 Make sure the trap hazardous gases have been ventilated from closed
vessels/drums/pipes/containers.
 Release the tension on springs or block the movement of spring driven parts.
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 Block or brace parts that could fall by gravity or from hydraulic or pneumatic
pressure loss.
 Drain process piping systems and close valves to prevent the flow of
hazardous materials.
If stored energy can re-accumulate, monitor it to make sure it stays below
hazardous levels. Always tag low point bleeds if they need to remain open to
prevent re-accumulation of energy. The tag will serve as a reminder that the
valve is open when putting equipment back in service.
Area Engineer and Shift Electrical Person is responsible to place the keys of all
the locks used in the LOTO into the Lock Box and print the Lock Box number, his
name, signature, date and time on PTW Form.
Shift Engineer/ Asst. Shift Engineer shall write his name with signature as
isolation verify on PTW Form.
Shift Engineer shall hang the Operational Lock on the Lock Box.
Hot Work Permit (HWP), Work at Height Permit (WAHP) and Confine Space
Work Permit (CSWP) requirement: To accomplish the said job if HWP, WAHP,
CSWP is required, Shift Engineer will prepare and apply it as per its own guide
lines and procedure and will attached it with Permit To Work.
Cross Reference of others PTW on same equipment/system: Shift Engineer
will give the cross reference of other(s) PTW those already issued and job is still
continuing on same equipment/system.
5.7. STEP # 4 –Risk identification and PPEs
Shift Engineer shall mention the appropriate safety gears (PPEs) required for the
person(s) involved in said job.
Shift Engineer shall attach the appropriate risk assessment sheet or Job hazard
analysis sheet if it is readily available, otherwise shall do the “what if” process with
craft person, to identify the risk.
Shift Engineer shall give special instruction (if required) to craft person about
hazards and safety of person(s) and system.
5.8. STEP # 5 - Verifications
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Verification of tags, locks and work area conditions by Craft Person must be
carried out prior to Approval / Authorization of the PTW. The verifications ensure
that the proper tags and locks are hung on the proper place of equipment and that
the place of equipment has been disabled in the proper position.
Verification step must be done after the person who hung the tags and locks has
signed off the PTW.
The step # 1, to 4 of PTW should be verified by the Craft Person prior to approval
of the PTW.
The verifier can take help from the person hanging the tags or any other Area
Engineer in LOTO verification.
If discrepancies are noted, it should be bringing in the notice of Shift Engineer and
remedial action shall be taken immediately.
After verifying, the person will print name, sign, date and time.
5.9. STEP # 6 – Shift Engineer Approval and Authorization to work
When the Shift Engineer is satisfied that all of the above checks have been carried
out, he will then approve the PTW by printing his name, sign, date and time in the
appropriate column.
5.10. Step # 7 - Craft Acceptance / Release
Craft Person(s) after reviewing the PTW and being satisfied that all hazards and
hazardous energy has been controlled, isolating device locks key has been placed
in box and the area has been barricaded if required, will hang their craft lock on the
appropriate lock box as mentioned on the PTW.
The Shift Engineer will explain the Craft Person if any other job is in progress in the
same Area or Equipment.
Then Craft person will log name, sign, date and time on the PTW.
Prior to commencement of the work, Craft Person will hang the copy of PTW at the
work place.
Craft person / Group Leader will deliver tool box talk to craft group (NPL person
and Contractors) at work location. If the job continues for more than one day and if
the conditions changed the Craft person / Group Leader will deliver fresh briefing
to its crew members on new hazards / risk arise due to change of conditions.
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If other craft person wants to work on that particular piece of equipment, he must
accept the PTW prior to commencement of work.
Craft person must not do anything that could reactivate the equipment or system or
possibly bypass isolating devices by installing new piping or wiring.
Craft person after completion of the assigned task and removal of the portable
earth / ground wires and housekeeping of work area, notify the Shift Engineer by
signing the PTW in the released column and remove craft lock(s). The locations
where closing of panel doors is required, the craft person shall call Shift/Area
engineer for verification of removal of portable earth/ground wires prior to closing
the panel doors.
5.11. Step # 8–Temporary LOTO Release
If TLTR is required for the equipment testing (Except Engine and Gen Set for the
time being till proper procedure is developed), the Craft Person shall request for
TLTR and log his name, signature, date and time on PTW.
5.12. Step # 9–Acknowledgement of Risk Assessment and JHA
Craft Person should ask that risk assessment and JHA was appropriate otherwise
he gives the suggestion(s) for its improvement.
5.13. Step # 10–De-isolation
Shift Engineer will ensure that the entire task is complete; all craft people accepting
the PTW have signed the PTW release column. All others associated Work
Permit(s) i.e., HWP, WAHP and CSWP with this PTW has been released. The
Shift Engineer/Area Engineer will then thoroughly check the equipment/system to
be sure all guards are in place and the equipment/system is ready for safe
operation. The Shift Engineer will remove Operational lock from Lock Box and will
allow the Area Engineer for removal of Lock and Tags.
Shift Engineer / Area Engineer shall verify removal of portable earth/ ground wires
etc. from the specified location.
The Area Engineer shall remove the Lock(s) and Tag(s) from the equipment
provided under said PTW and LOTO in correct order. After removing the isolation,
he shall hand over all tag out lock(s) and tag(s) to Shift Engineer and log his name,
signature, date and time on PTW as well as on LOTO.
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Shift Engineer / Asst. Shift Engineer shall verify the correct removal of tags / locks
and inverse position of isolating device as mentioned on LOTO Form.
Shift Engineer/ Asst. Shift Engineer shall write his name with signature as De-
isolation verify on PTW Form.
5.14. Step # 11–PTW Completion and equipment restored for operational use
Shift Engineer shall ensure and review.
All portable earth / ground wires etc. have been removed from the specified
location.
Review and count all the locks and tags which were removed.
After ensuring, Shift Engineer should log name, signature, date and time.
Shift Engineer after being satisfied will notify all operating people associated with
the equipment of its operating status.
5.15. Craft Person PTW acceptance change

If the work is incomplete and PTW acceptance change is required, then on duty
craft person will accept PTW and the craft person who has previously accepted will
sign off PTW and hand over lock box key to duty craft person.
6. PTW Cancellation
When a PTW is prepared upon request of Craft Person but the PTW steps are not
initiated or completed before acceptance by the craft person. It can be cancelled by
mentioning the reason of cancelation on PTW form and remove all isolation if
provided to normalize the system. The record of all the cancelled PTW shall be
maintained.
7. Special Situations
7.1. Temporary LOTO Release (TLTR) Procedure
There may be situations when testing, positioning, making adjustments or to
perform other work on an isolated equipment or system, a TLTR procedure is
necessary. It should be remembered that the TLTR should only be used for the
approved work.
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Only one Craft Person or Craft Group Leader shall accept a TLTR at a time. Any
other Craft Person or Craft Group Leader can only accept a TLTR once the TLTR
has been released by the previous Craft Person or Craft Group Leader. The only
exception to this is during PTW acceptance change is required then on duty craft
person will accept TLTR and the craft person who has previously accepted will
sign off TLTR.
The PTW is the responsibility of the on duty Shift Engineer during any TLTR.
7.2. Preparation and Application of TLTR
The Craft Person or Craft Group Leader first requests for a TLTR then Shift
Engineer suspend the PTW under working before issuance any TLTR
corresponding to the same PTW.
If other PTW are Approved and Accepted for the same equipment that is the
subject of the TLTR, the Shift Engineer shall ensure that these PTW must be
suspended before starting the TLTR Procedure.
7.3. Step – 1: TLTR Serial number

Shift Engineer shall fill the PTW number, TLTR number and date in the TLTR form.
7.4. Step – 2: Description of Activity
Shift Engineer after consultation with the craft person will write the details of
activities to be carried out under TLTR.
7.5. Step – 3: Locks and Tags Removal List Preparation
Shift Engineer shall identify the minimum number of Points of Isolation or Points of
Earthing that are to be released from their Safe Position for this TLTR and shall
specify their required temporary position. The Shift Engineer must consult the Area
Engineer and Craft Person or Craft Group Leader when identifying these Points of
Isolation or Points of Earthing.
7.6. Step – 4 Locks and Tags Removal
The Area Engineer will remove all locks and tags mentioned in locks and tags
removal list, restore the equipment in a desired position for the activity mentioned
on TLTR form, retain locks and tags in the lock box and write the lock box number
in the TLTR form.
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The Area Engineer will write his name, sign, date and time at appropriate place on
TLTR form.
7.7. Step – 5 Verification
The Craft Person or Craft group leader will verify that step-1 to step-4 has been
completed in correct manner and order in all respect then he write his name, sign,
date and time on TLTR form.
7.8. Step – 6 TLTR Approval and Authorization
When Shift Engineer satisfies that all the locks and tags mentioned in TLTR have
been removed, he will then Approve and Authorize the TLTR by writing his name,
sign, date and time at the appropriate column in the TLTR form.
7.9. Step – 7 TLTR Acceptance and Release
Craft person will write his name, sign, date and time on the TLTR acceptance
column after approval and authorization of shift Engineer.
After performing the approved activities under TLTR, a craft person shall write
name, sign date, time in release column and mention the test status Okay or Not
Okay.
7.10. Step – 8 TLTR Completion Control
When the assigned task for the TLTR has ended with testing status mentioned as
Okay then original PTW Work Suspension status is cancelled and then Craft
person will release the work permit.
When the assigned task for the TLTR has ended with the work status mentioned
as not Okay, the original PTW will be restored as follows:
The Area Engineer shall secure all of the Points of Isolation or Points of Earthing
that were released from their Safe Positions under the TLTR back into their Safe
Positions and shall then hang the Tag Out Lock, Multi-Tag Out Device and / or
Danger Tag on these Points of Isolation or Points of Earthing as prior to the
issuance of TLTR. After hanging the lock(s) and tag(s), the Area Engineer tag out
lock(s) key(s) in original PTW lock box, print his name, sign, date and time in TLTR
form at appropriate column.
Verification step must be done by Craft Person after the person who hung the tags
and locks signed off on the TLTR Form.
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When the Shift Engineer is satisfied that all of the above steps have been carried
out, then he will give the approval in the TLTR form. The PTW is now ready for
acceptance by the craft person(s).
7.11. Reduce Step Conditions
At times, strainer cleaning/changing or other activities are necessary at an
increased pace. The operation of the plants is dependent upon these systems. To
complete certain tasks quickly, few tag out procedure steps required to be
reduced. Knowing the possible ramifications of bypassing the safety procedures,
the General manager or his designee will specify that the area is under duress
because of frequent strainer cleanings/changes or other activities and will
authorize (in writing – after visiting the area) the use of reduced steps in the tag out
system. However, it is never allowed to complete the work without a PTW.
Preprinted PTW forms and tags should be used at this time as usual.
8. Honoring Tags and Locks
NPL staff is responsible for honoring all Tag Out Locks, Danger Tags, Craft Locks,
Operational Locks and Multi-Tag Out Devices.
Unauthorized removal of any Tag Out Lock, Danger Tag, Craft Lock, Operational
Lock or Multi-Tag Out Device could result in serious injury, death or equipment
damage and will result in strict disciplinary action.
9. Emergency Craft Lock Removal
Manager Operation can authorize Craft Person lock removal from the Lock Box in the
event locks are placed and the owner of the lock is not on the plant site due to any
reason or the lock key is missing.
The Craft Person’s managers shall insure the job has been completed in all respect
after consulting with Craft Person. The manager operation and the Craft Person’s
manager will complete a lock accountability form. Denote the time and date of
removal, reason for removal.
The craft person’s manager is responsible for notifying the individual of the lock
removal.
Lock accountability form will be attached to appropriate PTW. Maintain these records
for one (1) year.
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10. Authorization for PTW and LOTO

Staff members who will be involved in the preparation, compilation, approval,
acceptance, release, completion and cancellation of PTW and LOTO shall undergo
training and pass appropriate test. HSE Officer will provide the list of PTW test
passed staff member list to Shift Engineer.
11. Changes to the LOTO Procedures
The LOTO Procedure shall be revised in any of the following condition
Any NPL staff member may suggest any addition or deletion from the PTW and
LOTO Procedure, if he believes that an improvement is essential in the existing
procedures.
A risk assessment identifies an improvement in the existing system.
Recommendations on the basis of Audit findings.
Changes in Legislation or regulations.
Recommendations on the basis of investigation after an incident/ Accident.
The proposed change or addition to the PTW and LOTO Procedures shall be
presented to the HSE Committee for review and consent and then revised PTW and
LOTO Procedure shall be approved by the General Manager.
Once the revised LOTO Procedure have been approved by the General Manager,
then HSE Officer shall communicate the details of the revisions by means of training
to all NPL team member(s) specially person(s) involve in PTW and LOTO.
12. Activation of Emergency
If the work area is evacuated when an order to evacuate is given or when an
emergency alarm is activated for the total site evacuation, all PTW and LOTO
documents shall be treated as suspended automatically and the craft person(s) shall
not continue or restart work. Once the emergency situation is cleared the craft person
shall report to the Control Room. Shift engineer shall ensure that the verification of
step 5 in the PTW are re-done and are counter signed by the respective people. Shift
engineer will then counter sign to approve and authorize PTW as mentioned in step
6. The same PTW will then be re-issued to the craft person to carry out the activity.
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13. Management of Change

New equipment or equipment modification that changes the energy streams or
isolation points will be covered under “Management of Change Procedure”.
The concern HOD will modify the system related documents i.e., P&ID, schematic
drawings, manuals etc. and procedures including coding of the new installation to
facilitate the preparation of switching order.
14. LOTO Auditing and Training
HSE Office will be responsible for PTW and LOTO system audits that shall be carried
out on weekly basis.
The manager operation or his designee shall perform a random audit of the PTW and
LOTO and Others Permit in progress on monthly basis to ensure the implementation
of the procedure.
All PTW(s), which have remained open for a period exceeding three months, will be
reviewed and any damaged or defaced tags should be replaced with new tag(s) with
same detail. Tag out Quarterly Inspection Form shall be filled for defaced or damaged
tags.
15. Contractor personnel working with NPL
The Craft Person or Craft Person Group Leader shall brief contractor supervisors for
the activity and risk involve in the job and then he will brief their other crew
member(s).
NPL staff member must never assume that a contractor fully understands the PTW
Procedure.
NPL staff members are responsible for contractor’s personnel safety as well as their
own.
16. Enforcement
Enforcement is divided into two areas, administrative and physical harm.
Administrative pertains to any Team Member not adhering to the application of Tag
Out Procedure.
Physical harm pertains to an individual’s failure to follow procedure, which is the
cause of physical harm to him or another individual.
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Each incident will be considered individually and may involve an independent

All safety occurrences will be discussed in next EHS team meeting for appropriate
actions.
Failure to adhere to any /all aspects of this procedure may result in disciplinary
actions.
17. Documents Annexure:
Following type(s) of safety documents are being used under this procedure:
PTW
PTW log book
TTLR
TTLR log book
LOTO
LOTO log book
HWP
HWP log book
WAHP
WAHP log book
CSEP
CSEP log book
CWP
PTW quarterly inspection
Craft Person Lock removal (In Emergency)
154
Revision No 01
SAFE HANDLING OF MATERIAL Revision Date 11-10-2019
1. Objective
This procedure provides guidelines to prevent injuries that may result from the
improper handling of materials.
2. Scope
This procedure applies to materials handling activities at plant which may affect the
quality of operation and maintenance services.
3. General
 This procedure shall be reviewed periodically to ensure its adequacy, suitability
and effectiveness.
 The improper handling of materials is one of the most frequent causes of injury
in industries. Most injuries are caused by simple, sometimes repetitive actions.
Such injuries may be avoided by the employees giving full attention to the task.
 MSDS and manufacturer’s instructions may be used as reference document for
safe material handling.
4. Hazards Assessment
To assess the hazards of materials manual handling operations, consider the load,
the task, the environment in which the task is performed, and the operator. When
these factors interact with each other, they can create hazards that result in
injuries.
A load may be hazardous because of;
 weight
 size
 shape (making it awkward to handle)
 coupling (type of grip on the load)
 slippery or damaged surfaces
 absent or inappropriate handles, and
 imbalance (i.e., changing center of gravity)
The task or method of handling may be hazardous when it involves
 lifting or lowering
 repetitively
 quickly
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 for extended periods of time

 while seated or kneeling
 immediately after prolonged flexion
 shortly after a period of rest
 an inability to get close to the load
 moving the load over large distances
 accuracy and precision required because of
 fragile loads, or
 specific unloading locations
 materials positioned too low or too high
 hazardous movements or postures (e.g., twisting, extended bending and
reaching)
 multiple handling requirements (e.g., lifting, carrying, unloading)
Environmental factors include:
 temperature (beyond a 19-26°C range)
 relative humidity (beyond a 35-0% range)
 lighting
 noise
 time constraints (e.g., machine-paced work or deadline pressures)
 physical conditions such as
 obstacles
 floor surfaces (e.g., slippery, uneven or damaged)
Operator characteristics that affect the handling of loads include:
 general health
 physical factors
 height
 reach
 flexibility
 strength
 weight
 aerobic capacity
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 pre-existing musculoskeletal problems

 psychological factors
 motivation
 stress
5. Procedure
5.1. Preventing Cuts and Bruises
 Before handling materials, be alert to the possibility of sharp edges, nails,
slivers, sharp wire ends, or other projections that may cause cuts or punctures.
 Gloves should be worn when handling objects that are rough or can cause
chemical burns.
 Never carry glass, tin or similar material sheets under the arm. Wear gloves,
use both hands and carry it to the front or side, where it does not block your
vision.
5.2. Heavy Objects Lifting
 Strains and sprains of the back and other joints are the types of injuries
encountered most frequently from handling materials.
 If an object is heavy or large, check its weight by tipping or moving it before
attempting to lift or carry it.
 If an object is too heavy for you to lift, get someone to help you or use
mechanical means such as forklift or trolley or crane.
 When it is necessary for you to lift an object, use the following method;
Basic Lift
 Face the object; place your feet shoulder-width apart and near the object
to be lifted.
 Bend at the knees and squat by the object in a comfortable position.
Don’t stoop (bend) over it.
 Get a firm, balanced grip on the object.
 Keep your back straight (vertical) and your arms as straight as possible.
Do not twist your body as you lift.
 Lift the object by slowly straightening your legs, while keeping your back
straight and vertical.
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 When it is necessary to lift and carry an object from one location to

another, take the following precautions:
 Be sure you can lift and carry it.
 Be sure you have a clear route between the locations.
 Be sure your footing along the path is clear of obstruction.
 Be sure the space in which to place the object is clear.
 Walk carefully, twisting your body as little as possible.
 Set the object down carefully, reversing the lifting procedure.
 Never carry a heavy object on or off a truck, unless:
 The truck bed or tailgate is flush with and against the dock or loading
platform
 A suitable deck plate or ramp is securely in place
 Do not attempt to step up or down a high step when carrying a heavy or bulky
object. Use a ramp or skid instead.
 Use caution when handling all objects. Many times objects that are harmless in
themselves can cause injury if improperly or thoughtlessly handled.
Picture 5.1: Basic Lift {for small objects enough to straddle (overlap)}
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Picture 5.2: Power Lift {for objects too large for straddling and object shifts your centre
of gravity forward and you must push your buttocks out to compensate}
Picture 5.3: Tripod Lift {for objects with uneven weight distribution example: sacks of
food}
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Picture 5.4: Straight Leg Lift {lift when obstacles prevent you from bending your knees.
Be careful! put you at increased risk for muscle strain}
Picture 5.5: Overhead Lift
Picture 5.6: Pivot Technique

5.3. Handling of Pipes
 Pipes even in small sizes should not be carried by one worker in congested
areas. Two people should carry the pipe, with one person close to each end to
prevent injury to others.
 Do not drop one end of pipe while someone is holding the other end. Always
set the pipe down together.
 The practice of two workers carrying pipe on their shoulders is discouraged.
The hands should be used in its place.
 Never place your fingers in the open ends of pipe to move or carry it.
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 Wear gloves and exercise extreme caution when handling pipe and large
fittings. Burrs, sharp threads, and sharp edges are frequently present on these
items.
 Do not carry a smaller diameter pipe inside a larger diameter pipe.
5.4. Handling of Drums
 To loosen or tighten a cap, always use an appropriate cap opener.
 Hold a rag or similar item tightly over the cap when it is loosened, to catch any
possible spray from pressure in the drum.
 If a drum contains acid, caustic or other hazardous chemical, you must wear
goggles, face shield, and acid-resistant rubber gloves and clothing when
removing the cap.
 Drum handling device should be fitted with the fork of forklift truck while
handling filled drums stored in vertical position.
 A drum may be moved a short distance by tilting and rolling it on the bottom
edge. However, exercise extreme care in watching both the balance of the
drum and the changes of fingers or toes being pinched between the drum and
another object.
 Roll drums, if required by pushing them from behind with both hands on top of
the drum.
 Change direction by gripping one edge and pulling, then proceed to push with
both hands on top.
 Do not kick or roll the drum with your feet.
5.5. Handling Chemicals
Refer to Safe Chemical Handling Procedure (Doc Id: NPL/Safety/A006)
5.6. Handling Materials with Powered Equipment
 All materials too large or too heavy to be safely handled by hand shall be
handled with powered equipment like crane, fork truck etc.
 If the equipment operator cannot clearly see every part of the operation to be
performed, the operator shall use a signalman for assistance.
 When a signalman is used, the signalman shall be in a position to see every
phase of the operation and to be clearly seen by the equipment operator.
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 Any signals that might possibly be required should be thoroughly

understood by both the equipment operator and the signalman before
beginning the operation. Commands are to be given by the signalman only,
except for the command to stop.
 Workers shall never walk or stand under a suspended load.
 A safety hook with clasp should be used when lifting.
 Unstable or unsecured loads should not be lifted.
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OFFICE SAFETY Revision Date 11-10-2019
1. Objective
This procedure provides guidelines for reducing the risk of personal injury in the
administrative work environment.
2. Scope
This procedure applies to the administrative staff of the plant who is working in the office
buildings.
3. Definitions
N/A
4. General
The office is not generally considered to be a hazardous or dangerous place. However, a
number of potential hazards do exit, and it is the obligation of all personnel to ensure that
these hazards are recognized and that precautions are observed.
5. PROCEDURES
• General Hazards of the Office Environment and Safety Precautions
• Floors may present a potential slip or trip and fall hazard.
• Finishes should have anti-slip qualities.
• Loose carpet, defective tiles or boards, warped and worn floor mats under chairs and
warped or cracked plastic floor mats are to be repaired or replaced to eliminate tripping
hazards.
• Passage stairs and aisles must be remained unobstructed.
• Waste baskets, telephone and electrical cards and outlets, low tables, and office
equipment should be placed against walls, in corners, under desks, or in some other
suitable place to prevent tripping.
• File drawers, pencil sharpeners and typewriter carriages should not protrude into aisles.
• Stairways and exit shall be checked regularly to ensure they are unobstructed and
properly lighted.
• Electrical Cords and Outlets
• Computers, typewriters, adding machines and other electrical equipment should be

arranged to avoid the use of lengthy extension cords and should be grounded
• Chairs should be comfortable and have a wide base. Swivel chairs should be secure.
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OFFICE SAFETY Revision Date 11-10-2019
• Desk and file drawers should be equipped with safety stops. Glass tops on desks and
tables shall be free of cracks
• Paper cutters shall be equipped with guards. Paper hole punchers should never be
overloaded.
• Material Storage
• Boxes, paper and other heavy objects must be stacked in proper way so that those does
not create any fall hazard.
• Razor blades and other sharp objects should be carefully boxed or the edges otherwise
covered when stored in drawers.
• Keep the accumulation of trash and unused material to a minimum.
• Trash: Personnel shall not allow trash and waste paper to accumulate. Offices shall be
cleaned of all trash daily.
• Smoking: Smoking is only permitted in designated areas.
• Fire Hazards:
• Dust accumulation presents a potential fire hazard. Equipment, especially electrical

equipment should be routinely checked for dust accumulation and cleaned as necessary.
• Overloaded receptacles, extension cords and circuits may present a fire hazard. Check
equipment periodically for hot electrical cables.
• Computers
• Some persons may suffer from eye strain or headaches when working with computers.
Personnel who suspect their computer is causing these problems should request a
screen filter.
• Also, give your eyes frequent short breaks by looking up and focusing on distant objects
for a few seconds.
• To avoid wrist or forearm problems, including carpal tunnel syndrome, your upper arm
and forearm should form an approximate right angle, with your shoulders relaxed, when
your hands are on the keyboard. Your wrist and hand should be in roughly a straight line.
If you feel pain in your hands, wrists or arms continually while at work and the pain
continues when you are away from work, consider having an examination by a qualified
physician.
• During heavy thundering and lightening refrain from using computers, which may pose a
serious threat to electrocution
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CONFINED SPACE ENTRY Revision Date 11-10-2019
1. Purpose
The purpose of this procedure is to establish a confined-space program to control

and protect personnel from any confined-space hazards and to regulate entry into
confined spaces. This procedure defines the precautions that must be taken when
work is to be performed by employees in any potentially hazardous confined space.
2. Scope
This procedure is applicable to confined space within the boundaries of plant.
3. Definitions
3.1. Acceptable Entry Conditions
The conditions that must exist in a Permit- Required Confined Space to allow
Entry and to ensure that individuals involved with a Permit Required Confined
Space can enter safely.
3.2. Atmospheric Test Sheet
A safety document used to record the concentrations of specific gases and

atmospheric conditions before / during work in Confined Space.
3.3. Attendant
An individual stationed outside a permit required confined space with specific

responsibilities for the safety of the entrants and controlling entry to the confined
space.
3.4. Engulfment
The surrounding and effective capture of a person by a liquid or finely divided

and flow able solid substance that can exert enough force on the body to cause
death by strangulation, constriction, or crushing.
3.5. Entrant
Any NPL staff or contractor who enters into a Confined Space for any purpose
and is aware of confined space entry requirements.
3.6. Entrant Log
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A log used to record the entry and exits of entrants into a permit required
confined space.
3.7. Entry
The action by which any part of the body breaks the plane of an opening into the
Permit Required Confined Space.
3.8. Entry Point
An authorized point of entry into a Permit Required Confined Space as

determined by Craft Person.
3.9. Hazardous Atmosphere
• An atmosphere that may expose individuals to the risk of death,

impairment of ability to self-rescue (that is, escape unaided from a permit
space), incapacitation, injury, or acute illness from one or more of the
following causes;
• Flammable gas, vapor or mist in excess of 10% (ten percent) of its LEL
(Lower Explosive Limits).
• Airborne combustible dust at a concentration that meets or exceeds its

LEL (Lower Explosive Limits);
• This concentration may be approximated as a condition in which the dust

obscures vision at a distance of 5 feet (1.52m) or less.
• Atmosphere oxygen concentration below 19.5 percent or above 23.5

percent.
• Atmosphere concentration of any substance for which the PEL

(Permissible Exposure Limit) is exceeded for that substance. (The PEL
for any particular substances can be found on the MSDS for that
substance.)
• Any other atmospheric condition that is immediately dangerous to life or

health.
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3.10. Confined Space
Any space that is not designed for continuous human occupancy and may
include the following characteristics:
• Is large enough and so configured that a person can bodily enter and
perform assigned work
• Has limited/ restricted means of entry or exit
• Of enclosed nature with potential of insufficient oxygen and presence

of explosive and / or hazardous gases.
The list of all Confined Spaces shall be maintained by the EHS Committee and
made available to all NPL staff.
All Confined Spaces shall be clearly identified at all times by signs displayed at
all potential Entry Points.
3.11. Inerting
The displacement of the atmosphere in a confined space by a noncombustible

gas to such an extent that the resulting atmosphere is noncombustible.
3.12. PEL
Permissible Exposure Limit is a set of time weighted average exposure values,

established by U.S.A. Federal Occupational Safety and Health Act (OSHA), for
a normal 8-hour day and a 40-hour week.
3.13. LEL
Lower Explosive Limit is the lower limit at which a flammable substance will
ignite and support combustion.
3.14. Prohibited Condition
Any condition inside a confined space which contains a hazardous atmosphere;

conditions which are not acceptable entry conditions.
3.15. Tester
HSE officer and his designee is responsible for determining if acceptable entry
conditions are present, at a permit space where entry is planned. This person
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shall use the instrument specifically designed to test the anticipated

atmosphere.
3.16. Double Block and Bleed:
The closure of a line, duct, or pipe by closing and locking or tagging two in-line
valves and by opening and tagging a drain or vent valve in the line between the
two valves.
3.17. Blanking or Blinding:
The absolute closure of a pipe, line, or duct by the placing a solid plate (such as
a spectacle blind or a skillet blind) that completely covers the bore of the pipe
and that is capable of withstanding the maximum pressure of the pipe, line, or
duct with no leakage beyond the plate.
3.18. Oxygen Deficient Atmosphere:
An atmosphere containing less than 19.5% oxygen by volume
3.19. Oxygen Enriched Atmosphere:
An atmosphere containing more than 23.5% oxygen by volume
3 Confined Space Hazards
• Chemical
• Mechanical
• Electrical
• Restrictions to Access and Escape
• Hydraulic
• Pneumatic
• Thermal
• Biological
• Radioactive
• Gravity
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4 Responsibilities
Shift Engineer is responsible for ensuring that all procedures are followed prior
to, during and on subsequent release of the Confined Space Permit.
All persons involved in a Confined Space Entry should know hazards associated
with each particular Confined Space. The persons below are responsible for the
following actions and activities:
4.1. Shift Engineer
• Identifying all hazards associated with Entry into the Confined Space.
Specifying the amount and location of Entry points and Attendants for each
particular Confined Space.
• Identifying and implementing all points of isolation and the necessary safety
precautions to achieve Safety from the system and from residual Hazardous
Energy, which includes but is not limited to, depressurizing, draining, venting,
purging, cooling, washing down, etc. necessary to protect Entrants,
Attendants, and personnel outside the Confined Space.
• Specify the frequency of atmospheric testing inside the Confined Space and
conduct at required intervals.
• Verifying that all conditions stipulated on the Confined Space Entry Permit to
achieve Acceptable Entry Conditions prior to Entry have been established.
• Ensuring that no duties are performed by third parties that might expose the
Entrants and Attendants to risk or interfere with the Attendant’s primary duty
to monitor and protect Entrants.
• Make sure that any communication equipment which to be used to summon

either the external assistance is available and is working properly.
• Approving a Confined Space Entry Permit.
• Terminate the entry upon becoming aware of a condition or set of conditions

whose hazard potential exceeds the limits authorized by the entry permit.
• Terminate the work permit in emergency situations and activate the work
permit after refresh atmosphere analysis and suitable working conditions.
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4.2. Entrants
• Verify that there is an Attendant at each of the entry points for the permit
required confined space.
• Verify that all conditions stipulated on the permit have been achieved prior to
entry.
• Check entry permit for current date, potential hazards and get his name
entered in the entry permit or entry log sheet by the Confined Space
Attendant.
• Maintain communication link with the attendant to monitor the status inside
the confined space and to enable the attendant to alert entrants of the need to
evacuate the confined space should it become necessary.
• Alert attendant whenever any warning sign or symptom of exposure to a

hazard is detected and/or entrant detects a prohibited condition.
• Use appropriate PPE’s as described in the Permit
• Exit from the permit space as quickly as possible whenever:
• An order to evacuate is given
i. The Entrant recognizes any warning sign or symptoms of exposure to

a hazard.
ii. Entrant detects a prohibited condition.
iii. An emergency alarm is activated.
4.3. Attendant
✓ Knows hazards associated with each particular confined space being

entered (i.e., what can happen).
✓ Remain outside the Confined Space at the Entry Point specified during Entry
operations until relieved by another Attendant
✓ Ensure that all entrants are logged whenever they enter or exit the confined
space through an entry point
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✓ Maintain appropriate communication link with the Entrant via visual

monitoring, voice or walkie-talkie channel and also make communication with
Shift Engineer via walkie-talkie channel to monitor and alert the status inside
and outside the Confined Space.
✓ Monitor conditions inside and outside the space to determine if it is safe for
Entrants to remain in the space and order Entrants to evacuate under the
following conditions:
i. Detect a prohibited condition.
ii. Detect the behavioral effects of potential exposure.
iii. Detect a situation outside the permit space that could endanger
Entrants in the space.
✓ Take the following actions when unauthorized persons approach or attempt

to enter a confined space while entry control is in effect.
I. Warn the unauthorized persons that they must stay away from the
confined space.
II. Advise the unauthorized persons that they must exit immediately if
they have entered the confined space.
III. Inform the authorized entrants and the entry supervisor if

unauthorized persons have entered the confined space.
✓ Call plant rescue/emergency response staff as soon as the Attendant

determines that Entrants may need assistance to escape from Confined
Space hazards
NOTE: Attendant shall enter the Confined Space except when relieved by
another person who can become the Attendant.
✓ Performs no duties that might interfere with the his primary duty to monitor
and protect Entrants
✓ Maintain all safety barriers around the Entry Point
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✓ Anytime during a confined space entry that conditions change or the

Attendant suspects a problem, the Attendant has full authority to stop all
entry into confined space and evacuate all Entrants.
4.4. Tester
✓ Test internal atmosphere of a permit space before, and on 12-hour intervals,

or as needed, to ensure the safety of those entering the Confined Space.
✓ Tester shall re-check atmospheres for re-issuance of permits after a plant

emergency situation or condition of the entry changes. NPL staff familiar with
using an approved testing device shall perform testing.
✓ Prior to testing ensure the validity of calibration from calibration tag/record,

inspect and field test the testing device. The testing device shall be
inspected for the following conditions:
• Examine the case, meters, and attachments to detect any cracks or

other defects.
• Check the sampling hose along its length for obstructions or tightness.
• Make sure the battery is properly installed and fully charged.
Note: Testing equipments shall be calibrated as per manufacturer

recommendations and calibration recode should be maintained.
4.5. Craft Person responsibility for Contractors
When a contractor is retained by NPL to perform work in a Confined Space;

the following responsibilities shall be undertaken by Craft Person.
✓ Inform the contractor that NPL has a permit space entry program and that
they must comply with all requirements of the NPL program prior to entering
any Confined Space.
✓ Confirm that all conditions required for confined space entry are achieved.
✓ Inform the contractor of the hazards associated with the Confined spaces to
be entered.
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✓ Inform the contractor about the precautions taken for the protection of his
people in or near the Confined Space.
✓ Set-up coordination and procedures between the contractor and Craft

Person if entry is to be made by both parties.
✓ Discuss with the contractor after the entry is completed any problems or
hazards, which arose during the entry in and around the confined space.
✓ Make available to contractors, the information regarding hazards of the

Confined Spaces to be entered as well as entry operations and procedures.
5 Steps for Preparation for Confined Space Entry
5.1. Isolation of Confined Space
For any Confined Space where isolation, draining, venting, and purging is required to
make it safe to enter then LOTO shall be required. The methods of isolation may
include the following in addition to the specific ones described under the LOTO;
• Disconnecting belt and chain drives and mechanical linkages on shaft-driven

equipment.
• Securing mechanical moving parts within a confined space with latches,

chains, chocks, blocks or other devices.
• The objective is to control any situation where the unexpected energization,

start-up or release of stored energy would cause injury to the workers in the
confined space.
• In certain other situations, it may be necessary to prevent flammable, toxic,

irritating or oxygen displacing gases and vapors from entering the confined
space. This includes all hazardous material, high pressure, high temperature
and other lines that could introduce a hazard to the space. Methods for
preventing entry of these materials includes:
• De-pressurizing and disconnecting contaminant supply lines and

providing a blank or blind which is capable of withstanding the
maximum upstream pressure.
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• Isolating a confined space from a line, duct or pipe by double block

and bleed method
• Inserting a blank sized for the proper pressure in piping nearest the
confined space.
• All hazardous material shall be removed prior to Entering the Confined

Space. This shall be achieved by purging, Inerting, flushing and ventilating. If
Inerting with nitrogen is used, fresh air ventilation will be necessary with the
ventilating equipment drawing air from a clean source.
5.2. Ventilation of Confined Space
• Forced air ventilation may be used continuously on all Confined Spaces with
the ventilating equipment drawing air from a clean source
• Special ventilation consideration may be necessary to reduce welding fume

exposure levels to acceptable P.E.L. requirements when welding inside
Confined Space.
• Flue Effect” ventilation on the boilers may be the exception to forced air
ventilation.
5.3. Protection of Confined Space
Appropriate barriers, boundaries and signs to be established surrounding

Entry Points and other openings of Confined Spaces
• Any horizontal opening will be provided a perimeter boundary, if no

permanent boundaries are present.
• Barriers will consist of red and white warning tape or hard barricading
by scaffolding pipes.
• Signs will be attached to all barriers that state “danger”, reason for,
date, time established, and person responsible for barrier
• All openings to confined spaces which are not being used shall have
barriers and signs stating: “danger - confined space”
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• Robust physical barriers shall be used if the confined space is

immediately adjacent to a road or any area where vehicles or mobile
plant may be present
• The attendant shall be responsible to maintain barriers.
5.4. Communication with Entrants
Entrants and Attendants shall be provided with walkie-talkie to allow

communication between themselves and the Control Room. Whenever
practicable the Attendant should be in eye or voice contact with the
Entrants.
5.5. Atmospheric Testing
5.5.1. Testing of Gas Detector
Prior to testing, the Gas Detector shall be inspected by the Tester. The
Gas Detector shall be inspected for the following conditions:
• examine the case, meters and attachments to detect any cracks or

defects
• check the sampling hose along its length for obstructions or tightness
• make sure the battery is properly installed and fully charged
• check validity of the calibration certificate.
• field/fresh air tested prior to use by the Tester.
• Be sure to allow the recommended response time after drawing the

sample.
• The Tester shall record all results in the Gas Detector calibration log
to ensure its accuracy and identify any malfunctions.
5.5.2. Pre-Entry testing
These tests shall be performed by the Tester before anyone Enters a

Confined Space.
• The initial tests must be performed from outside the Confined Space.
Samples should be taken through a pick hole or slightly opened cover
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on the side of the Confined Space to keep wind or air pressure from
blowing contaminants into the Tester’s face.
• The Tester should determine exactly where and how the sample is to
be taken. A LOTO may be required to access the Confined Space.
• As testing is performed, pause at each location or level to allow the

Gas Detector’s recommended response time after drawing the
sample.
• Test all areas that can be reached by the remote probe, including the
top and bottom of the space, as well as the middle.
• If forced ventilation is present, turn it off and perform an atmospheric

test. Turn the ventilation back on and repeat the atmospheric test to
determine the effectiveness of the ventilation.
• Immediately after Entry into a Confined Space test again for all
possible hazards. Test in the direction of travel as well as one meter
on either side plus all areas that could not be reached from the
outside, including around pipes and irregular shaped surfaces where
contaminants might leak into or accumulate.
• Before entering a confined space for testing, only trained tester

wearing appropriate air respirator or self-contained breathing
apparatus (SCBA) shall enter. In this instance, an Attendant must be
present.
• The Tester shall test the internal atmospheres of Confined Spaces for
the following conditions in the order given. These readings shall be
recorded on an Atmospheric Test Sheet which shall be attached to
the Confined Space Entry Permit.
The Tester shall sign to confirm this information;
• Oxygen content: The oxygen concentration level shall be monitored

continuously and shall be in the 19.5% to 23.5% range
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• Flammable gases or vapors: Concentrations shall not exceed 10%

of the LEL. If the area’s oxygen level is not in the range given above,
check that the Gas Detector is functioning properly.
• SO2 Content: The Sulphur dioxide concentration level shall be

monitored and shall be less than 2 ppm.
• CO Content: The CO (Carbon Monoxide) concentration level shall be

monitored and be less than 10 ppm.
• H2S Content: The H2S (Hydrogen Sulphide) concentration level shall

be monitored and be less than 10 ppm.
• Heat: The Tester shall also sense the temperature inside the
Confined Space where deem necessary. Although the limit is
whatever is bearable for the Entrant, an indication of the temperature
inside will give the Entrant guidance as to the duration that he will feel
comfortable inside the Confined Space.
• Dust: Dust levels must not exceed its LEL.
NOTE: The space should be tested for the conditions listed above, as well as
any other conditions or hazards, which may be caused by the work in or around
the space. Always consider materials and/or chemicals that may be used inside
a confined space (i.e., aerosol cans, de-greasers, lubricants etc.).
5.5.3. Re-Evaluation of Entry Permit:
The area Team Leader or designee shall monitor conditions, which could
require re-evaluation, and up-grade to permit required confined space once
again.
NOTE: If air quality conditions become questionable, resume procedures.
6. Confined Space Entry Permit
Prior to an entry being made into a confined space, a document form (permit)
shall be filled out for the specific entry location. The permit shall be filled out by
the craft person or craft person group leader and submitted to Shift Engineer for
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testing and Authorization. Confined Space Entry Permit may be associated with
other Safety Documents like PTW and LOTO and Hot Work Permit etc.
A Confined space entry permit must include:
• Name of permit space to be entered,
• Name of requester / craft person
• Atmospheric Test results
• Tester's initials or signature
• Name of Entrants and Attendants
• Purpose of entry and known space hazards
• The minimum environmental conditions which are acceptable for entry and
working in the space
• Measures to be taken to isolate permit spaces and to eliminate or control

space hazards
• Date and authorized duration of entry
• Communication equipment to maintain contact during entry
• Any personal protective equipment that is necessary for the entry or rescue
of the workers in the confined space.
• If hot work will be necessary in the space, a separate Hot Work permit must
be attached to the entry permit.
• Any other information needed to ensure employee safety.
• A means for assuring and certifying that all pre-entry requirements have
been met.
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When all parties complete the permit, Confined Space Permit will be posted at
the entry portal so Entrants can confirm that preparations for entry were
performed.
Permit will remain valid as long as work is continued; termination of a permit

shall be performed by the Shift Engineer under the following conditions.
i. The job is completed;
ii. Conditions change
• The same permit will be re-issued for continuation of the job by the next Shift
Engineer, after the fresh atmospheric testing (if required).
• Before releasing confined space entry permit, craft person and Area
Engineer shall confirm that confined space is clear of any material, tools,
equipment, scaffolding, workers, debris etc. After closing door of confined
space, Craft Person will sign on clearance section of confined space entry
permit and Shift Engineer will close this permit.
• Upon termination of a permit, the document shall be placed in a binder

designated by Shift Engineer and retained for a period of one year. This will
facilitate the review of the permit process, and provide a basis for making the
necessary changes to the permit program.
7. Cancellation of Confined Space Entry Permits
The Confined Space Entry Permit must be cancelled when an assignment is

completed or when new conditions emerge. New conditions must be noted on
the canceled and new permit.
8. Personal Protective Equipment
• The Confined Space Entry Permit shall specify the type of Personal
Protective Equipment (PPE) like Head Protection, Eye and face protection,
hand protection, protective clothing, foot protection and hearing protections
shall be used by the Entrants.
• A dust mask shall be worn by the Entrant if significant quantities of dust are
present within the Permit Required Confined Space.
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• A body harness may be required by the Entrant if work is to be performed

above ground level.
• An air purifying respirator and cartridge or Self Contained Breathing

Apparatus (SCBA) shall be used by the Entrant if Entry into a Confined
Space containing a Hazardous Atmosphere is required and it is not
physically possible to entirely remove the Hazardous Atmosphere.
9. Safety equipment
The Confined Space Entry Permit shall specify the type of safety equipment that
shall be used when performing work inside the Confined Space. Such
equipment may include but is not limited to the following:
• Ventilation equipment
• Emergency Rescue equipment such as respirator, CPR facility, full body

harness, life lines and retrieval equipment
• A lifeline and Full Body Safety Harness with appropriate retrieval mechanism
will be required on all vertical entries
• Fire extinguishers suitable for the type of fires that is appropriate to the
hazards that may be present in Confined Space.
10. Electrical safety precautions
• The Confined Space Entry Permit shall specify the type of electrical
equipment that may be used when performing work inside the Confined
Space.
• Electrical equipment supplied from the mains should only be used where
there are no practicable alternatives. Battery powered electrical equipment or
pneumatic powered equipment shall be used whenever possible.
• Preference should be given to use the Low voltage lights (24 V) and 72 V
tools inside the Confined Spaces. If this is not possible then they should use
220V supply through ELCB.
• Electrical equipment supplied from the mains should contain Ground Fault
Circuit Interrupters / Residual Current Devices.
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• Electrical equipment supplied from the mains shall have a valid Portable
Appliance Test (PAT) certificate.
11. Entry Points and Attendants
• Signs signifying Entry Points and all other openings of the Confined Space
where Entry is not permitted (for example, for ventilation) shall be posted at
their prescribed locations
• The Attendant of a specified Entry Point shall remain at the Entry Point until
relieved by another Attendant during the confined space permit.
12. Emergency Response Team
The Shift Engineer may request that an Emergency Response Team who are
suitably trained and equipped to rescue persons from Confined Spaces in case
of any incident can be called for help during Confined Space Entry operations.
13. Symptoms of exposure
Before handling or working with any chemical, the Material Safety Data Sheet
(MSDS) for details of the hazards, instructions for proper handling and
appropriate safety precautions.
• Acid: Burning of eyes, skin, and respiratory tract.
• Ammonia: Corrosive to body tissues, larger concentrations can be

suffocating and extremely irritating to eyes, mucous membranes and lung
tissue.
• Carbon Monoxide (CO): Headache, palpitations, dizziness, nausea,

unconsciousness and eventual death may occur if not removed to fresh air.
• Caustic: Burning of eyes, skin, and respiratory tract.
• Chlorine: Irritation of throat, eyes, nose and respiratory track with tearing,
runny nose, sneezing, coughing, choking and chest pain. Severe breathing
difficulties may occur. Pneumonia may result. Severe exposures may be
fatal.
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• Diesel: Slight eye irritation, prolong contact will cause skin irritation or
dermatitis, avoid ingestion, prolong breathing of vapors, can cause
headache, vertigo, anesthetic stupor.
• Fuel Gas (Methane): High concentrations may cause asphyxiation. No

systemic effects, even at 5% concentration in air. Vapors are non-irritating to
the nose and throat and are practically harmless to the skin because it is
very volatile and evaporates quickly, but may cause some frostbite.
• Oxygen Deficiency: These indications are for a healthy average person at

rest. Factors such as individual health (e.g. fitness level, smoker, obesity)
and degree of physical exertion can affect these symptoms and the oxygen
levels at which they occur: Oxygen Content and Symptoms of acute
exposure at atmospheric pressure (% by Volume)
▪ 15-19% Decreased ability to perform tasks. May impair coordination

and may induce early symptoms in persons with heart, lung, or
circulatory problems.
▪ 12-15% Breathing increases, especially in exertion. Pulse rate

increases. Impaired coordination, perception, and judgment.
▪ 10-12% Breathing further increases in rate and depth, poor

coordination and judgment, lips slightly blue.
▪ 8-10% Mental failure, fainting, unconsciousness, ashen face,

blueness of lips, nausea and vomiting.
▪ 6-8% Eight minutes may be fatal in 50 to 100% of cases; 6

minutes, may be fatal in 25 to 50% of cases; 4-5 minutes, recovery
with treatment.
▪ 4-6% Coma in 40 seconds, followed by convulsions, breathing

failure, death.
• Solvents: Headache, nasal and respiratory irritation, nausea, drowsiness,

fatigue, central nervous system depression, convulsions and loss of
consciousness.
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14. Training
EHS Committee must ensure that all people are trained adequately on the
Confined Space Entry procedure. Whenever the procedure is modified, it should
be communicated to all NPL staff and its contractors.
NPL staff and/or contractors who are required to do the following must be
trained in accordance with a structured competency-based training program:
• Enter and perform work in confined spaces
• Supervise confine space entry work
• Issue entry permits
• Carry out the stand-by role
• Involved in rescue and First Aid procedures;
• Design and lay out the workplace;
• Maintain equipment, used for and during confined space entries; Purchase,
distribute, fit, wear and maintain personal protective equipment; and
• Perform confined space assessments
This program shall include at least the following:
• The hazards of confined spaces
• Assessment procedures
• Control measures
• The selection, use, fitness and maintenance of safety equipment
• Established standard operating procedures, including lockout and isolation

procedures
• Emergency procedures
• First Aid and cardio-pulmonary resuscitation
• Fire protection and suppression
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All Attendants must be made aware of the communication procedure, use of

communication equipment, procedure for summoning rescue and recognizing
changes in the acceptable condition
15. Validity
The maximum duration shall be one shift or as specified by the issuing authority
based on the risk assessed. After each shift the permit should be revalidated by
reassessing the conditions.
16. Auditing
The entire Confined Space Procedure shall be audited at least once a year. NPL
staff involved in Confined Space Procedure shall be trained and qualified. The
training shall be validated at least once a year. A list of authorized people shall
be maintained.
Inspection would involve:
▪ Operation Team leaders shall perform a random audit of the in progress

Confined Space Permits to ensure effective implementation of the procedure.
EHS Team will conduct an annual inspection of Confined Space paperwork.
▪ Annual inspections will consist of an evaluation of all Confined Space Permits

issued for that year. Discrepancies will be noted and immediately rectified by
concerned people involved.
▪ In the event that Procedure discrepancies are discovered, appropriate people

will be given proper training (training class). If discrepancies continue after
training, additional training will be given. A “failure to follow and learn
procedure” may be reason for termination.
17. Enforcement
✓ Enforcement is divided into two areas, administrative and physical harm.
i. Administrative pertains to any Team Members not adhering to the

application of Confined Space Procedure.
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ii. Physical harm pertains to an individual’s failure to follow procedure,

which is the cause of physical harm to another individual.
✓ Each incident will be considered individually and may involve an

independent investigative group to provide determination of fault.
✓ All safety occurrences will be discussed at the next EHS Committee

meeting and appropriate actions taken.
✓ Failure to adhere to any and all aspects of this procedure may result in
disciplinary actions.
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Annexure I
Confined Spaces at Plant
Sr. Locations Equipment Not designed Person Limited/ Potential of

# Code for continuous can restricted Insufficient O2 and
human bodily means of entry Explosive and / or
occupancy enter or exit hazardous gases
1 Boiler #1 steam drums ✓ ✓ ✓ ✓
12 Boiler # 1 flue gas path (Boiler hopper, ✓ ✓ ✓ ✓
LP Evaporator, CO, HP Evaporator and
SH stage)
LP Evaporator, ECO, HP Evaporator and
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Revision No 01
SH stage)
SH stage)
SH stage)
SH stage)
SH stage)
SH stage)
SH stage)
SH stage)
SH stage)
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Revision No 01
SH stage)
23 Boiler # 1 outlet flue gas duct ✓ ✓ × ✓
34 Boiler # 1 Flue gas stack ✓ ✓ × ✓
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45 Boiler# 1-6 soot pit ✓ ✓ × ✓
46 Boiler# 7-11 soot pit ✓ ✓ × ✓
6 Boiler# 1-6 washing water tank ✓ ✓ ✓ ✓
7 Boiler# 7-11 washing water tank ✓ ✓ ✓ ✓
8 Boiler feed water tank ✓ ✓ ✓ ✓
9 Fire/Raw water tank VBE 901 ✓ ✓ ✓ ✓
10 Treated water storage tank # 01 (80 M3) VBC 901 ✓ ✓ ✓ ✓
11 Treated water storage tank # 02 (20 M3) VBC 902 ✓ ✓ ✓ ✓
12 HFO storage tank # 01 PAB 901 ✓ ✓ ✓ ✓
15 HFO day tank # 01 PBC 901 ✓ ✓ ✓ ✓
16 HFO day tank # 02 PBC 902 ✓ ✓ ✓ ✓
17 HFO buffer tank # 1 PBA 901 ✓ ✓ ✓ ✓
18 HFO buffer tank # 2 PBA 902 ✓ ✓ ✓ ✓
19 LFO storage tank PAE 901 ✓ ✓ ✓ ✓
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20 LFO day tank PBF 901 ✓ ✓ ✓ ✓

21 New Lube oil tank QAC 901 ✓ ✓ ✓ ✓
22 Lube oil service tank QAM 901 ✓ ✓ ✓ ✓
23 Used lube oil tank QAD 901 ✓ ✓ ✓ ✓
24 Oily water buffer tank DAB 901 ✓ ✓ ✓ ✓
25 Sludge tank DDB 901 ✓ ✓ ✓ ✓
26 Engine Hall "B" Oily water sump # 01 ✓ ✓ ✓ ✓
27 Engine Hall "A" Oily water sump # 02 ✓ ✓ ✓ ✓
28 FT House Oily water sump # 03 ✓ ✓ ✓ ✓
29 Unloading area Oily water sump # 04 ✓ ✓ ✓ ✓
30 Workshop oily water sump# 01 ✓ ✓ ✓ ✓
31 Workshop oily water sump# 02 ✓ ✓ ✓ ✓
34 Fuel Tanker Lorry ✓ ✓ ✓ ✓
35 Maintenance water tank Engine Hall "A" VBA 901 ✓ ✓ ✓ ✓
36 Maintenance water tank Engine Hall "B" VBA 902 ✓ ✓ ✓ ✓
37 Engine # 1 water expansion vessel VEA 011 ✓ ✓ ✓ ✓
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48 Engine # 1~ 6, Cooling tower acid ✓ ✓ ✓ ✓
storage tank
49 Engine # 7~11, Cooling tower acid ✓ ✓ ✓ ✓
storage tank
50 STG, Cooling tower acid storage tank ✓ ✓ ✓ ✓
51 DG# 1~ 6, Cooling tower inward header ✓ ✓ ✓ ✓
water line
52 DG# 7~11,Cooling tower inward header ✓ ✓ ✓ ✓
water line
53 STG, Cooling tower inward header water ✓ ✓ ✓ ✓
line
54 DG# 1~ 6,Cooling tower outward header ✓ ✓ ✓ ✓
water
55 DG# 7~11,Cooling tower outward header ✓ ✓ ✓ ✓
water line
56 STG, Cooling tower outward header ✓ ✓ ✓ ✓
water line
57 DG# 1~ 6,Cooling tower ✓ ✓ × ✓
58 DG# 7~11,Cooling tower ✓ ✓ × ✓
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59 STG, Cooling tower ✓ ✓ × ✓

60 Engine # 1 Crank Case SQA 011 ✓ ✓ ✓ ✓
71 Sewage Manholes ✓ ✓ ✓ ✓
72 Cable Trenches Switch gear Room To ✓ ✓ ✓ ✓
132kv Grid
73 Cable Trenches Switch gear Room To ✓ ✓ ✓ ✓
Auxiliary Transformer Room
74 Excavation more than four feet deep ✓ ✓ × ✓
75 Containers (material present and open ✓ ✓ × ✓
after long time)
Note: Engine crank case will be a confined space if;
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Revision No 01
- Less than 50% doors will open
- Lube oil present in crank case sump
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EMERGENCY PREPAREDNESS Revision No 01
AND RESPONSE Revision Date 21-03-2018

1. Policy
It is the policy of NPL to establish an Emergency Response Program and guidelines for
the protection of plant people, equipment damage, environment and surrounding
community.
2. Purpose
The objective of the Emergency Preparedness and Response System is to: -
1. Recognize and plan for appropriate responses to an emergency so that the safety
risks associated with the emergency to be prevented or mitigated.
2. Train and prepare individuals working inside the installation so that they can respond
effectively in the following:
• Potential Risk Assessment
• Fire detection and Alarm System
• System for Intervention and Actions to control any incident
• Emergency Evacuation Procedure / Drills in order to meet the emergency
situations, like Bomb Threatening Message or Terror Act / Threat, etc.
3. Scope
This procedure applies to all emergencies include accidental releases of toxic gases,
chemical spills, fires, explosions, natural disasters and personal injury at the plant which
can directly affect the quality of operation and maintenance services of NPL.
4. Definitions
4.1. Emergency: An emergency is an unforeseen or sudden occurrence that poses an
immediate risk to health, life, property, or environment. Most emergencies require
urgent intervention to prevent a worsening of the situation, although in some
situations, mitigation may not be possible and agencies may only be able to offer
palliative care for the aftermath.
Types of Emergencies are following;
• Fire & Explosion
• Chemical/Oil Spillage
• Gas Leakage
• Terrorist Attack
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• Earth Quake
• Flood
• Bad Weather
• Personal Injuries & Diseases
4.2. Emergency Coordinator: An employee within plant premises (i.e., available to
respond to an emergency by reaching the scene within a short period of time) with
the responsibility for coordinating all emergency response measures. He must be
thoroughly familiar with all aspects of the facility’s contingency plan, all operations
and activities at the site, the location and characteristics of waste handled, the
location of all records within the facility, and the site layout. Shift Engineer will be
the Emergency Coordinator.
4.3. Emergency Response Team: Emergency Response Teams are the first lines of
defense in emergencies. Emergency Response Teams must be trained in the
types of possible emergencies and the emergency actions to be performed.
Operation shift staff will be the Emergency Response Team at site.
Emergency Response Team must trained in dealing the following areas:
• Use of various types of Firefighting Equipment.
• First aid, including cardiopulmonary resuscitation (CPR).
• Equipment Shutdown procedures.
• Evacuation procedures.
• Chemical/Oil spill control procedures.
• Use of self-contained breathing apparatus (SCBA)
• Search and emergency rescue procedures.
• Natural disaster (Earthquake, Flooding, Lightning etc.) operation procedures.
• Use of rescue equipment.
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5. Incident Categories:
Category Title Definition & Effect Causing Incident

1. Small Fire,
2. Small Hydrocarbon Spill,
Incident, which may (<1bbl spilled)
involve injury or damage 3. Process Leakage,
0 Minor Incident
to plant controllable by 4. Small leakage of Hazardous
personnel on the spot Chemicals,
5. Minor Gas release (Toxic or
Flammable)
Incident, which may 1. Fire,
involve injury, damage or 2. Small explosion with minor
serious damage to plant knock-on effects,
Moderate
1 beyond resources of 3. Spill containable (Tier 2&3)
Incident
personnel on the spot and or >100bbl spilled,
controllable by Emergency 4. Gas Release but
Response Team controllable.
Incident involving injury,
1. Major Fire,
death or major damage to
2. Major Explosion,
plant or environment
3. Major Spill, (Tier 3)
2 Major Incident beyond resources of Site
4. Major Gas Release
Emergency Response
5. Major or multiple injuries or
Team and external Aid
illness.
required.
Escalating incident 1. Toxic Gas Cloud,
involving large-scale injury, 2. Flammable Gas Cloud,
death or damage, beyond 3. Disastrous Fires and
3 Disaster the resources of External Explosion
and Internal Emergency 4. Earthquakes, Flood or other
Services and threatening Natural Disaster
civilian population.
6. Emergency Evacuation Plan:

6.1. Objective:
The purpose of this procedure is to facilitate and to organize individual’s actions during
workplace emergencies and get NPL and Contractor people out of danger quickly and
efficiently. A disorderly evacuation under emergency condition can lead to confusion,
injury and property damage.
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6.2. Possible Situations:

A wide variety of emergencies both man-made and natural may require a workplace
to be evacuated. These emergencies include but are not limited to fires, bomb
threats, toxic material releases etc.
6.3. Responsibilities:
6.3.1. Observer or First on Scene
• Activate alarm from local manual call point to inform Control Room if it is
not activated or Inform by walkie talkie, local control room telephone
extensions 32061 or 32062 from nearby station or on PTCL number
0494388275. If cannot do all above, shout loudly to alert the colleagues.
• Try to understand the type of emergency and communicate to Emergency
Coordinator as detailed as possible.
• Location, extent and type of Fire / Accident / Incident
• If it is safe to fix the problem, try to fix it without putting anyone at Risk.
• When relieved by emergency response team, proceed to assembly area.
6.3.2. Emergency Coordinator (SHIFT ENGINEER)
• Respond to the alarm /call.
• Arrange and mobilize emergency response team
• Inform ambulance driver and arrange ambulance
• Inform Safety and Admin & Security Manager.
• Inform to the security gates and Reception, and will request to stop the
entrance of contractors/visitors. Also brief the security for entrance of
external Fire tender and ambulance.
• Proceed to scene of incident.
• Communicate by using wakie talkie.
• Inform other team leaders and Plant General Manager (GM).
• Guide external Emergency Services / Fire Fighting team.
• Nominate a person for head count.
• Coordinate Emergency response team.
• Help in Search and Rescue.
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• Do identification of casualties.
• When Incident scene is in secure position, announce EMERGENCY
OVER or “ALL CLEAR”.
• Plant if previously shutdown due to emergency shall be started as per
standard procedure recommended by OEM.
• Assist with investigation.
6.3.3. Emergency Response Team
• Proceed to scene of incident.
• Isolate the energized equipment’s / sources.
• Deal with Emergency situation.
• Communicate on walkie talkie.
• Give necessary assistance e.g. Evacuation, first aid etc.
• Report to Emergency Coordinator when incident is under control.
6.3.4. Plant General Manager (GM)
• Proceed to control room.
• Declare himself as Emergency Main Controller in case of disaster
situation.
• Alert mutual aid partners.
• Check call out response.
• Support the on scene response.
• Liaise with local authorities.
• Commence investigation of the incident.
6.3.5. Ambulance Driver
• Respond to call out.
• Immediately report at scene.
6.3.6. Maintenance Team:
• Respond to call out.
• Carry out specified task
• Help out the Emergency Response Team
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6.3.7. All Site Personnel (Except emergency response team)

• Make safe exit and report to muster points.
• Assist as required.
• If required, after head count, will be evacuated to safe place.
Note: People before leaving will make sure their work area is in safe condition and
equipment they were using is in safe position.
6.3.8. All Contractors:
Contractor workers will be made aware of Emergency Response Plan prior to
commencing the work. Prior to leave the site they will ensure that their work
area is in safe position. On emergency call they will report in assembly area.
6.3.9. Roll Call at Assembly:
To ensure that all personnel are accounted for and searches mounted for any
missing persons, a head count after any evacuation, must be carried out.
Head count will be made by Shift Engineer nominated person. Head count
shall be made as per staff attendance sheet and visitor/contractor entry
sheet.
6.3.10. Responsibility of Plant Security Team:
• Admin and Security Manager shall pass necessary information to Security
Supervisor.
• Security/Gate Supervisor or his designee will collect the plant entry sheets
in case of emergency and submit at assembly area.
• Security Guards should not block the people, in case of emergency exit
from the plant.
• Security Guards should not block the entrance of fire tender and/or
ambulance.
• Information should be given to security gates about the emergency
situation and ALL Clear announcement.
• Security Guards should not leave the gate without the permission of
Admin and Security Manager or his designee.
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6.4. Annual Drill:

An annual drill will be conducted to test the emergency program and its
record will be kept by HSE Officer for at least one year.
Note:
• Muster plan is attached at the end of this section.
• There are three muster points at plant and located below area ;
1- Beside Project Building along the road
2- In Between chemical shed and effluent basin.
3- In front of washing shed
• It is essential that people remain at their assembly point until all roll calls
have been completed. Instruction to return to work will be given by
assembly point controller following the decision by Emergency
Coordinator.
• For typical situations and incidents, consult to the reference procedures.
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6.5. Evacuation in Case of Adverse Weather Condition

1. In the event of an adverse weather emergency or flood emergency on plant,
the Plant General Manager (GM) or his designee, will initiate the appropriate
announcements concerning the emergency flood or hurricane warning and
the instructions for preparation and/or evacuation when and if necessary.
2. In the event of a major weather emergency or disaster, the Admin and
Security Manager will coordinate with the local or state authorities and plant
people.
3. Any NPL personnel who discovers an emergency weather condition or
problems like flood due to severe weather or facilities damage, should follow
these procedures:
✓ Stay out of the area. Do not enter until electrical power has been turned off.
✓ There is an extreme danger of electrical shock if the water has contacted
any electrical devices. Post people at all entrances to the flooded area to
prevent entry by unauthorized personnel.
✓ ERT team will be responsible for pumping water out of the area.
7. Fire Preparedness and Response Program:
7.1. Purpose:
To prepare and provide safety against potential fires and minimize the risks of
damaged or personal injuries in the event of a fire at NPL.
7.2. Classifications of Fire:
Fire Classification
Fire Classification Description
Solid combustible materials that are not metals like, Paper, wood,
A cloth, etc. where quenching by water or insulating by dry chemical
is effective. (Class-A fires generally leave an Ash)
Any non-metal in a liquid state, on fire. This classification also

B includes flammable gases like, gasoline, oil, grease, acetone etc.
(Class-B fires generally involve materials that Boil or Bubble). AFFF
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foam is effective for extinguishing the Oil fires and gases fire will be
quenching with the help of CO2 and DCP extinguishing media.
Live electrical equipment where the non-conductivity of extinguish

C agent is vital where quenching by CO2 and DCP (dry chemical
powder) is most effective.
Material used in laboratories like, potassium, sodium, aluminum,

D magnesium. It takes special extinguishing agents (Metal-X, DCP,
foam) to fight such a fire.
7.3. Responsibilities:
The responsibilities of observer or First on Scene, Emergency Coordinator (Shift
Engineer), Emergency Response Team (ERT), Plant General Manager (GM),
Ambulance Driver, Admin and Security Manager, Security department and other
people are the same as above in section 6.3. Some other responsibilities of other
areas are as follows,
7.3.1. Observer or First on Scene
See above section 6.3.1 for Observer or First on Scene responsibilities. Other
responsibilities are;
In-case of Minor Fire:
Minor fire is one that can be extinguished with portable extinguisher.
• Inform Control Room (CR).
• Extinguish the fire by using suitable extinguisher.
In-case of Major Fire:
Major fire is one that cannot be extinguished with portable extinguishers alone
• Inform CR.
• Check Manual/Automatic fire system operated or not, if not then operate it (must
have knowledge about its operation).
7.3.2. On Duty Area Engineer.
See above section 6.3.3 for Emergency Response Team responsibilities. Other
responsibilities are;
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• Check the fire pumps is operational.

• Regular inspection of fuel tank yards for cleaning and fuel leakage.
• Inspection and rectification for fuel leakage from fuel lines.
7.3.3. All Site Personnel
See above section 6.3.7 for All Personnel responsibilities. Other responsibilities are;
• Make safe and fire free working area.
• Perform smoking only at designated area.
• Don’t block firefighting equipment’s
7.4. Pre-Fire Event Activities/Control
7.4.1. Fuel Tanks and Pipelines (Fuel System)
1. The tanks area is provided with dyke for maintaining a safe distance from other
working areas.
2. General entry to the fuel tank yards area is restricted.
3. The sources of ignition are always avoided or controlled in tanks area by:
✓ Regular cleaning of dry leaves and grasses.
✓ Regular inspection of tank earthing/bonding apparatus for proper functioning,
✓ Prohibiting smoking & open flames.
✓ Implementing & complying Permit to Work system while conducting any job
involving hot work like welding/cutting, etc. inside the plant premises.
✓ Tanks are regularly tested for thickness and are painted to prevent corrosion.
✓ Dyke-wall is regularly inspected for damages and is repaired accordingly.
✓ Ensuring all precautions of safety while unloading and transfer of Lube/
diesel/ HFO oils.
✓ Fuel Tanker Lorries are regularly inspected for damage in paint, body parts
(i.e., tyres, fuel tank etc.) and tank earthing. If found any fault then complaint
to contractor for necessary action.
✓ Regular inspection of fuel pipelines for leakage, if leakage observed then
rectify it immediately.
7.4.2. Steam Pipelines:
1. Regularly inspect the steam pipelines for leakage, if leakage observed than
rectify it immediately.
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2. Immediately remove the flammable material from vicinity or protect it with fire
proof sheet.
7.4.3. Gas Cylinder Storage & Handling
1. The particular storage area is identified and highlighted a safe zone from other
working areas.
2. Only trained persons are allowed to transport and handle empty or filled Gas
cylinders.
3. The sources of ignition are always avoided or controlled in the area and made
safer by:
✓ Regular check of gas cylinder hose/tubing used.
✓ Ensuring Regular Inspection of protective caps provided on gas cylinders by
Maintenance Engineer.
✓ Prohibiting smoking & open flames.
✓ Ensure proper labeling of all Gas cylinders.
✓ Ensure timely check of cylinder pressure.
✓ Make sure that all liquefiable gas cylinders are kept upright position.
✓ A provision should be there for storage of empty and filled gas cylinders.
✓ Ensure all Gas cylinders are equipped with Flash Back Arresters / NRV/
Pressure regulators in working condition.
✓ Ensure that Gas cylinders avoid direct sun light by safe roofing of storage
place.
7.4.4. Fire / Emergency System Inspection, Testing and Maintenance Plan
7.4.4.1. Purpose:
This document establishes the minimum requirements for the periodic
inspection, testing, and maintenance of fire protection systems.
7.4.4.2.Scope:
The purpose of this document is to ensure healthiness and to provide
requirements that ensure a reasonable degree of protection for life and
property from fire through minimum inspection, testing, and maintenance
methods for fire protection systems (detection and suppression).
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7.4.4.3.Fire System Testing and Preventive Maintenance Plan:

Responsible Reference
(Department) NFPA 25
Sprinklers 1. Inspection for corrosion,
EHS,
paint, physical damage Annually 2-2.1.1
Maintenance
2. Replace faulty one.
1. Water flow test. 7-3.1.3
2. Automatic & Manual
system test. EHS, 7-4.3
Annually
3. Record the response Operation
Time. 7-4.3.1
Alarm Devices Inspection for physical

Electrical Annually 2-3.3
damage and calibration.
1. Testing the water flow
alarms
Electrical Quarterly 2-3.3
2. Pressure switches
signals
1. Calibration 5 yearly or
Gauges Electrical when 9-2.8.2
required
Strainers, Filters Inspection & Cleaning Maintenance Annually 4-4.2
Monitor Nozzles
Lubrication Maintenance Annually 4-4.4
Test EHS Monthly 4-3.2

Monthly, 4-2.2.7
Fire Hoses Test EHS
Annually NFPA 1962
Hydrants Test EHS Annually 4-3.2
EHS,
Lubrication Annually 4-4.3.1
Maintenance
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Fire Pump Auto Cut In Test for 30

Operation Weekly 5-3.2.2
minutes.
Preventive Maintenance Maintenance Annually 5-3.2.2
Hydrostatic Flow Test EHS Annually NFPA 1911
Foam System 1. Foam Sample
Annually
2. Foam Concentration
Annually 8-2.12
Testing EHS,
Quarterly 8-3.6
3. System Testing Operation
As & when 8-3.3
4. Manual Actuation Electrical
Possible
devices Test
Monthly
5. Foam Pump Operation
Foam NFPA 25
Chambers at Cleaning Operation Annually
Fuel oil Tanks
Lubrication of outside Shift
Valves Maintenance Annually 9-3.5
Engineer and Yoke.
Check Valves Internal Inspection Maintenance 5 yearly 9-4.2
Heat & Smoke
Preventive Maintenance Electrical Annually NFPA 72
detectors
Pull Stations Preventive Maintenance Electrical Annually NFPA
7.4.4.4.Fire / Emergency System Audits / Inspection and Follow up:

Responsible
(Department)
Fire Extinguishers Inspection & Follow up EHS Monthly
Fire Cabinets Inspection & Follow up EHS Monthly
Emergency Shower/ Eye EHS
Inspection Monthly
wash
Exit Light Inspection EHS Monthly
Plant Calling System Audit, Inspection & Follow Electrical Monthly
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up.
Audit and Follow up for
Fire Alarm Panels Electrical Monthly
any standing Alarm
SCBA & Other
Inspection EHS Monthly
Emergency PPEs
7.5. During Fire Incident

7.5.1. Fuel Tanks Fire
✓ Fire Alarm will receive from tanks in CR.
✓ Shift Engineer will inform Area Engineer / Decanting Supervisor and Emergency
Response Team. Area Engineer / Decanting Supervisor will confirm the Heat
detection Alarm for Fuel Tank and Smoke physically and then intimate to Shift
Engineer about Fire. With the consent of Shift Engineer, Area Engineer will
activate the fire foam system and pour the foam in respective fired fuel tank
immediately.
✓ Meanwhile Emergency Response Team (ERT) will be rushed at fuel tank yard
and start water sprinkling through ground monitor or from fire hoses, if required
and possible.
✓ ERT team must wear fire Emergency Response PPEs before dealing the fire.
✓ If smoke and heat invade all around tank yard area and firefighting is risky then
ERT Team should evacuate the area.
✓ Shift Engineer will inform GM plant or Admin & Security Manager to call External
Authorities for rescue / help. (Authorities / Plant Management numbers list is
below at the end of this procedure (APPENDIX “A”)
✓ All personal will perform their responsibilities as given above in section 6.3 & 7.3.
7.5.2. Fire in Fuel Tanker Lorry
✓ If fire observed in Fuel Tanker Lorry then immediately activate the fire alarm from
decanting / nearest area.
✓ Decanting Supervisor / Security Supervisor will pass instructions to the drivers of
other Tanker Lorries for the mobilization of vehicles from affected area and park
them at safe place.
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✓ Decanting staff will initiate the firefighting and later on help the ERP Team in
extinguishing the fire.
✓ Shift Engineer will inform GM plant or Admin & Security Manager to call External
Authorities for rescue / help if require.
✓ All personal will perform their responsibilities as given above in section 6.3 & 7.3.
Note:
➢ ERT team must wear fire Emergency Response PPEs before dealing the fire.
➢ Each fire breakout must be reported as per Incident /Accident Reporting
Procedure within 24 hours.
7.5.3. Other Plant Area Fire:
Following sequence of events will be observed during any fire emergency,
• Inform CR.
• A small fire can be extinguished with the dry chemical powder or CO2 Fire
extinguishers available in fire area.
• Emergency response team (ERT) will handle the situation with Fire
Hydrant/Sprinkler system if required.
• Orderly evacuation of the building.
• Head count at designated assembly point.
• Search and Rescue for trapped staff members.
• Identification of casualties.
• Medical Care for injured.
• Security of building, prevent unauthorized entrance.
7.5.4. HVAC System:

Operation of the fire alarm in the buildings having HVAC system automatically
shuts down the HVAC and ventilation fans, in order to clear the smoke when
the main fire outbreak is extinguished, the ventilation fans may be started. The
switches of these fans MUST NOT ARE OPERATED except on the
instructions of Shift Engineer.
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Buildings where operation of fire alarm did not shut down the HVAC system
then manually shut down this system immediately. In such building HVAC
system electrical supply switch should be located at visible place and marked.
Emergency Response Team Responsibility during Firefighting
Sr. No Designation Position Responsibility
Team
01 Shift Engineer Leader/ All aspects/ Incident coordinator/First Aider
Coordinator
Remain in control room
Help out the Shift Engineer for;
✓ Isolate the electrical supply of equipment
Team
02 CRO ✓ Call Ambulance
Member
✓ Inform GM Plant & Admin & Security
Manager.
✓ Proceed to scene of incident.

✓ Isolations of equipment in incident areas
✓ Deal with Emergency situation (Nozzle
Area Engineer
ERT Team Man)
03 (ERO, Boiler
Member ✓ Communicate on walkie talkie.
Engineer)
✓ Give necessary assistance e.g.
Evacuation, first aid etc.
✓ Report to Emergency Coordinator.
Area Engineer ✓ Rig the hose pipe at the emergency
(Asst. ERO, ERT Team location,
04
Boiler Operator, Member ✓ Support nozzle man (ERO)
Helper) ✓ Operate hydrant valve
ERT Team ✓ Assets Area Engineer & Emergency

05 Shift Mechanic
Member Coordinator.
Shift Electrical ✓ Searcher / Required Electrical isolations

Staff (Elect. ERT Team of incident areas
06
Engineer, Member ✓ Assets Area Engineer & Emergency
Electrician) Coordinator.
✓ Work as second ERT Team
General Shift ERT Team
07 ✓ Assets Area Engineer & Emergency
Staff Member
Coordinator.
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7.6. Post Event activity :

✓ The soil which gets contaminated due to the fire and fire extinguishing activity
will be replaced by new ones. The contaminated soil will be stored separately
and will be send to waste contractor for further disposal.
✓ Collect and properly dispose off the debris/ waste material generated in fire
incident.
✓ Accident investigation shall be done to find out root causes and suggest
Corrective Action.
✓ The incident report shall be discussed with all employees
✓ Review and updating of HIRA and relevant documents to be done.
8. Chemical Spill / Release Response Program
8.1. Purpose:
Although every effort is made at NPL to prevent spills of potentially hazardous
chemicals or oils in the workplace. Accidents may result the release of chemicals /
oils.
This procedure is provided to mitigate the effects of spills of potentially hazardous
chemicals / oils in workplace.
8.2. Spill Type:
1. Oil Spill
2. Chemical Spill
8.3. Level of spill:
For Oil Spill:
1. Minor Spill / Tier 1 (≤ 10 liters spilled)
2. Moderate Spill / Tier 2 (10-200 liters spilled)
3. Major Spill / Tier 3 (>200 liters spilled)
For Hazardous / Corrosive Chemical Spill:
1. Minor Spill / Tier 1 (≤ 1 liter spilled)
2. Moderate Spill / Tier 2 (>1-5 liters spilled)
For Non Hazardous / Non Corrosive Chemical Spill:
1. Minor Spill / Tier 1 (≤ 10 liter spilled)
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2. Moderate Spill / Tier 2 (>10-40 liters spilled)

8.3.1. Minor Spill / Release:
A spill of liquid materials which involves the release of a type or quantity of oil /
chemical which does not pose an immediate risk to health and does not involve
chemical contamination to the body.
This spills requiring an on-site worker to respond and take necessary corrective
actions as soon as possible.
8.3.2. Moderate Spill/Release:
A spill of liquid materials which involves the release of a type or quantity of a
chemical / oil that poses an immediate risk to health.
This level spills requiring response by on-site or off-site trained staff but posing
no danger to the public.
8.3.3. Major Spill/Release:
A major chemical / oil leak where;
✓ There is a contamination of the drains or outbreak of fire or explosion.
✓ A Hazardous Chemical Leak that is thought to be a hazard to personnel /
Environment.
✓ External authorities may call for help.
A major incident beyond the resources of a single facility, where there are
subsidiary problems to complicate the situation such as fire, explosion, toxic
compounds, and threat to life, property and the environment. Assistance will be
required from local, regional, and/or provincial organizations.
8.4. Response Program:
8.4.1. In case of Minor Leakage:
✓ Inform CR if required.
✓ Shift Engineer will inform to Emergency Response Team if required.
✓ Locate the source of the spill, and stop the spill.
✓ To ensure secondary containment drain valves are close.
✓ Remove ignition sources and unplug nearby electrical equipment.
✓ Establish exhaust ventilation. Vent vapors to outside of building.
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✓ Choose and use appropriate PPE (goggles, face shields, gloves, clothing,
etc.).
✓ Cordon the spill to avoid spreading.
✓ Make arrangement to collect or dispose off the spilled hazardous substance
safely and properly.
8.4.2. In case of Moderate / Major Leakage:
In case of Major chemical/ oil Leakage or Hazardous Material:
✓ Inform in CR
✓ Shift Engineer will inform to other plant people and Emergency Response
Team.
✓ Isolate the spill area.
✓ Check that is secondary containment drain valves close.
✓ Remove ignition sources and isolate nearby electrical equipment.
✓ Establish exhaust vapour source, if possible.
✓ Choose and use appropriate PPE (goggles, face shields, gloves, clothing,
etc.).
✓ Cordon the spill to avoid spreading.
✓ Make arrangement to collect or dispose off the spilled hazardous substance
safely and properly; use spill response kit.
✓ If evacuation required, then follow “Emergency Evacuation Plan”.
8.5. Spills involving Injured People:
If a spill involves personal injury, follow the procedures appropriate to the type of
spill above and, concurrently;
✓ Move the victim from the area of the spill (if this can be done without
further injury to the victim or emergency response people) immediately.
✓ Locate the nearest emergency eyewash or safety shower.
✓ Remove any contaminated clothing from the victim if possible and flush all
areas of the body contacted by chemicals with high volumes of fresh
water for at least 15 minutes.
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9. Confined Space Rescue

1. If there is a need of persons to be rescued from the confined space, inform Shift
Engineer who will arrange rescue team.
2. Wear SCBA during Rescue Operation in confined space if required.
3. Take confined space rescue stretcher if required.
4. Casualties at a fire have first priority and if possible, should be evacuated to the safe
place. Do CPR and First Aid and shift it to nearest hospital.
5. Shift Engineer will arrange Ambulance for shifting the Injured / casualties to the Hospital.
10. Bomb Threat Message:
10.1. Purpose:
This procedure outlines the responsibilities of people in dealing with bomb /
threat warnings.
1. In the event of a telephonic Bomb Threat, the receiver of the call should
endeavor to keep the caller talking and try to obtain as much information as
possible.
2. The call receiver must inform Shift Engineer.
3. Shift Engineer will inform Admin & Security Manager and GM Plant.
4. Admin & Security Manager / Shift Engineer (off days & off hours) will arrange
evacuation of the site if he feels the need of evacuation. (Follow Evacuation
Procedure as mentioned above in section 6).
5. If a suspected object found within the plant boundary then Admin and
Security Manager will call and coordinate with Police (Tel. 049-4424578, 049-
4420005 Pattoki) and Civil Defence or Bomb Disposal Squad (Tel. 049-
9250129 Kasur) will be informed and site will be kept clear.
6. Shift Engineer will announce to shut down the plant on the instructions of
Plant Management, if the situation is not safe for the area and plant.
10.2. Action on Completion of Search
1. Civil Defence / Policy / Bomb Disposal Squad leader will inform to Admin and
Security Manager about the scenario when they have completed a search.
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2. The Admin and Security Manager / Shift Engineer (off days & off hours) will
be notified when the emergency condition is over and will decide when
people can be allowed back into their work area on the recommendations of
Civil Defence / Policy / Bomb Disposal Squad department.
3. The people MUST NOT leave the Assembly Point without the personal
permission of the Admin and Security Manager / Shift Engineer (off days &
off hours).
11. Earth Quake Incident
11.1. Purpose
The purpose of this plan is to provide strategic guidance for effective emergency
management to earthquake events. The plan describes;
1. Appropriate responses to an earthquake emergency so that the safety risks
associated with the emergency may be prevented or mitigated.
2. The roles and responsibilities of teams and personnel that have a role in
planning for, responding to and recovering from an earthquake event.
3. The earthquake response framework which describes the elements that
should be considered for emergency planning.
4. The strategic control priorities, the response management and coordination
arrangements, and the management of earthquake response at all levels.
11.2. Scope
This procedure will apply to all employees, contractors and visitors involved
directly or indirectly with functions of Nishat Power Limited. It covers
precautionary measure to be taken against disaster; before, during and after an
earthquake event.
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11.3. Likelihood
For establishing the seismic parameters for the project area, two levels of
seismic hazard have been considered. The Operational Basis Earthquake
(OBE) which is an event which can occur several times during the lifetime of the
structure without causing any serious damage and the structure remains
operational. The other is the Design Earthquake, which is an "event that has a
very remote but a real chance of occurrence either due to the tectonic features
near the site or due to the background features. This earthquake is known as
Maximum Considered Event (MCE). The structure are designed to withstand the
seismic motion of this event without collapse but may undergo some repairable
damage.
NPL is located in Low Hazard Seismic Zone where ground acceleration factor
is g/20 or less and possible damage is negligible.
11.4. Preparation before an Earthquake
Check workplace and secure those items from falling in case of earthquake
which are of significant importance to plant operation.
1. Know locations of emergency equipment and exits.
2. Discuss the company’s disaster/evacuation plan. Participate actively in
evacuation drills.
3. Take training of first aid and rescue.
11.5. Earthquake Emergency Response Plan
11.5.1. Responsibilities
Below mention responsibilities are in addition to standard responsibilities
mentioned in different sections for other emergencies.
11.5.1.1. Plant General Manager (GM)
• He or his designee will keep liaison with LEA (law enforcement
agencies) and District Management, for any information and
coordination during earthquake emergency situations.
• He or his designee will coordinate with other HODs to analyse the
requirement of safe plant shut down and evacuation of employees.
• He or his designee shall announce for plant evacuation.
215

11.5.1.2. Emergency Coordinator

Emergency Coordinator shall be considered as centralized person at
plant site to monitor all activities related to earthquake emergency
plan.
• He will coordinate with ERT and External Aid Partners.
• He shall receive information/instructions from GM / Operation
Manager and arrange in-house meetings to communicate and issue
necessary instructions accordingly.
• He will coordinate with ERT members and Admin and Security
Manager in order to ensure that all employees are aware of their
responsibilities and assignments.
• He will look after all ground activities of emergency response.
11.5.1.3. Admin and Security Manager
• He will ensure to arrange necessary equipment like
(dozer/tractor/excavator/crane/helicopter), rescue vehicles, drivers
and labour to coop with emergent situation.
• He will ensure necessary room, food and water arrangements for the
employees staying at plant.
• He will conduct the crowd control drills at main gate to train the
guards for any crowd attempt trying to enter in NPL boundary to get
shelter.
• He will ensure the security of the plant and community through watch
towers by guards and weapons
• He will coordinate with Police for assistance against any untoward
situation.
• He shall monitor the damaged buildings, houses and other
infrastructure and pass on information to Emergency Coordinator
• He will ensure the availability of ambulance which use for transferring
of any casualty to hospital.
11.5.1.4. ERT TEAM
• Facilitate evacuation of employees if required.
216

• Shall do all on ground emergency response activities related to

earthquake incidence.
11.5.1.5. HSE Officer
• He will coordinate with Emergency Coordinator in an Emergency.
• He will train the employees for first aid and maintain the first aid
boxes.
• He will train employees for use of drinking water and food during
earthquake incidence and other measures against environmental
unhygienic conditions.
11.5.1.6. IT Staff
• Take a backup of file server data over portable hard drives.
• Switch off servers, network equipment’s etc. (if required).
• Move copies of backup hard drives to different safe locations
11.5.2.Communication
The communication plays an important role to achieve the objectives
promptly in case of an earthquake. The following mode of communication
will be used at plant site to deal with the emergency situation
immediately:
✓ Walkie Talkie systems
✓ Emergency alarm
✓ Land Line emergency numbers
Through above mentioned systems of communication, the observer at
site can promptly pass on the information to the Shift Engineer and
members of the emergency team, accordingly to the disaster in the plant,
so that the situation may be contained.
217

11.5.3.Disaster Management
11.5.3.1. Scrap Removal
Disposal of debris is a major concern following any natural disaster. The
type of debris encounter after a disaster will be much the same:
damaged buildings, downed trees, building materials, and household
and other types of hazardous waste.
Demolish, remove, and reconstruct to ensure debris removal is done
quickly as per Solid Waste Management Procedure at minimum risk to
both the workers and the environment.
It is also recommended for the simple reason that hazards are not
always immediately visible and safe disposal options are not always
clear. Items requiring special disposal;
✓ Chemicals
✓ Batteries
✓ Explosives
✓ Fuel containers, metal or plastic
✓ Medical waste
11.5.3.2. Site Evacuation
Earthquakes will occur without warning and such actions to be taken
will depend to a great extent on the circumstances prevailing at the
time. Evacuation under such circumstances will be as per evacuation
procedure. However, the following dangers may be expected
following an earthquake.
✓ Falling objects
✓ Weakened structures
✓ Fallen power lines
✓ Exposed cables
✓ Leakage of gases or flammable and toxic substances
✓ Gaps or holes in walkways, catwalks, etc.
✓ Damaged equipment kept running and unattended
✓ Broken glass and other sharp objects
218

✓ Panic and trauma experienced by staff

All persons shall protect themselves as best as possible during an
earthquake by finding the nearest safe location as per triangle rule,
such as:
✓ Get next to an object, next to a large bulky object that will
compress slightly but leave a void next to it.
✓ In a wide open area
✓ Outside and away from the building
Note: All persons must leave the building after the shaking stops. Duty operation staff
will decide themselves and leave operational area. Immediately after the earthquake
and if plant remains in operation, check the entire unit for any unusual incident such as
those mentioned above.
11.5.3.3. Search and Rescue
Emergency Response Team will be divided into 3- 4 groups. Each
group will have at least one person from the area to be searched.
Security staff, admin staff and other department staff will help the
emergency response team. Each department will have employee list
for the inspection of equipment.
11.5.3.4. Fire Fighting
In case of fire during / after earth quake, procedures mentioned in
firefighting sections will be applicable.
11.5.4.Operational Recovery
11.5.4.1. Post Disaster plan
Follow the below instructions as and when required:
✓ After an earthquake do not light matches, cigarettes or turn on
electrical switches. Flashlights are one of the best light sources
after a damaging earthquake. Proceed with an extreme caution.
✓ Make a quick check for injuries or trapped people. Provide
emergency first aid if needed. Do not try to move seriously injured
persons unless they are in immediate danger from further injury.
219

✓ Turn off all appliances and offices machines. Extinguish all open
flames. Check power lines and cords. If problems exist in electrical
lines or gas lines the mains should be shut off.
✓ Be prepared for aftershocks – they are weaker than the main
shock but can cause additional damage psychological trauma.
✓ Inspect your work area carefully for structural damage. Carefully
open exit doors – they sometimes jam. The initial quake may
damage the structure and an aftershock could knock down
weakened walls. Use extreme caution when moving around in
damaged areas – they may collapse without warning. Check to
see that sewage lines are intact before flushing toilets.
11.5.4.2. Restore of equipment

The principal objective of this is to provide repair and reconstruction
solutions and options that:
✓ are appropriate to the building, structure and damage equipment
✓ take account of the likely future performance of the equipment
✓ meet equipment normal running requirements
✓ are acceptable to insurers and property owners
Investigate the damage done by the earthquake and to derive cost
effective and repair procedure for the piping, structure and buildings.
12. Fire Extinguishing Program
12.1.1. Purpose:
To provide and ensure maximum safety of people in the event of fires
through the proper placement, use, maintenance, training and testing of
portable fire extinguisher, fire hydrant, foam and sprinkler system.
12.1.2. Different Inspections:
✓ Allocate proper fire extinguisher posts on new location as and when required
after site survey of potential fire hazards.
220

✓ Visual inspections, maintenance and testing should be conducted on

monthly, quarterly, annually, etc. (as per procedure Fire Prevention and
Extinguisher System )
Note: Records of all inspections and annual maintenance data should be
retained for at least one year.
12.1.3. Trainings:
EHS department shall provide training to all people upon initial employment
and at least annually, thereafter. Training may include:
✓ Introduction to the chemistry of fire
✓ The Four Classifications of Fires and the methods / agent for combating
each classification
✓ Training on basic components of portable extinguisher and their proper
use.
✓ How to response on fire and operate firefighting equipments.
13. Eyewash / Shower Program
13.1. Purpose:
This program is provided to protect the eyes and bodies of NPL people from
injury due to accidental exposure to toxic chemicals, fumes, or improper
activities near chemical hazards. This is a precautionary measure prior to
emergency treatment against severe injury or blindness.
13.2. Program:
✓ Each area should ensure for availability of proper PPE in respective chemical
hazardous areas
✓ Each NPL person should be well aware of the proper PPE, while handling a
hazardous material
✓ Eye/face wash shower is located within suitable distance in hazardous areas
Note: Such units shall be checked and tested on a regular basis as per
Eyewash/Shower Inspection Procedure
221

14. Employee Training

Training is important to the effectiveness of an emergency plan. Before implementing
an emergency action plan, a sufficient number of persons must be trained to assist in
the safe and orderly evacuation of employees. Training for each type of disaster
response is necessary so that employees know what actions are required.
Additional Training.
In addition to the specialized training for Emergency Response Team members, all
employees will be trained in the following:
✓ Use of firefighting equipment’s
✓ Evacuation plan
✓ Alarm systems.
✓ Reporting procedures for personnel (Headcount at muster points)
✓ Shutdown procedures in Emergencies.
✓ Types of potential emergencies
These training programs will be provided as follows:
✓ Initially when the plan is developed.
✓ For all new employees.
✓ When new equipment, materials, or procedures are introduced.
✓ When procedures have been updated or revised.
✓ When exercises show that employee performance must be improved.
✓ At least annually.
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APPENDIX A
COMMUNICATION INDEX
Person/Organization Designation Email Phone / Mobile No

Plant Staff Contact List
Muhammad Nawaz General Manager [email protected] 0333 - 4060661
Sajid Hussain Sr. Manager Operation [email protected] 0334 - 4442299
Muhammad Ashraf Dept. General Manager [email protected] 0348 - 4844622
Javaid Iqbal Sr. Manager Electrical [email protected] 0303 - 4446966
Maj® Shoiab Chishti Manager Admin & Security [email protected] 0331 - 4062800
Imtiaz Hussain Manager Mechanical [email protected] 0348 - 4844625
M. Irfan Hafeez Dept. Manager Operation [email protected] 0348 - 4844627
Tahir Mahmood Malik Manager Mechanical (S&S) [email protected] 0335 – 6172222
Munawar Ali Manager Civil [email protected] 0332 - 4184700
Ayaz Khan Dept. Manager Store [email protected] 0345 - 4493939
Irfan Shafiq Dept. Manager IT [email protected] 0340 - 8401886
Hasan Azhar Dept. Manager Electrical [email protected] 0300 - 0660933
223

M. Akhtar Rasul Asst. Manager HSE [email protected] 0348 – 4844673

Muhammad Imtinan Asst. Manager Planning [email protected] 0348 - 4844657
Majid Ali Asst. Manager Admin [email protected] 0348 – 4844628
Rana Ishtiaq Nisar Admin Officer [email protected] 0348 – 4844672
Muhammad Nawaz Sr. Shift Engineer [email protected] 0348 – 4844658
Altaf Hussain Sr. Shift Engineer [email protected] 0348 – 4844659
Khalid Mahmood [email protected]
Shift Engineer 0348 – 4844660
Saleemi
Abid Mahmood Shift Engineer [email protected] 0340 – 8402356
Junaid Mehboob Shift Engineer [email protected] 0345 – 8545955
Head Office Staff Contact List
Ghazanfar Husain [email protected] 0300 – 8455636
CEO
Mirza [email protected] 042- 35717090-6
Muhammad Khurram [email protected]
CFO 0333 - 4448914
Khan
Faraz Ahmad Manager Account [email protected] 0336 - 4083500
Noman Umar Dept. Manager Finance [email protected] 0334 - 4442230
AMBULANCE DRIVER
Sultan Khan Shift “A” 0300 - 4670099
224

Imran Ali Shift “B” 0345 - 4718458

Naeem Ahmad Shift “C” 0308 - 4400137
Basharat Ali Shift “D” 0303 - 4486126
LOAD DISPATCH UNIT
051 - 9250438,
NPCC (PTCL/Hot Line) Shift Engineer 9250439/ 200, 202,
203
Ilyas Ahmad G.M (So) NPCC 051 - 8311557
Rana Khalid Mahmood Director Power Control 051 - 9250854
Abdul Rehman Director RCC 051 - 9257329
FIRE BRIGADE
Rescue 1122 Phool
1122 & 049 - 4511022
Nagar
049 - 4420006, 0344-
Fire Brigade Pattoki
6291912
Fire Officer Pattoki 0344 - 6291912
Fire Brigade Chunian 049 - 4310006
Fire Brigade Kusur 049 - 9250129
Fire Brigade Sundar
042 - 35297083
Industrial Estate
225

MEDICAL SERVICES
CMH Chunian 0494-3336151
THQ Hospital (Pattoki) 049-4420312
Ambulance (Phool
049-4421615
Nagar)
Ambulance (Pattoki) 049-4510945
Umar Hospital
049-4510380
(Jumber)
POLICE STATION
DSP Pottoki 049-4424578
Policy Choki Jumber 0333-4410370
Policy Station Sadar
049-4420005
Pattoki
CIVIL DEFENCE
Civil Defence Kasur 049-9250129
226

APPENDIX B
40 Mint
13 Mint
15 Mint
48 KM 13.8 KM 13.7 KM
26.7 km 4.6 km
17 Mint 06 Mint
10.7 KM 3.1 KM 12.5 KM 18.8 KM
10 Mint 05 Mint 15 Mint 20 Mint
227
Revision No 02
FIRE SYSTEM IMPAIRMENT Revision Date 31-05-2021
1. Introduction:
There will be occasions when isolation of the fire detection or fire suppression system
for the entire plant/facility or a specific area is required. The probability of a fire or
explosion causing major damage whenever a fire protection system is impaired. The
longer the fire protection system is impaired, the greater the probability of damage.
Therefore, it is necessary to minimize the duration of any fire system impairment. The
Impairment of fire system may be due to construction, rectification work, modification
work or an emergency condition.
Effective management of impairments, to minimize their extent and duration, can

reduce the potential of increased human and property loss.
2. Scope:
This procedure applies to fire suppression system (hydrants, sprinkler, hose reel, fire
pumps, foam, fire water pipe work, associated power source components etc.) and
fire detection system (fire detectors, sensors, alarm systems and their components).
3. Definitions:
3.1. Fire Protection Systems: Sprinkler systems, standpipe systems, fire hose
systems, underground fire service mains, fire pumps, water storage tanks, water
spray fixed systems, foam-water systems, special extinguishing systems, fire
service control valves, fire alarms systems, fire & gas protection systems and
emergency lights.
3.2. Fire Watch: A person or persons designated to physically patrol the area to look
for fires where the fire protection system (detection, suppression or alarm) is
impaired.
At least one trained staff person from emergency response team shall be
deployed to complete fire watch duties of the unprotected / impaired building area
in each operational shift.
Fire watch must be provided with the following equipment;
228
Revision No 02
• Suitable means of communication (cell phone, portable radio, etc.)
• Flashlight
• Clipboard and pen
• Copy of the Fire Watch Log Sheet
• Keys and / or access to provide entry to all rooms /spaces
3.3. Impairment: Fire protection systems (suppression or detection system), either in

whole or in part, that have been taken out of service, due to any reason, are
considered to be impaired.
3.4. Emergency Impairment: when a fire protection system is out of service due to
an unexpected occurrence, such as a ruptured pipe or an unexpected power
outage, accidental damage, equipment malfunction, following a fire or incident a
sprinkler system or fire detection system may need to be isolated in order to check
and /or replace affected components
3.5. Hidden Impairment or Concealed Impairment: It is most serious type of

impairment. It occurs when a fire protection system is inadvertently left out of
service upon completion of work, a system is shut down without proper
notification, or a system is maliciously shut.
3.6. Planned Impairment: when a fire protection system is out of service due to
planned repairing/maintenance work, such as modifications to the water supply or
sprinkler system, routine service or maintenance on the system and/or its
components, modifications or extensions in existing systems.
3.7. Level of Impairment:
3.7.1. Level “1” Impairment: When a limited number of components of a fire

detection/protection system are found defective or removed from service for
one shift / 8 hours.
229
Revision No 02
Level “1” impairment represents a minimal impact to the overall life safety of
the personnel, plant equipment and buildings.
3.7.2. Level “2” Impairment: A shutdown of an entire fire detection/suppression

system or major portion like a building, a zone removed from service for more
than one shift / 8 hours and significantly affect the personnel, plant equipment
and buildings safety.
3.8. Impairment Coordinator: Impairment Coordinator is required before impairment

to be done so that he can take necessary impairment steps / procedures to
prevent from fire accident at plant during an impairment is in place. Shift Engineer
will be the impairment coordinator at plant and his roles in impairment are as
follows:
• Authorizes the shutdown of the fire detection and suppression systems.
• Arrange additional appropriate resources for fire suppression and fire detection
in impaired area.
• Ensures that the impairment procedures are being followed and completed.
• Verifies that steps to restore systems to service have been followed and that
the systems are restored to service as soon as possible.
• Inform site EHS committee members and emergency response team before
system impairment and after impairment cancelled through email and
telephone. Contact with Manager Operation and Manager HSE for advice if
situation is risky and fire threat level in high.
3.9. Impairment Notice Form: Impairment notice form for fire protection equipment’s
should be issued and attached with applicable work permit to remind personnel
that protection is temporarily unavailable. Impairment notice form duly filled by
Impairment Coordinator and signed off before and after completion of desire work.
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Closed / complete impairment notice form will be submitted in HSE department

for record purpose.
If a single competent in cluster/ zone need to impair than there is no need to issue
impairment notice form.
3.10.Impairment Notice Tag: Impairment notice tags will be prepared by impairment

coordinator and place at impaired/ effected components/ parts/ of fire protection
system. This tag may include the following (Annexure 1);
• Impairment date and time
• Impaired equipment name and number
• Nearby alternative available fire protection systems.
• Name and signature of Area Engineer and Impairment coordination.
4. Fire Protection System

Different types of fire protection systems are installed at site and an effective
impairment management procedure applies on them:
Fire Suppression System includes;
• Water Sprinklers
• Hydrant & Monitor
• Hose reel
• Fixed water surface cooling
• Foam
• Fire Pumps &
• Associated power source components
Fire Alarm & Detection System includes;
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• Heat detection
• Smoke detection
• Flame detection
• Alarm sound & Beacon system
• Fire panels and power sources
5. Impairment Procedure:
5.1. Before the System Impairment:
• Determine the expected duration of impairment and effected area.
• Inspect effected area and determine the increase in risk due to impairment.
• Notify Control room, emergency response team and EHS committee member’s
through email and telephone so they can be ready to handle any emergency
that might occurred.
• Cancel all Hot Work Permits in the area to be impaired. If hot work permit
required to continue hot work in impaired area, then get approval from GM
Plant.
• Assign a fire watch for patrolling in fire protection impaired area as per
impairment level.
• Plan to have appropriate temporary fire protection in hand: extra fire

extinguishers or charged fire hose lines if applicable.
• Shut down any hazardous operations involving flammable liquids or spark

generating equipment.
• Relocate combustible materials (if possible) from an impaired area. Expedite

the work, workers, materials, equipment and tools should be ready before any
system is shut off.
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• Attach Impairment Notice Form along with applicable work permit after
issuance of permit.
• Attach Impairment Notice Tag on impaired equipment / device / system.
• Notify employees in area that fire protection systems will be shut off.
• If the impairment is prolonged, consider setting up temporary protection by

placing extra fire extinguishers or running a hose from nearby hydrant.
• Determine how quickly temporary protection can be taken into service in case
a fire occurs during the impairment.
• Lastly, shut down the affected fire protection system and start the work.
5.2. During the Impairment

• Prohibit all hot work including cutting, grinding, chipping and welding etc.
excluding in Hot Work Permit free area.
• In impairment level 2, fire watcher will petrol the impaired area at interval of “2”
hours for equipped building and “4” hours for open area.
5.3. After Impairment Cancelation:

After completion of work following activities will be performed by Impairment
Coordinator;
• Normalize the fire suppression and fire detection system and ensure that the
fire protection system is placed back to “automatic” service.
• Remove Impairment Notice Tags once system restores.
• Notify Emergency Response Team (ERT), EHS committee members and

affected employees that fire protection system is back in service.
• Keep completed Impairment Notice Form in record for five years.
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5.4. Emergency Impairment

• For unplanned impairments such as a pipe leaking or breaking up immediate
action must be taken to control a major loss.
• Stabilize the situation and immediately follow the procedures outlined in “Before
the System Impairment”.
• After repairs and system restoration, follow the procedures in “After the System
Impairment”.
5.5. Hidden / Canceled Impairment Prevention

The hidden impairment can be prevented by:
• Inspecting all valves, devices or points weekly to assure that they are in normal
position.
• Inspect, test and maintain all fire alarm and fire detection devices yearly or as
and when required.
If the protection system is found impaired, the conditions should be immediately

reported to the Impairment Coordinator.
6. Contractors Must Follow Impairment Procedures

All contractors that work on the fire protection system or need to shut off the fire
protection system during construction, remodeling or short duration repairs must
follow the Fire System Impairment procedure. A copy impairment notice form is to be
issued to the NPL craft person. Contractors must coordinate with Craft Person.
7. Employee Training
All plant staff needs to get training about impairment procedure.
During the training, the Impairment notice is shown and trainees are instructed on how
to follow the steps on the format.
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Annexure 1:
FIRE PROTECTION SYSTEM

IMPAIRMENT TAG
Impairment Date & Time: _______________________
Equipment / Device No: ________________________
Equipment / Device Location: __________________

________________________________________
Nearby Available Fire Protection System
Fire extinguisher No: ________________________

Location: ____________________________________
Hydrant / Hose reel No: _____________________
Location: ____________________________________
F. Detection device No: ______________________
Location: ____________________________________
Other device / Equipment No: _________________
Name: ______________________________________
Location: ____________________________________
_______________________________________
Tag placed by (Name & Sign): _________________
Impairment Coordinator
(Name & Sign): ___________________________
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HAZARD IDENTIFICATION AND Revision No 01
RISK ASSESMENT Revision Date

Last Review
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1. Purpose
This procedure describes the method by which all hazards will be identified, assessed for
risks and appropriate control measures take into place.
2. Scope
This procedure is applicable to all buildings, equipment, operations and maintenance
activities within the boundary of Nishat Power Limited.
3. Definitions
3.1. Hazard: an event or physical condition that has the potential to cause fatalities,
injuries, property damage, infrastructure damage, damage to the environment,
interruption of business, or other types of harm or loss.
3.2. Hazard identification: the process of defining and describing a hazard, including its
physical characteristics, magnitude and severity, probability and frequency, causative
factors, and locations or areas affected
3.3. Risk: means the likelihood of injury, illness or damage to plant or property arising from
exposure to any hazard.
3.4. Inherent Risk: the amount of risk/danger when things go wrong before taking control
measure.
3.5. Residual Risk: the amount of risk left over after natural or inherent risks have been
reduced by risk controls.
3.6. Risk Assessment: the process of assessing the risks associated with each of the
hazards identified so the nature of the risk can be understood. This includes the
nature of the harm that may result from the hazard, the severity of that harm and the
likelihood of this occurring.
3.7. Risk Control: Taking actions to eliminate health and safety risks so far as is
reasonably practicable. Where risks cannot be eliminated, then implementation of
control measures is required, to minimize risks as far as is reasonably practicable.
3.8. Monitoring and Review: This involves ongoing monitoring of the hazards identified,
risks assessed and risk control processes and reviewing them to make sure they are
working effectively.
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4. Responsibilities
4.1. Employee
• Immediately report (verbally or written) any hazard or potential hazard (including a
near miss) to their manager or HSE Manager and suggest an Improvement by Unsafe
Act/Near miss form.
• Take necessary corrective preventive measures during working as per given in risk
assessment sheet or personal safety checklist and also highlight the other hazards/
risks those are missing in existing risk assessment sheet or personal safety checklist.
4.2. HSE Manager:
• Prepare, share and review of Hazard Identification and Risk Assessment (HIRA)
sheets for operation, equipment, maintenance tasks and area/building/locations.
• HIRA will be prepared on the basis of hazard identification during safety rounds,
management safety audits/walks, incidents/accident records, discussion with
employees & engineers etc.
• Ensure the proper implementation of corrective/preventive measures as per HIRA all
the time.
• Conduct employee training regarding reporting and control of hazards and their risks.
4.3. Concerned Managers:
• Help out HSE manager for proper implementation of corrective/preventive measures
as per HIRA all the time.
• Participate in safety walks/audits and share their opinion for controlling the hazards to
make working area safe.
• Take necessary disciplinary action against the employees whose did not take proper
necessary safety measures during work.
4.4. Plant Management:
• Actively participate in safety walks/audits and provide resources to control the hazards
and their risks within the plant premises.
5. Type of Hazards:
The following type of hazards to be found in the normal workplace.
5.1. Mechanical: Entanglement, trapping, friction / abrasion, cutting, shearing, stabbing /
puncturing, impact, crushing, drawing in, fluid injection, ejection, compressed air, hand
tools, pressure/ vacuum systems, stored energy.
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5.2. Transport: Fork lift trucks, mobile cranes, reversing vehicles, manoeuvring vehicles,
loading and unloading, pedestrian vehicle interface.
5.3. Access: Lighting, scaffolding, slips trips and fails, objects falling or moving, confined
space, obstruction or projection, contact with hot/cold surface or object, hot/ cold
working environment, dangerous parts of machinery, falling from heights, drowning,
excavation, housekeeping.
5.4. Electricity: Work with exposed live conductors, work adjacent to exposed live
conductors, damage to electrical apparatus, incorrect installation of equipment, electric
shock, burns, ultra violet radiation, arcing, overheating etc.
5.5. Substances / Chemicals: Asphyxiates, toxic, irritant, sensitizing, flammable, corrosive,
explosive, carcinogens, fumes, inhalation, particles/ dust, ingestion, abrasion of skin or
eye.
5.6. Handling Lifting: Safe storage/ stacking, manual handling operations, lifting and
carrying, rigging and slinging, mechanical aids.
5.7. Fire and Explosion: Combustible materials, flammable liquids/gases, spraying of
flammable liquids, gas cylinders, hot work, ignition sources
5.8. Radiation: Ionizing radioactive sources, non-ionizing, radiography, ultra violet light,
microwaves and radio frequencies, lasers
5.9. Biological: Bacterial, fungal, food hygiene, legionella, leptospirosis, animals
5.10. Environment: Noise, vibration, light, humidity, ventilation, temperature, climate,
pressure/ vacuum
5.11. Behavioural: Intellectual errors (slips, lapses, mistakes). Violations of rules. Failures
in interpersonal communication. Work overload. Insufficient personal discretion.
Failures in role design. Failures in managing foreseeable change at work. Lack of
requisite employee support.
6. Hazards may be identified by
6.1. Observation - use your senses of sight, hearing, smell and touch - combined with
knowledge and experience.
6.2. Material Safety Data Sheets (MSDSs) - obtain from manufacturers and suppliers. Read
these carefully to identify possible harm from hazardous substances and precautions
that need to be taken.
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6.3. Hazard and risk surveys - conduct hazard spotting surveys of main work areas. Talk
to others about their safety concerns.
6.4. Contractor and visitors - include in your survey’s areas and activities in which
contractor or visitors could be at risk.
6.5. Record analysis - keep records of identified hazards, near misses, injuries and workers
suggestions to help identify possible trends.
6.6. Discussion groups - are useful for identifying hazards and recommending solutions.
6.7. Safety audits /walks - consider creating EHS committee to investigate safety and help
to prepare a management plan.
6.8. Information - keep informed of hazards in the plant through the latest available
information.
7. Hazard Identification & Risk Assessment

• Hazard identification and risk assessment must take place for:
• The nature of the hazards (e.g.; electrical, fire, noise, mechanical. Manual
handling, etc.)
• Frequency and duration of activities.
• Likelihood and consequences
• Who are affected by the risk;
• Employees directly with the work
• Other employees.
• Special groups as young workers, disabled workers, etc.
• Available information related to the risk
• Monitoring and emergency procedures
• Are there any special statutory requirements that might apply?
• The effectiveness of the existing control measures
• Risk assessments will be undertaken using a HIRA Form or documented equivalent
such as the Workplace Hazard Identification.
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8. Risk Ranking and Rating Matrix

Risk Rank = Consequences × Likelihood
Risk Level
Sr. No Risk Level Risk Rank

1 Low 1-5
2 Moderate 6-9
3 High 10-15
4 Extreme 16-25
Likelihood Consequences
5 A-Almost Certain 1 Insignificant
4 B-Likely 2 Minor
3 C-Possible 3 Moderate
2 D-Unlikely 4 Major
1 E-Rare 5 Catastrophic
Risk Rating Matrix
Likelihood (L)
Almost
Consequences Rank Rare Unlikely Possible Likely
Certain
1 2 3 4 5
Insignificant 1 1 2 3 4 5
Minor 2 2 4 6 8 10
Moderate 3 3 6 9 12 15
Major 4 4 8 12 16 20
Catastrophic 5 5 10 15 20 25
Risk
Score Consequences Likelihood Risk Level
Rank
5-CatastrophicA-Almost 5-Catastrophic A-Almost Critical 25
Certain Certain
5-CatastrophicB-Likely 5-Catastrophic B-Likely Critical 20
4-MajorA-Almost Certain 4-Major A-Almost Critical 20
Certain
4-MajorB-Likely 4-Major B-Likely Critical 16
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5-CatastrophicC-Possible 5-Catastrophic C-Possible High 15

3-ModerateA-Almost Certain 3-Moderate A-Almost High 15
Certain
4-MajorC-Possible 4-Major C-Possible High 12
3-ModerateB-Likely 3-Moderate B-Likely High 12
5-CatastrophicD-Unlikely 5-Catastrophic D-Unlikely High 10
2-MinorA-Almost Certain 2-Minor A-Almost High 10
Certain
3-ModerateC-Possible 3-Moderate C-Possible Moderate 9
4-MajorD-Unlikely 4-Major D-Unlikely Moderate 8
2-MinorB-Likely 2-Minor B-Likely Moderate 8
3-ModerateD-Unlikely 3-Moderate D-Unlikely Moderate 6
2-MinorC-Possible 2-Minor C-Possible Moderate 6
5-CatastrophicE-Rare 5-Catastrophic E-Rare Low 5
1-InsignificantA-Almost 1-Insignificant A-Almost Low 5
Certain Certain
4-MajorE-Rare 4-Major E-Rare Low 4
1-InsignificantB-Likely 1-Insignificant B-Likely Low 4
2-MinorD-Unlikely 2-Minor D-Unlikely Low 4
3-ModerateE-Rare 3-Moderate E-Rare Low 3
1-InsignificantC-Possible 1-Insignificant C-Possible Low 3
2-MinorE-Rare 2-Minor E-Rare Low 2
1-InsignificantD-Unlikely 1-Insignificant D-Unlikely Low 2
1-InsignificantE-Rare 1-Insignificant E-Rare Low 1
9. Elimination/Control Strategies
• Risks that have the potential to cause serious injuries or fatalities should be
eliminated/controlled immediately. Low priority risks should be monitored and
addressed after higher risks have been eliminated or reduced to an acceptable level.
• The Manager HSE in consultation with relevant line managers shall give final approval
for specific elimination and control strategies to eliminate and control the risks in a
priority order (high risk to low risk).
• Selection of the most appropriate strategy involves balancing the cost of implementing
against the benefits derived from it. In general, the cost of managing risks needs to
be equal with the benefits obtained.
• The elimination/control strategy shall be selected from the following (in the order
specified) to eliminate the risk. If elimination is not reasonably practicable, the risk
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needs to be reduced to the lowest level reasonably practicable. Emphasis shall be on

controlling the risk at the source of the risk
• Eliminate/control hierarchy of risk:
• Eliminating the Risk (Remove the hazard)
• Reducing the Risk (Design out the hazard)
• Adopt a safer process,
• Isolate the hazard
• Control Measure (Engineering Controls) such as
o changing work practices/methods,
o job rotation,
o routine maintenance and housekeeping procedures,
o training on hazards and correct work procedures.
• Maintain PPEs and its usage for certain hazards.
10. Procedure:
• Two types of Hazard Identification and Risk Assessment (HIRA); area/buildings and
equipment (maintenance and operation) wise will be prepared by Manger HSE.
• In HIRA sheet following will be included;
1. Equipment/ Area/ Tasks
2. Risk Identification
• Activity
• Potential Hazard(s)/Aspect(s)
3. Risk Analysis
• Consequences (OH&S, Environment, Fire, Explosion, Property/Equipment
Damage)
4. Risk Evaluation
• Severity (A) (Severity without Controls)
• Existing Preventive Control(s)
• Likelihood (B)
• Potential Risk Ranking (A+B = AB)
• Recovery Measures (After Incident)
5. Risk Treatment
• Recommended Additional Control(s) (C)
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• Residual Risk Ranking After Additional Control (A + B + C)

• Additional Control & Implementation
• Hazards and their risk will be identified in joint visit of concern area/building,
maintenance and operation tasks of equipment/ tools, unsafe act and unsafe
conditions near-misses and incident reports.
• Joint visit of area will be made by Area Engineer, Area In-charge and Manager HSE.
In visit identify all hazards, their risks and necessary corrective/control measures.
• For equipment maintenance and operation HIRA, detail of tasks with relevant hazards
will be identified by Maintenance Engineer, Area Engineer and Manager HSE and will
decided their proper control measures.
• Before performing any critical job, fresh HIRA will be prepared and shared with job
performing staff.
• HIRA to be shared with plant staff once prepared.
• The following are the circumstances that may require a HIRA to be reviewed;
• Changes in process, work methods or materials
• The introduction of new technology.
• Any change in control measures
• New hazard information
• Results of monitoring and health surveillance.
• As consequence of accidents
• As a consequence of enforcement action or legal legislation
11. Implementation
The HSE Manger shall ensure that all employees adhere and implement the control
measures defined in risk assessment.
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OCCUPATIONAL HEALTH AND Revision No 01
HYGIENE PROCEDURE Revision Date 02-05-2019

1. Purpose
The purpose of this procedure is to create awareness among plant staff about health risk
associated with their job and how to mitigate them in order to bring the associated risks
under control for safe execution of assigned job.
2. Scope
This procedure is applied to all employees working at plant and performing operation &
maintenance activities.
3. Definitions
3.1. Occupational Hygiene: It is the discipline of anticipating, recognizing, evaluating
and controlling health hazards in the working environment with the objective of
protecting worker health and well-being and safeguarding the plant community at
large.
3.2. Anticipation – this involves identifying potential hazards in the workplace before
they are introduced.
3.3. Recognition- this involves identifying potential hazard that a chemical, physical or
biological agent – or an adverse ergonomic situation –poses to health.
4. Responsibilities
4.1. Site Management
 Provide and maintain a safe system of work.
 Identify hazards and evaluate risks.
 Take steps to eliminate or mitigate all hazards before resorting to PPE.
 Provide information, training and supervision.
 Provide means to apply safety measures.
 Do not permit employees to work unsafely.
 Enforce health and safety measures at work.
 Ensure that every person on the premises knows the site HSE rules and
regulations.
 Ensure that team leaders have work-related safety training.
 Ensure regular medical screening/examination of staff.
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4.2. HSE Manager

 Conduct regular health and hygiene related inspections, audits and monitoring
throughout the plant premises and report to concern department.
 Conduct information and training sessions with plant staff.
 Suggest improvement in working environment.
 Prohibit dangerous work environment or activities.
 Investigate and search the workplace for hazards and potential dangers.
 Ensure that workers are properly following health and safety procedures.
4.3. Employees
 Take reasonable care of their own health and safety and of others who may be
affected by their acts or omission.
 Ensure compliance of HSE policy.
 Report unsafe act and condition to HSE department for corrective measures
5. Procedure
5.1. Occupational Hygiene Hazards
During working employees can be exposed to the following hazards and excessive
exposure to these stressors may result in acute injury, chronic illness, permanent
disability or even death

Type of occupational Type of exposure
hygiene hazard
Chemical Dust, Fumes, Smoke, Mists, Gases etc.
*(see detail below)
Physical Illumination, Noise, Vibration, Temperature, Radiation
etc.
Ergonomics Heavy lifting, Un-natural posture, Repetitive motion
Psychological Odd timing shift work, bullying and distance from family
and work stress
Biological Poor hygiene, medical examination, drinking & washing
facilities, snake bites etc.
5.1.1. Chemical Exposure
Chemical hazards exposure may exist in many forms, from liquid to fumes to dusts,
and can be absorbed, inhaled, or ingested into a workers body. Some common
chemicals that can potentially be hazardous are cleaning and operational chemical
products, fuel and lube oils and pesticides. Many chemicals can be harmless in small
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doses but even some common chemicals can cause symptoms in those who are
particularly sensitive and most chemicals can cause adverse effects in large doses
or when proper safety precautions are not taken.
NPL takes following precaution measures to control chemical exposure includes;
 Proper ventilation
 Personal hygiene such as hand washing, which can reduce the amount of
chemicals absorbed by the skin.
 Personal protective equipment’s (gloves, glasses, face masks, aprons etc.)
 Maintaining equipment in order to prevent leaks and breakdowns.
Plant staff will ensure the use of proper PPEs during manipulation of chemicals to
prevent themselves from chemical exposure.
5.1.2. Noise
Long-term exposure to noise – both wanted and unwanted sound – can lead to
hearing loss for workers. Noise issues can be addressed in several ways at site,
including designing a facility to minimize noise, separating workers from noisy
machinery as much as possible and using devices, such as ear muffs or ear plugs,
to protect workers.
Plant staff will ensure the use of ear plug or ear muff in those areas where noise
level is greater than 85dB. In fuel treatment house, both engine halls and HRSG
area the level of noise is greater than 85dB.
Biannual monitoring of noise level will be performed by HSE representative and
shared its report with plant management for necessary action if required.
5.1.3. Ergonomics
The goal of ergonomics is to reduce stress and eliminate injuries associated with bad
posture, overuse of muscles and repeated tasks. For example, proper ergonomics
can help prevent carpal tunnel syndrome, tendonitis and lower back injuries.
While performing an ergonomics intervention, it’s important to involve workers in the
process to ensure tasks are fit to the worker and workers are properly trained on
aspects such as how to lift boxes correctly.
Regular monitoring of working platforms and areas will be performed by HSE head
and shall share the observations with plant management for necessary corrective
measures.
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5.1.4. Temperature
Both high and low temperatures can cause problems for workers. If temperatures are
too high, workers are vulnerable to heat stroke or heat exhaustion; heat stroke is a
medical emergency that requires immediate attention.
Staff need to make adjustment for heated atmosphere by drinking small amount of
water frequently and take breaks in cooled and aired atmosphere whenever
possible.
Prolonged exposure to low temperatures can lead to hypothermia or frostbite. Staff
will need to wear warm clothing and take breaks in warmer temperatures when
possible.
5.1.5. Indoor Air Quality
Indoor air quality can be disturbed by many factors which may include fuel heating,
exhaust gases, dusts and particular matter. Polluted air can cause the health issues
ranging from upper respiratory irritation, chronic cough, asthma and other lungs
diseases.
Therefore, proper ventilation for fresh air will be ensured in working area. Air filtering
in HVAC system can help to remove contaminants from the air.
Quarterly monitoring of NOx and SO2 gases in ambient air will be performed and will
maintain these gases levels within PEQS limits.
5.1.6. Illumination/lighting
The intensity of illumination is measured by the foot-candle. Foot-candle is the
illumination given by a source of one candle to an area one foot away from the
source. For checking illumination digital Lux meter is used. Advantage of good
lighting are;
 Safeguard the eye sight.
 Reduce hazards and accident.
 Saves the work time and enhance the quality of work
Biannual monitoring of Lux level will be performed by HSE department to evaluate
the illumination as per standard. Lux monitoring report will be shared with plant
management for taking necessary corrective measures if required.
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5.1.7. Radiation
There are two types of radiation – non-ionizing radiation and ionizing radiation.
Ultraviolet (UV) radiation and laser radiation are the types of non-ionizing radiation
most likely to cause skin burns of staff. These radiations emit form welding and
cutting process. Proper shielding and PPEs should be used to protect from the effect
of these radiations.
5.1.8. Biological Hazards
Living organisms such as fungi, viruses and bacteria can enter the human body and
cause both acute and chronic infections.
Plant staff can be at risk for these hazards such as mold and bacteria that cause
Legionnaire’s disease.
Poor hygienic conditions of water supply, collection and disposal of wastes and
sanitary facilities may increase the risk of biological hazards.
5.1.8.1. Safe Water Supply
The provision of safe and adequate water supply is the most important element
of NPL health policy.
Water can be used for the following purposes at plant;
 cooling purposes in the machines
 cleaning and washing of equipment
 used by employees to keep their personal hygiene
 serve as a means for waste disposal in water carrying systems
 for drinking purpose
NPL will provide the safe drinking water to its staff. Complete analysis of drinking
water will be conducted to evaluate the quality of water as per PEQS standards.
5.1.8.2. Sanitary and Washing Facilities
NPL will provide adequate and hygiene sanitary (latrines and toilets) and
washing facilities to plant staff. In these facilities, a supply of running water, hand
washing soap and tissue paper will be provided.
Admin department will ensure the regular inspection and cleaning of these
facilities on daily basis. Inspection checklist will be displayed in each wash room
which will be filled on daily basis.
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5.1.8.3. Effluent Water Disposal

Industrial effluent if not treated properly and disposed off in fresh water facilities
will pollute aquatic environment and water supply.
NPL will ensure to discharge treated effluent water into water canal.
5.1.8.4. Good Housekeeping
Housekeeping includes cleanliness of the work place, washing and toilet
facilities and cooking and meal facilities. Good housekeeping plays a key role in
the control of occupational health hazard. Immediate cleaning of any accidental
spill of toxic materials, dirt and dust is a very important control measure.
NPL will maintain its good standard of housekeeping where chemicals,
equipment, grocery items will be stored, handled and use in safe manners.
Continuous cleaning of work place will be carried out so that harmful dirt and
dust may not accumulate on roof ceilings, pipes, and other objects within the
work area.
Highly trained janitorial staff will be deputed for cleaning and waste handling
activities. Plant staff will ensure the proper housekeeping of working areas.
Monthly housekeeping evolution will be performed jointly by HOD of HSE
department, Housekeeping Supervisor and Area Supervisor.
Housekeeping and hygienic condition of kitchen and food storage facilities will
be inspected EHS Committee on fortnightly basis.
5.1.8.5. Staff Medical Examination:
All employees will undergo complete medical checkup before their joining to
plant in order to verify their fitness to work
Kitchen Staff
Kitchen staff presents at plant will be screened initially for TB, Hepatitis B, and C
and HIV. Undergo above medical screening on annual basis.
Kitchen staff will always wear neat and clean clothes, apron and shoes. Proper
cutting of face and head hairs and hand nails will be done on regularly. Use cap
and apron during cooking and serving the meal.
Staff will store and serve the food in hygienic conditions.
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Revision No 01
SOLID WASTE MANAGEMENT Revision Date 11-10-2019
1. Purpose
The purpose of this procedure is to;
- Identify the expected waste during plant operation and describe their
classification, storage, transport and disposal requirements.
- To ensure that waste has been managed in accordance with plant disposal
procedure.
- To ensure neat and clean environment of plant premises and local community.
2. Scope
This procedure applies on plant staff and all types of activities carried out at NPL.
3. Definitions
3.1. Waste
Waste is a byproduct which is considered useless by the user and it has to be
discarded or disposed off.
3.2. Hazardous waste
The waste that is dangerous or potentially harmful to our health or the environment. It
includes medical waste, oily rags/absorbent pads, boiler soot etc.
3.3. Waste Management
The collection, transportation, processing or disposal of waste materials, usually once
produced by human activity.
4. Role and Responsibility
4.1. Plant Management:
Plant management shall ensure that resources are available to support the
implementation of this procedure.
4.2. Head of Department (HOD)
HODs shall ensure the implementation of this procedure where it is relevant to their
area of responsibility.
4.3. HSE Manager
He shall ensure the compliance of procedure and also review and update this
procedure as and when required.
5. Solid Waste Management:
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Environmental impact can be minimised by ensuring that the materials are used
efficiently and are not unnecessarily disposed of. Solid waste management should be
done by following hierarchy;
1. Elimination (don’t generate the waste in the first place)
2. Reduction (minimise the waste)
3. Re-use and recycling
4. Treatment (convert the waste into something less environmentally or personally
hazardous e.g., dilution or chemical treatment of hazardous chemicals prior to
disposal to minimize its negative effects to the environment and people).
5. Disposal
5.1. Waste Elimination and Reduction
The volume of waste produced shall be reduced by;
 Purchase of materials in less quantity to avoid from its spoilage or expire.
 Use of reusable rather than disposable material.
 Avoiding purchase of goods with excessive packaging.
 Avoiding wastage of materials.
 Better handling and storage practices to prevent damage.
5.2. Reuse
Wherever possible items should be reused rather than discarded, e. g:
 Reuse of paper, card board etc.
 Reuse of chemical containers for same material.
 Handle and store packaging material in a way so that it can be reused.
Materials that can be reused should be segregated from the waste stream prior to
storage for future reuse.
5.3. Recycling
A number of discarded materials can be recycled rather than disposal. These should be
segregated manually within the waste stream and stored separately.
Recyclable materials include:
 All metals
 Plastics
 Paper
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5.4. Solid Waste Collection, Segregation and Disposal

Wide range of solid wastes are generated by operation and maintenance activities.
These wastes require different disposal options, from reuse, recycling or specialized
waste disposal such as incineration, land filling etc.
By effectively segregating waste types on site, we can;
 Avoid mixing of contamination free waste with contaminated or hazardous
materials.
 Minimize the quantities (and hence cost) of waste requiring specialized disposal.
 Ensure that the waste disposal option is suited to the waste type.
 Minimize the potential for environmental damage at the waste disposal site.
 Minimize the potential for safety incidents.
 Have more scope for developing on-site management systems.
Waste segregation is achieved by using specific skips (drums) for different wastes
placed at different locations of plant.
All waste bins shall be clearly labeled for use with particular waste. This should include
both written instructions, use of symbols and colour coding (see in below table &
picture).
Pplant staff shall put the waste in designated waste bin/container and keep away the
waste material from useable material to prevent mixing.
Segregation shall commence at the waste production source and be maintained
through on site transport and at the designated storage area.
Finally, the segregated waste is handed over to EPA approved contractor for safe
disposal
Waste Type Source Collection, Storage and Disposal
Electrical appliance - Operation, maintenance Waste collected in Yellow colour

waste and civil work containers. Segregated these
Ferrous and Non- wastes and temporally stored at
ferrous metals scrap yard. Contractors received
Used Tyres/Rubber these wastes for reuse,
material recycling and land filling as per
Glassware their contract obligation with
Demolition wastes NPL.
Plastics items
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- Paper - Kitchens Waste collected in green colour

- Card board - Offices containers. Segregated these
- Food waste - Operation and wastes and temporally stored at
- Wooden material maintenance activities scrap yard or waste storage
- Tree/Plant residue area. Contractors received these
wastes for reuse, recycling and
land filling as per their contract
obligation with NPL.
- Medical waste - First Aid Waste collected in Red colour
- Oily Rags/Absorbent - Cleaning activities containers. Segregated these
pads - Operation and wastes and temporally stored at
- Oily Filters maintenance activities scrap yard or waste storage
- Sludge area. Contractors received these
- Paints Remaining wastes for reuse, recycling and
- Boiler soot land filling as per their contract
- Batteries obligation with NPL.
5.5. Safe Handling of Waste

All waste should be handled with care and appropriate protective equipment worn as
required. Used chemical containers should be handled in the same manner as filled
containers to minimize chance of chemical spillage.
When handling and storing waste chemicals, the requirements of the Material Safety
Data Sheets (MSDS) shall be observed.
5.6. Use of PPEs
PPEs must be worn (depending upon the type of hazard) while handling waste. Refer
to MSDS or contact HSE team where special PPE is required to minimise the risk level.
It should be noted that solid waste may have physical as well as chemical or biological
hazards. All PPEs should be in good condition, fit for purpose and maintained where
required in accordance with manufacturer’s requirements.
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5.7. Waste Bin Colour Coding
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5.8. Waste Bin Location at Site
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6. Training and Awareness

All staff will be familiar with site solid waste management procedure and will implement
in their routine activities.
HSE department will perform the following;
 Deliver training to plant staff for the safe handling and disposal of solid waste.
 Display relevant environmental site notices and environmental awareness
posters at prominent workplace locations.
 Maintain records of training attendance, housekeeping audits and inspections.
Team leader will ensure the following;
 Conduct toolbox talks before starting the job to ensure the proper
housekeeping of working site.
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HOUSEKEEPING Revision Date 02-05-2019
1. Objective
This procedure provides guidelines for good plant housekeeping which promotes the
corporate image, provides for a safe and pleasant work environment and reduces
the risk of fire. Good housekeeping helps to eliminate accidents and fire hazards,
save space, time, and effort in material handling and improves employee morale by
developing pride in a neat and orderly work environment.
2. Scope
This procedure applies to all activities which are related to housekeeping and may
affect the quality of operation and maintenance services at plant.
3. Responsibilities
3.1 Housekeeping Supervisor
Housekeeping Supervisor will perform the following jobs;
 Continually conduct housekeeping audits of all plant sites and inform to
contractor supervisor for taking necessary measures.
 Ensure that all premises of plant must be neat and clean all the time.
 Report to Admin and Security Manager for any complaint about housekeeping.
 Ensure timely removal of wastes from collection containers.
 Ensure the use of PPEs by housekeeping staff.
 Ensure the cleaning of drain channels.
3.2 Employees
All employees must:
 Follow this procedures and the instructions of their HODs and EHS department
for implementation of 5S’s.
 Report any unsafe or hazardous conditions or acts that may cause injury to either
themselves or any other employees.
 Keep work areas uncluttered, orderly, sanitary and free of other hazards that
could result in personal injury.
 Remove all type of waste materials like damage machinery parts, cotton rags,
dusts, tools, wooden pieces etc. from working site and make it neat and clean.
3.3 Head of Department
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HOD will ensure that all employees must follow the housekeeping procedure and give
value suggestions for the improvement of housekeeping standards.
3.4 Manager HSE
The Manager HSE will;
 Check the implementation of housekeeping program in safety rounds and
monthly housekeeping evaluation.
 Conduct safety training for housekeeping staff.
3.5 Manager Admin and Security
The Manager Admin and Security will;
 Implement the housekeeping program.
 Arrange housekeeping tools and materials for housekeeping.
 Make communication with waste management company for the removal of
wastes from site.
 Make communication with rodents and insect control company for the control of
rodents and insect at site.
4. Procedures
 Maintain all tools, materials, equipment, buildings, vehicles and properties in
clean condition and good order.
 All employees, regardless of position, are required to contribute to cleaning the
plant. All personnel will clean up as work progresses and will ensure that work,
equipment and tools are cleaned when a job is completed.
 No job is completed until
 Tools and equipment’s are clean, put away and placed at their original
storage locations in orderly manners.
 Scrap and waste are disposed of.
 All work areas are in a clean and safe condition.
 Do not scatter tools and materials around the work area.
 Clean up oil or chemical spill sites immediately to prevent slipping or fire hazards.
 Dispose of waste, trash, used rags, used insulation, machine parts etc. as often
as necessary to maintain a safe working environment. Dispose of them only in
designated containers.
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 Do not throw waste materials overboard or dump them at the site or outside the
side other than in approved and designated places. Plant management is
responsible for designating such places.
 Immediately remove all protruding metal straps, etc., from boxes, packing cases,
and crates. Remove nails, staples, etc., from boards or flatten them; stack the
boards with the flattened nail or staple ends facing down.
 Store tools, materials and equipment in an orderly manner in tool store welding
shops or other acceptable locations when not in use. Use shadow boards and
tool boards to identify tool locations and to simply inventory counts.
 Cross-tie or otherwise secure, stacked material to prevent it from falling.
 Keep aisles and walk ways clean and clear and storage of material and
equipment is prohibited in these areas.
 A good paint job is to be maintained throughout the plant. This encourages
employees to be neat and orderly. A well-painted facility not only protects the
surface but adds greatly to the general appearance and makes cleaning easier.
o Exercise care when painting to ensure that instrumentation, electrical
equipment and other sensitive equipment are not painted over.
o Neutralize or remove rust before painting.
 Immediately correct or note on a plant attention report, any product leaks or
seepage from valves, flanges, vessels, bleeders, etc. If a leak cannot be
corrected immediately place a drip tray under it and identify the tray for regular
cleaning until repairs can be made.
 Maintain all equipment and structures in good overall condition.
 Do not store materials, tools, etc., in a way that obstructs access to fire
extinguishers, fire hoses or other safety equipment’s.
 Check parking areas routinely for oil contamination. Vehicles that leak oil will not
be allowed to park at site.
 Do not allow lube oil filters or fuel oil filters to drip or leak onto walkways, open
ground or paved areas. Store them in leak-proof and fire-proof containers until
handover to approved waste management company.
 Maintain bathrooms and showers in a neat and clean condition at all times.
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 Notices and signs are to be properly located and affixed to surfaces. No taped
messages or hand-written notes and instructions, using pencil and colored
markers will be allowed on equipment or control panels.
 Employees involved in housekeeping activities will use PPE and follow
instructions:
 Inspect PPE before use and check for signs of wear or damage.
 Keep PPE clean.
 Store PPE properly according to instructions on labels or received during
training to prevent damage or contamination from dirt or chemicals.
 Replace PPE when it is worn out, damaged or no loner provides the
protection that is required.
 Housekeeping will be regularly monitored to ensure a high standard of sanitation
and safety in all work areas, as well as to identify deficiencies. Housekeeping
Supervisor will conduct regular inspections of work areas to monitor hazards and
ensure that housekeeping and safe work practices are implemented.
 Regular monitoring of rodents and insects shall be carried out to control their
population.
 A housekeeping evaluation round of plant premises shall be taken every month.
 Safety training for housekeeping staff will be conducted to inform them about the
hazards involved in housekeeping activities.
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CHANGE MANAGEMENT Revision No 02
PROCEDURE Revision Date 11-12-2021

1. Purpose
The purpose of Change Management Procedure is to develop a system through which all
changes at Nishat Power Limited can be addressed and executed in a safe and environment
friendly manner with t ultimate aim to improve plant’s Safety, Reliability, functionality and
Profitability
2. Scope
Even small changes to equipments, processes or systems can have a significant potential
effect. Modifications under the scope of this procedure, irrespective of cost, whether temporary
or permanent, would include the following:
I. Any change in operation.
II. Any change of substance including, change in formulation, in ratio of ingredients or
source of supply of raw materials.
III. Any change to equipment, including its specification, which:
IV. Could affect its processing capability, control or integrity of the facility in foreseeable
transient or steady running situation.
V. Is in contact with process fluids, steam or piped services
VI. Could affect flow, temperature, pressure, composition or material of construction
VII. Any addition or subtraction of operating equipments from plant.
VIII. Any change to operating conditions, for example changes to process flow, temperature,
pressure or composition defined outside operating parameters.
IX. Any change in the layout/ structure of site or building.
X. Any addition/ modifications in OEM supply tools, jig and fixture etc.
XI. Excluded from the scope is replacement of plant equipment or materials that is of the
equivalent specification to that which has been removed.
3. Types of Changes
The types of change can be divided into following categories;
3.1. Technical Changes
Technical changes involve changes to process chemicals, technology, and/or equipment at
NPL. Changes to facilities that can affect a covered process must also be managed and can
follow a MOC procedure.
Technical improvements/changes can be initiated in following cases;
I. Identification of recurring problems.
II. Observation identified during Technical, Process or Insurance Audit.
III. Modification proposed in Technical Bulletins.
IV. Manufacture Feedback.
V. Changes to Process Safety Information (PSI), such as Material Safety Data Sheets
(MSDS), Process & Instrumentation Diagrams (P&IDs), Process Flow Diagrams
(PFDs), etc., should also follow MOC process.
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3.2. Procedural Changes

Procedural changes involve changes to operating procedures and other NPL procedures.
Before such changes go into effect, all necessary evaluations, approvals, quality verifications,
notifications, and training must be performed.
4. Procedure
4.1. Change Request and Justification
The Initiator will fill up the Change Management Form along with relevant details and
attachments, such as:
I. Modification title
II. Modification type
III. Nature of problem
IV. Proposed modification/ concept with supportive detail documents
V. After filling up the form, the initiator will present MOC to his head of department for
concept review and approval.
VI. Approval of Concept
The Initiator head of department shall review the proposed modification and shall discuss it in
plant management meetings and get consent for MOC approval.
4.2. Assessment and Evaluation
The Operation and Maintenance (mechanical, Electrical etc.) head of departments shall
technically evaluate the modification and shall assign responsibility along with completion date
for different technical activities necessary for safe execution of the modification.
HSE Committee shall assess the requirement of Process Hazard Analysis (HAZOP studies).
When the hazard analysis (HIRA) is completed, the performance team will ensure all the
recommendations of HIRA are implemented.
HSE department then assess the modification and approves the concept along with additional
comments if required.
4.3. Temporary Protection By-Pass
Operation Manager shall be authorized for temporary protection by-pass (both soft and hard
wired) for an expected duration of 24 hours (maximum) in all modes of plant operation (start-
up, shutdown & normal). Prior to initiate the protection by-pass process, Operation Manager
shall ensure that this particular protection shall not have any short term or long-term adverse
impact on equipment and/or personnel. Temporary by pass must be normalized within its
expected duration/condition as mentioned in the Temporary safety by pass log sheet. This
procedure shall be used only for temporary by-passing of protections (both hard wired and soft
form).
For any permanent change, the procedure for change management shall be followed.
I. The log book shall be used to log the details of temporary protection by-pass which
shall remain in control room.
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II. Any protection by-pass carried out during unit startup & shutdown shall be clearly
mentioned and record in the ‘unit startup report’ by Shift Engineer so that Operation
Manager could review it with the report.
III. The maintenance (Electrical & Mechanical) person must normalize the bypass within its
expiry or expected duration/condition as mentioned in log sheet.
Overall ownership of this log sheet shall remain with the Operation Manager
4.4. Final Approval
The Change Management Form is presented to GM for approval. After final approval, the
initiator hands over the form to relevant Head of Department for detailed engineering if
required.
4.5. Detailed Engineering
The assigned people will complete detailed engineering of the modification as identified by
respective time limits during assessment and evaluation. Once detailed engineering is
completed, the form is handed over to executor for execution of work.
4.6. Work Execution
Once the detailed engineering is completed, the assigned craft person, in accordance with
NPL HSE rules and regulations, executes the modification.
4.7. Completion Report
After the completion of the job, the responsibilities are shared as under:
Craft Person fills out the following and hands over the form to Initiator.
I. Drawing will be updated by relevant department.
II. PPS Coding number and PPS strips will be hanged by relevant department
III. Operating procedure will be update by relevant department.
HSE Manager /HSE Committee will updates the WHIS/HIRA and maintain the record.
MOC custodian shall closed the Change Management, after ensuring that,
I. Work order number.
II. PTW number.
III. P&ID or layout drawings has been modified and available for use.
IV. PPS numbers are in place.
V. Dependencies have been prepared or modified.
VI. Manuals are updated.
VII. All protections and alarms are intact.
4.8. Placement of Drawings
Discarded and Modified/As-built drawing shall be reviewed by the Head of Department (HOD)
before sharing with concerned departments. A copy of Modified/As-built drawings shall be
placed in Controlled common share folder named as “Modified Drawings Folder”. Modified
drawings folder contains subfolders of different departments drawings. Head of Department
(HOD) will be the custodian of his department drawings folder and he will be the authorized to
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replace drawing in relevant folder. Discarded drawing shall be stamped/marked as “Discarded

Drawing” and Modified/As-built drawing shall be stamped/marked as “Modified Drawing”.
5. Training
All NPL people shall be trained to understand the purpose and function of this procedure.
Auditing. A review of the documents associated with change management procedure shall be
completed at-least once annually by HSE Committee.
6. Records
Title Maintained by Retention Period
Change Management Form
HSE Department 5 years after completion of Job
(NPL-HSE-A026)
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WORK AT HEIGHT Revision Date 23-11-2017


1. Purpose
Fall from height may cause serious/fatal injuries. NPL employees/contractors staff must
use work at height precautions according to the procedure to prevent from an accident.
2. Scope
The procedure will apply to all works within the boundary of NPL where there is a risk of
fall from height.
3. Definitions
3.1. Working at Height: Working more than 6 feet above or below ground level defined as
working at Height, Examples of working at height;
 Working on sloppy roofs and surfaces
 Cleaning and maintenance of windows, large doors and walls
 Cleaning and maintenance of supply air fan structure
 Air-conditioning maintenance
 Erecting signs and displays
 Ladder and scaffold work
 Working near holes, pits and shafts
 Working on fragile, slippery or sloping surfaces.
 Working outside the guard rails
 Working in man lift, at overhead cranes etc.
3.2. Access" and Egress" include ascent and descent.
3.3. Fragile Surface means a surface which would be liable to fail if any reasonably
foreseeable loading were to be applied to it.
3.4. Ladder includes a fixed or moveable ladder having two feet resting on the horizontal and
two feet against the vertical and a stepladder, which is a ladder having four feet resting
on the horizontal.
3.5. Life Line is a rope or wire used to remove an individual from a hazardous environment
in the event of an emergency.
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3.6. Personal fall protection system means –
 fall prevention, work restraint, work positioning, fall arrest or rescue system, other
than a system in which the only safeguards are collective safeguards; or
 rope access and positioning techniques.
3.7. Full Body Harness is equipment that consists of belts, which go around the body in
such manner that they distribute the force generated on an individual as he/she falls,
thus reducing potential injury. This equipment must comply with ANSI Z359.1 standards.
3.8. Fall Restraint System is a system of equipment designed to prevent the wearer from
falling; usually consisting of a safety waist belt or a full body harness, a non-shock
absorbing safety lanyard and an anchor point.
3.9. Work Equipment means any machinery, appliance, apparatus, tool or installation for
use at work.
3.10. Danger Area is an area underneath the work at height in which there is a high risk of
harm.
3.11.Working Platform:
 any platform used as a place of work or as a means of access to or egress from a place
of work.
 Includes any scaffold, suspended scaffold, cradle, mobile platform, trestle, gangway,
gantry and stairway which is so used.
4. Procedure
In order to safeguard the health and safety of its workers and others that may be affected
by its workplace activities the NPL has developed this procedure, based on the
requirements of the Work at Height.
The Work at Height requires that:
 all work at height is properly planned and organized;
 staff are competent that involved in work at height.
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 the risks from work at height are assessed
 appropriate work equipment is selected and used;
 the risks from fragile surfaces are properly controlled
 all equipment for work at height is properly inspected and maintained.
4.1. Organization and Planning.

In organizing and planning it will be ensured that work at height is –
 Properly planned, including planning for emergencies and rescue;
 Covered by a suitable and sufficient risk assessment, which has been carried out as
required before the start of work.
 Appropriately supervised
 Carried out in a manner that is, as far as is reasonably practicable and safe.
4.2. Control Measures
Where there is a risk of a person:
 falling a distance that is likely to cause personal injury, or
 being struck by a falling object.
NPL will ensure that, where it is reasonably practicable, work at height will be avoided.
Where it is not reasonably practicable to avoid work at height the company will ensure
suitable and sufficient control measures are implemented to prevent any person falling a
distance liable to cause personal injury.
Unauthorized persons must, so far as is reasonably practicable, be prevented from

entering the danger area by the provision of suitable guarding systems (barriers),
warming signage and spotters which must be clearly indicated.
Control measures should reflect the probability and severity of risk as identified in the
Work at height hazard sheet (risk assessment) and follow the hierarchy of risk
management detailed here.
a) fixed edge protection (roof work)
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b) fixed scaffolds
c) mobile scaffolds
d) mobile elevated working platforms e.g. scissor lifts, cherry pickers etc.
e) slung nets / crash decks / air bags
f) personal suspension e.g. fall arrest / static line devises
g) ladders
h) information instruction and training
4.3. Preparation to Work at Height
Before work permit issuance Team leader and HSE Officer will carry out risk assessment.
The risk assessment will cater duration of the work, choice of equipment best suited to
minimize the risk of persons and/ or materials falling, and prevailing weather conditions
as well as damage to machinery.
4.3.1. Selection of Equipment

4.3.1.1. Access Equipment:
Different types of access equipment’s can be used for working at height. It

includes scaffolds (mobile or fixed), ladders (portables, fixed), hoist, winch and
cherry picker etc.
Erection, use, dismantling and maintenance of all access equipment’s should

be carried out by craft person or third party as per standard procedures.
Inspection and verification of all access equipment’s will be made by HSE

Officer or his designee before the issuance of work at height permit.
4.3.1.2. Personal Protection Equipment (PPE)
Employees shall use compulsory and/or task specific PPEs.
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Before each use all fall protection equipment (belts, anchor lines, harnesses,
ropes or lanyards, hooks, connectors) should visually inspect by craft person and
only healthy/certified equipment will be used.
4.3.2. Permit To Work Preparation:
During the process of permit to work preparation, point # 1 to 4 and 6 to 9 shall be

filled by Craft Person/ Craft Group Leader and counter check by Shift Engineer.
Scaffold inspection and verification (point # 5 & 10) shall be made by HSE
Officer/his designee and Scaffold inspection checklist will attach with Work at
Height Permit.
Approval and Authorization (point # 11) of permit to work will be given by Shift
Engineer. Acceptance and Release of Permit will be made by Craft Person/Craft
Group Leader.
5. Enforcement
 Administrative pertains to any Team Member not adhering to the application of Work
at Height Procedure.
 Physical harm pertains to an individual’s failure to follow procedure, which may cause
of physical harm to him or another individual or property damage.
Each incident will be considered individually and may involve an independent

All safety occurrences will be discussed in next EHS team meeting for appropriate
actions.
Failure to adhere to any /all aspects of this procedure may result in disciplinary actions.
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SCAFFOLD ERECTING, Issue Date 23-11-2017
ALTERING AND Revision No 0

Revision Date 0
DISMANTLING PROCEDURE Last Review 23-11-2020


1. Introduction:
This procedure provides practical guidance for people those are involved in safe erecting, altering
and dismantling metallic/fiber modular tower/mobile scaffolding.
2. Scope:
This procedure covers suspended, mobile and fixed, prefabricated, frame-type tower scaffolds (tower-
frame), constructed from aluminum or other lightweight components, such as fiberglass and stainless
steel and founded on the ground or another solid surface.
3. Definitions:
3.1. Competent person; means a person who has acquired through training, qualifications or
experience of knowledge and skills to carry out that task.
3.2. Platform unit; frame assembly of one bay length incorporating a working surface that is
capable of connecting to its support structure in such a way as not to be inadvertently
dislodged. One or more platforms may be required to suit the bay width.
3.3. Base lift: the first level of transoms and ledgers above the jacks or base plates.
3.4. Closed platform; a platform that is constructed and that is capable of functioning as a working
platform, but is temporarily closed to any loading or access.
3.5. Hop-up bracket (platform bracket): a bracket that is attached to a scaffold to enable a
platform to be placed adjacent to a bay of an independent scaffold.
3.6. Erection platform: a temporary platform that is placed on the scaffold or temporarily
constructed as part of the scaffold to assist with the installation (or removal) of the standards,
transoms, ledgers, guardrails and mid-rails for the platform.
3.7. Safe work method statement:
 identifies the high risk work.
 specifies hazards relating to the high risk work and risks to health and safety associated with
those hazards.
 describes the measures to be implemented to control the risks.
 describes how the control measures are to be implemented, monitored and reviewed.
3.8. Scaffold standard: a vertical structural member of the scaffold that transmits a load to a
supporting structure.
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3.9. Solid surface: a surface with adequate stiffness and strength to sustain imposed loads from
the scaffold.
3.10. Temporary edge protection: a guardrail and midrail or proprietary system installed to
provide fall protection for scaffolders in advance of the placement (or after removal) of the
permanent edge protection.
3.11. Toeboard: a scaffold plank or purpose-designed component fixed at the edge of a platform
to prevent material from falling off the platform.
3.12. Working face: the face of a building or structure at which the scaffold has been erected to
enable work to be carried out at some stage of the project.
3.13. Working platform: a platform on a scaffold, positioned at a work location for supporting
personnel, equipment and materials, and used to provide a working area.
4. Scaffold Component Identification:
Diagram showing the use of temporary platform and edge protection frames
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1. temporary platform (used during erection and dismantling)
2. temporary edge protection frame (used during erection and dismantling)
3. full bay working platform
4. ladder access platform (a working platform with opening section for ladder access)
5. castors
6. end frame
7. guardrail
8. ledger (horizontal braces)
9. plan brace
10. diagonal (face) brace
11. outriggers/stabilizers
12. ladder
13. midrail
5. Planning and preparation

Tower-frame scaffolding is used by a variety of jobs in industries.
Risk assessments and safe work method statements must be completed prior to erecting, altering or
dismantling scaffolding and are the joint responsibility of the contractor persons erecting scaffolding
and NPL concern department. These should consider the site specific issues and the intended use
of the scaffold.
Scaffold Erecting Supervisor will discuss the safe erection methods with scaffold erecting team. OEM
safety guidelines and usage instruction must be followed.
Only competent staff shall erect, alter or dismantle the scaffold.
When working near overhead power lines make sure electrical wires and apparatus are de-
energized, if not possible, isolate or shield with a non-conductive material by considering wind, fog
and rain effect on power lines. If high tension electrical wires are not de-energized or isolated or
shielded, then make sure the standard 4 m approach distance from overhead should be maintained.
If working will carried out under the high tension lines than consult with both electrical and operation
managers before performing scaffold.
Implement precautions to prevent scaffold being impacted by moving vehicles during erection,
altering or dismantling, e.g. provide barriers, rerouting of traffic or traffic management.
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When erecting, altering or dismantling scaffold on or adjacent to a walkway, implement safety
measures to separate the people from the scaffold activity, e.g. barriers, rerouting of pedestrian ways.
In the absence of manufacturer’s or supplier’s information, a competent person should be used to
develop safe erection instructions.
6. Erection of Scaffolds
6.1. Prior to Erection - All Scaffold Assemblies
Job site must be inspected to determine ground conditions, strength of supporting structure,
fall arrest anchor points, proximity of electric power lines, overhead obstruction, wind
conditions, and the need for overhead or weather protection. These conditions must be
evaluated and adequately addressed.
1. Frame spacing and sill size can only be determined after the total loads to be imposed on
the scaffold and the weight of the scaffold have been calculated.
2. Stationary scaffolds more than 125 ft. in height must be designed by a professional
engineer.
3. All equipment must be inspected to see that it is in good condition and is serviceable.
Damaged or deteriorated equipment must not be used
4. Scaffold plank must be inspected to see that it is graded as scaffold plank, is sound and in
good condition, and is free from saw cuts, cracks, notches, splits, delaminations and holes.
5. A Competent Person can deviate from these guidelines only if it can be shown that the
resulting scaffold design complies with applicable codes and generally accepted scaffold
engineering practices.
6. The scaffold assembly must be designed to comply with federal, state, provincial and local
requirements
6.2. Fixed Scaffold
Scaffold must be erected, moved or disassembled only under the supervision of Competent
Persons. Safety equipment including safety glasses and hard hats must be worn by all persons
erecting, moving, dismantling or using scaffolds
1. All scaffold legs require the use of a base plate and a mudsill or other adequate firm
foundation. Base plates must be in firm contact with the sills/foundation and frame legs and
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should be centered on the sills. Be especially careful when scaffolds are to be erected on
soft or frozen ground. Any part of a building or structure used to support the scaffold must
be capable of supporting the load to be applied.
2. Compensate for uneven ground by using screw jacks and base plates, and sills if required
by ground conditions. Do not use unstable objects such as blocks, loose bricks, and similar
objects or materials.
3. Tag placed with marking “scaffold under erection” at visible location.
4. Plumb and level scaffold. Be sure scaffold stays plumb and level as erection progresses.
5. Ties, guys, bracing and/or outriggers may be needed to assure a safe, stable scaffold
assembly. The height of the scaffold in relation to the minimum base width, wind loads, the
use of brackets or cantilevered platforms, and imposed scaffold loads determines the need
for away and stability bracing. The following general guidelines apply:
 A scaffold must always be secured when the height of the scaffold exceeds 4 times the
minimum base width.
 Ties must be placed as near as possible to horizontal members. The bottom tie must
be placed no higher than 4 time the minimum scaffold base width. Subsequent vertical
tie placement will depend upon the scaffold width. Scaffolds 3 ft. and narrower must be
tied at vertical intervals no more than 20 ft. apart. Scaffolds wider than 3 ft. must be tied
at vertical intervals no more than 26 ft. apart. The uppermost tie should be placed as
close to the top as possible and, in no case, more than 4 times the minimum base width
from the top
 Horizontal ties must be placed at the ends of the scaffold runs and at no more than 30
ft. horizontal intervals in between.
 Ties must be installed as the erection progresses and not removed until scaffold is
dismantled to that height.
 Side brackets, cantilevered platforms, pulleys, hoist arms, enclosed scaffolds, sloped
surfaces, and windy conditions introduce overturning and uplift forces which must be
considered and compensated for. These situations require additional bracing, tying or
guying.
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 Circular scaffolds erected completely around or within a structure may be restrained
from tipping or by use of "standoff" bracing members.
 A free standing tower must be guyed at the intervals outlined above or otherwise
restrained to prevent tipping or overturning
6. Outrigger frames or outrigger units can be used to increase the minimum base width. If
used on a free standing tower, they must be installed on both sides of the tower.
7. Work platforms must be fully decked with platform units in good, sound condition. Platform
units may be individual scaffold grade wood planks, fabricated plank, fabricated scaffold
decks or fabricated scaffold platforms.
 Scaffold platforms and walkways must be atleast 18 in. wide.
 Each end of each plank must overlap its support by a minimum of 6 in. or be cleated.
 Each end of each platform 10 ft. long or less must overhang its supports by no more
than 12 in. Each end of each platform longer than10 ft. must overhang its supports by
no more than 18 in. Larger overhangs must be guarded to prevent access to the
overhang. Materials must not be stored on overhangs. Do not stand on platform
overhangs.
 Each plank on a continuous run scaffold must extend over its supports by at least 6 in.
and overlap each other by at least 12 in.
 Spans of 2 in. by 10 in. nominal scaffold grade plank must never exceed 10 ft. No more
than one person must stand on an individual plank at one time. Loads on planks must
be evenly distributed and not exceed the allowable loads for type of plank being used.
 Secure platform units to scaffold to prevent uplift caused by high winds or other job site
conditions. Use latches, if supplied by platform manufacturer, or other suitable means.
Outriggers, or other means, may be used to increase the minimum base dimension of a
scaffold tower. The resulting base dimension, however, may no longer be the minimum (or
limiting) base dimension.
8. Guardrails must be used on all open sides and ends of scaffold platforms. Both top and
midrails are required then the height of toprail should be 39-42 inches. Where guardrails
are required use at lower heights if falls can cause injury.
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9. Toeboards must be installed whenever people are required to work or pass under a
scaffold platform. When materials are to be stacked higher than the toeboard, screening is
required from the toeboard or platform to the top guardrail.
10. Access must be provided to all work platforms. If access is not available from the structure,
access ladder units or stairways must be provided. When access ladder units are provided,
a rest platform must be installed at vertical intervals of 35 ft. or less. Attachable ladder units
must extend at least 3 ft. above platforms. Install access ladder units as scaffold erection
progresses.
11. Use fabricated decks or cleated plank to minimize platform interference in access areas.
12. Do not store materials on side or end bracket platforms.
13. Cantilevered platforms must be specifically designed for that purpose, the frames pinned
to prevent uplift and adequate ties provided to prevent overturning.
14. Materials must never be placed on cantilevered platforms unless the assembly has been
designed to support material loads by a qualified person. These types of platforms cause
overturning and uplift forces which must be compensated for.
15. After erecting scaffold, be sure screw jacks are in firm contact with frame legs.
16. Special care must be taken when putlogs are used:
 Putlogs must only be mounted using putlog hangers, with all bolts and nuts installed
and tightened.
 Putlogs must overhang their supports by at least 6 in.
 Lateral bracing and knee bracing are both required for putlog spans greater than 10 ft.
 Putlogs used as side or end brackets require special mountings and special bracing.
17. Do not install platforms between free standing towers.
18. Material hoists and derricks should not be mounted on a scaffold unless the scaffold is
specifically designed for that purpose.
19. Check the entire scaffold assembly before use.
Thoroughly inspect the completed assembly to see that it complies with all safety codes, all
fasteners are in place and tightened, it is level and plumb, work platforms are fully decked,
guardrails are in place, and safe access is provided
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6.3. Rolling/Moving Scaffolds
The following additional precautions apply to the erection of rolling towers:

1. Height of the rolling tower must not exceed 4 times its minimum base width, or 40 ft.
whichever is lower.
2. Secure all casters to frame legs or screw jacks with a nut and bolt or other secure means.
3. Screw jacks must not increase the height of the scaffold by more than 12 in. Towers must
be kept level and plumb at all times.
4. Horizontal diagonal bracing must be used at the bottom and top of rolling towers where the
top work platform is more than 9 ft. above the surface. When rolling towers are to be
erected higher than 9 ft. the first brace must be no more than 2 ft. above the casters, the
others at no greater than 21 ft. intervals above. Fabricated planks with hooks may be used
as diagonal braces.
5. All frames must be fully cross-braced.
6. Platform units with hooks, or cleated planks, must be used on rolling towers.
6.4. Suspended Scaffold
1. Outrigger beams, parapet clamps or roof hooks may be used to support the suspended
scaffold. Be sure the building is capable of supporting the necessary loads. In addition,
each of these devices must be attached to a structurally sound portion of the building with
a suitable tieback to prevent accidental movement of the outrigger beam, parapet clamp
or roof hook.
2. Tiebacks must have the equivalent strength of the hoisting rope. Tiebacks shall be installed
without slack. Whenever possible, tiebacks must be installed at right angles to the face of
the building. If tiebacks cannot be installed at right angles, two opposing angle tiebacks,
without slack, shall be used for each outrigger beam, parapet clamp and roof hook.
3. Parapet clamps and roof hooks must only be installed on structurally adequate parapets
that can withstand the bending loads imposed on them by the parapet clamp or roof hook
under maximum load conditions
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Any outrigger beam, parapet clamp or roof hook used to support the suspension wire rope(s)
must be properly anchored or tied back to prevent a catastrophic failure of the suspended
scaffold. Tiebacks shall be installed without slack/loose to a structurally sound portion of the
building
4. The outrigger beams shall rest on suitable wood bearing blocks which are perpendicular
to the outrigger beams.
5. Overhang of outrigger beams must not exceed the maximum allowable dimension as
shown in the appropriate instructions for the load being used.
6. Counterweights shall provide a minimum safety factor of 4:1 against overturning. Each
shall be made of a non-flowing material and permanently marked with its weight. All
counterweights must be securely fastened to the outrigger beam or to some other securely
attached structural member designed for that purpose. Refer to user instructions to
determine the number of counterweights.
7. All overhead rigging, counterweights, anchorages and connections must be secured and
adequately restrained from movement in any direction.
8. When installing the traction type hoisting machines, make sure wire ropes are long enough
to extend from the highest point of support to the lowest point of the structure plus 3 ft.
extra for the 30 series hoist. This allows for reeving.
9. Do not install scaffold in the vicinity of power lines until the power service company has
been contacted and the electrical power has been disconnected.
10. Never install scaffolds in the vicinity of exposed electrical circuits until it is assured that
such exposed circuits cannot affect any part of the scaffold assembly.
11. Handle all equipment with care, and prevent wire ropes from becoming kinked. Do not drop
equipment during handling, loading or unloading. Do not install or use damaged equipment.
12. Connection of wire rope to the rigging must be made with proper fittings designed for that
purpose. See the operating and maintenance instructions provided with the hoist
equipment. Never wrap wire ropes around overhead rigging or use makeshift devices.
Hoisting machines on two-point suspension scaffolds must be located on the same
centerline as the rigging.
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13. Two or more scaffolds must not be combined in a run by lapping platforms on one stirrup
or by bridging between them, except for multi-point suspension scaffolds or specially
engineered systems. Doing so could cause rigging or platform to fail.
14. Assure platform and toeboards are properly installed and platform staging is secured to
the stirrups. Make sure that guardrails and midrails are properly installed on all open sides
and ends of the work platform. Use wire mesh screen between guardrail and toeboards
where required.
15. Install overhead protection when a falling object hazard exists.
16. Angulated rope suspension systems, lashing or other devices shall be used to minimize
swaying of scaffolds. Window cleaner's anchors shall not be used for this purpose
7. Use of Scaffolds
7.1. All Fixed Scaffolds
1. Before you use the scaffold, a Competent Person must:
 inspect the scaffold assembly to be sure it has not been altered, is assembled
correctly, is level and plumb, all base plates are in firm contact with sills, all bracing
is in place and securely tightened, all platforms are fully decked, all guardrails are
in place, safe access is provided, it is properly tied and/or guyed, there are no
overhead obstructions, there are no energized electric power lines within 10 ft. of
the scaffold assembly, tag placed with marking scaffold in use at visible location and
correct any deficiencies prior to use.
2. Use only proper access. Do not climb cross braces. Do not climb any scaffold component
unless it is specifically designed for that purpose. Do not stand on platform overhangs.
3. Climb safely!
 Face the rungs as you climb up or down.
 Use both hands.
 Do not try to carry materials while you climb.
 Be sure of your footing and balance before you let go with your hands. Keep one hand
firmly on frame or ladder at all times.
 Clean shoes and rungs to avoid slipping.
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4. Do not work on slippery platforms.
5. Do not overload platforms with materials. Special care must be taken when putlogs are
used.
6. Do not store materials on platforms supported by putlogs. They are designed for personnel
only
7. Do not extend working heights by standing on planked guardrails, boxes, ladders or other
materials on scaffold platforms.
8. Do not loosen, detach or remove any component of a scaffold assembly except under the
supervision of a Competent Person. Components that have been removed must be
replaced immediately.
9. Do not erect scaffold on wagons, trucks or other wheeled vehicles.
10. Stand only within the platform area; do not try to extend work area by leaning out over
guardrailing.
7.2. Rolling/Moving Towers
All of the above precautions plus:
1. Do not ride manually propelled rolling scaffold. No one must be on a rolling tower while it
is being moved.
2. Lock all casters before getting on a rolling tower. Casters must be locked at all times the
scaffold is not being moved.
3. Do not bridge between rolling towers.
4. Remove all materials from scaffold before moving a rolling tower.
5. Be sure floor surface is clear of obstructions or holes before moving scaffold.
6. Be sure there are no overhead obstructions or energized electric power lines in the path
when moving a rolling tower.
7. Rolling towers must only be used on level surfaces.
8. Move rolling towers from the base level only. Do not pull or push from the top.
7.3. Suspended Scaffolds
1. All damaged equipment should be tagged, set aside and your employer notified
immediately so it is not used by others.
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2. Weight of personnel, material, hoist, components and scaffold must not exceed rating of
the hoists and rigging system used.
3. Never step onto a suspended scaffold unless you are wearing a properly attached fall
arrest device.
4. When using the drum type hoisting machines, at least four turns of the wire rope must
remain on the drum at all times. The end of the wire rope must be properly secured to the
drum.
5. Do not use suspended scaffolds in corrosive atmospheres or with corrosive chemicals.
Wire ropes, aluminum platforms and other parts of the scaffold are susceptible to serious
damage if exposed to fire, undue heat, corrosive atmospheric conditions or corrosive
chemicals. Take precautions to protect wire ropes when using welding equipment. If
exposure to these conditions occurs or is suspected, immediately discontinue use of the
scaffold
Do not secure the bottom end of the wire rope used to suspend the scaffold. Wire rope can
become kinked and break if the bottom end is prevented from rotating freely as the scaffold is
raised and lowered
6. Periodically inspect the wire rope for damage and wear; lubricate as needed and retighten
the twin base wire rope clips. Inspect and test each time before use and/or after re-rigging.
7. Inspect rigging, platform and hoists each time before use to make sure the equipment has
not been altered.
8. Ensure that periodic lubrication and other specified maintenance procedures are fully
complied with. Never alter, remove or substitute parts or components of the hoisting
machine or scaffold.
9. Before using electrically operated hoists, assure that the electrical power source and all
power source connections are properly grounded, that the power source is of the proper
phase and voltage for the hoist, and be sure insulation of wire and connections are in good
condition.
10. Impose loads on suspended scaffolds gently and without impact. Do not load equipment
beyond recommended load capacities.
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11. Do not weld from a suspended scaffold unless all precautions noted in the operating and
maintenance instruction book are implemented and followed.
12. Ground Fault Interrupters must be installed when electrical equipment is used or is located
on suspended scaffolds.
13. When using a rolling outrigger system the following additional special precautions apply:
 Use casters, outrigger base frames and outrigger beams only within the limits specified
on the instructions and literature supplied with the equipment.
 Be sure loads imposed on the structure by the caster are dissipated by using devices
to distribute the loads.
 Use guide channels and move system only with suspended platform at its lowest
position.
 Do not ride the suspended platform while the rolling outrigger system is being moved.
 Keep counterweights within the scaffold base dimension and secure them in position.
 If outrigger height must be increased, do not raise higher than two times the system's
minimum base dimension without increasing the rigging base dimension.
 Tie the outrigger beam to the structure when in use.
14. When using an air operated hoist, never disconnect the air hose while the compressor is
running and the lines are pressurized.
15. Restrain platform from movement during use immediately or when not being moved.
16. If damage or defects develop in the wire ropes, hoisting machine or other scaffold
components, discontinue use immediately and notify your employer.
17. Never use scaffold in the vicinity of exposed electrical circuits or power lines until it is
assured that such exposed circuits or power lines cannot affect any part of the scaffold
assembly.
18. Contact Safeway for special rigging or application information
Severe injury or death can result from improper use or assembly of hoist suspended scaffold
products. Do not use this scaffold unless you have personally determined that:
 You have read and understand the operation manual.
 You are wearing a fall arrest device that is attached properly.
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 The roof support system is complete, properly anchored and not overloaded.
 Hoists are not overloaded.
 Platforms are not overloaded.
 Guardrails are properly installed.
8. Dismantling of Scaffolds
8.1. Fixed Scaffolds
The following additional precautions apply when dismantling a scaffold:
1. Prior to removal or loosening of any component, consider the effect the removal of the
component, or the loosening of a joint, will have on the strength of the remaining assembly.
2. Tag placed with marking “scaffold under dismantling” at visible location.
3. Check to see if scaffold has been altered in any way which would make it unsafe. If so,
reconstruct where necessary before beginning the dismantling process.
4. Use only proper access. Do not climb cross braces or vertical members. Do not climb
scaffold components unless they are specifically designed for that purpose.
5. Do not remove ties until scaffold above has been removed.
6. Visually inspect each plank to be sure it is supported on both ends and is safe to stand or
work on.
7. Do not accumulate removed components or equipment on the scaffold.
8. Lower components in a safe manner as soon as dismantled. Do not throw components off
scaffold.
9. Stockpile dismantled equipment in an orderly manner.
10. Remove scaffold components immediately after detaching from scaffold.
8.2. Suspended Scaffolds
The following additional precautions apply when dismantling suspended scaffolds.
1. Prior to removal or loosening of any component, consider the effect the removal of the
component, or the loosening of a joint, will have on the strength of the remaining assembly.
2. Check to see if scaffold or rigging has been altered in any way which would make it unsafe.
If so, reconstruct where necessary before beginning the dismantling process.
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3. Disassemble the platform prior to removing any counterweights or tiebacks.
4. Lower components in a safe manner. Do not throw components off roof.
5. Stockpile dismantled equipment in an orderly manner. Understanding and following these
safety guidelines will increase your personal safety and the safety of your fellow workers.
9. Altering of Scaffolds
Ensure at all times that temporary platforms, guardrails, midrails and temporary edge protection
frames are used in the same manner as the erection process. Before altering the scaffold Permit
To Work must be suspended/release. After making alteration in scaffold, inspection should be
made again before starting the work.
10. Moving and relocating the Scaffold

 Ensure no persons or materials are on the scaffold.
 Where fitted, raise outriggers/stabilizers a minimal distance sufficient only to move scaffold.
 Unlock castors and move scaffold.
 Follow planned travel path - maintain prescribed distance from overhead power lines and avoid
openings, penetrations or unprotected edges.
 Lower and secure outriggers/stabilizers and lock castors before accessing the scaffold.
11. Permit for Scaffold Erecting, Altering and Dismantling:
During the process of permit to work preparation, point # 1 to 8 from scaffold work permit # to
scaffold supervisor name and signature including precautions and instructions shall be filled by
Craft Person/ Craft Group Leader and counter check by Shift Engineer. HSE Officer or his
designee will inspect and verify the healthy condition of scaffold material and hazard free
scaffold erecting area/location with the help of craft person or craft person group leader and
mark signature in Permit. After checking and verification (point # 5 & 10) approval and
Authorization (point # 11) of permit to work will be given by Shift Engineer. Acceptance and
Release of Permit will be made by Craft Person/Craft Group Leader.
12. Enforcement:
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 Administrative pertains to any Team Member not adhering to the application of Work
at Height Procedure.
 Physical harm pertains to an individual’s failure to follow procedure, which may cause
of physical harm to him or another individual or property damage.
Each incident will be considered individually and may involve an independent investigative
group to provide determination of fault.
All safety occurrences will be discussed in next EHS team meeting for appropriate actions.
Failure to adhere to any /all aspects of this procedure may result in disciplinary actions.
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1. Objective
This procedure provides inspection guidelines for eye and body shower. In inspection
healthiness of eye and body shower will be observed.
2. Scope:
This procedure applies on all eye and body showers inside NPL premises.
3. Responsibilities
3.1. Mechanical Manager
 Repair any devices that are not working properly
3.2. EHS Department
 Provide general oversight of this program.
 Perform monthly inspection / tests and verify proper operation of eyewash and
shower units throughout the NPL.
 Contacts Mechanical Manager or other Facilities if unit is not functioning properly
3.3. Users
 Know the location of the emergency units in the building and ensure that the
emergency units are clear of obstructions.
 Insure that appropriate signage for the stations are visible.
4. Procedure
Emergency eyewash and body showers are required in areas where personnel can
come into contact with hazardous materials that could harm eyes or skin.
All eyewash and shower stations must be inspected monthly and the results logged
(see Emergency Eyewash Inspection Form).
4.1. Fixed Eye / Body Wash Station:
 Ensure eye wash/shower is clear of obstructions and easily visible from all
directions (adequate signage Colour).
 Flush monthly, and record the flushing on the Emergency Eye / Body wash
Inspection Form.
 What to check when flushing:
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 Eyewash protection caps must be in place and in good condition (if present).
 The ON/OFF valves must be operational, activated by a single motion.
 Water flow remains ON when valve is open.
 Water flows freely and is directed at the proper angles to flush the eyes or
body as appropriate.
 Water temperature should be suitable for eye and body washing (≥ 16 oC &
≤38oC).
 Run the eyewash/shower for 1-3 minutes. The running (or collected) water must
be clear:
 If the water is clear, turn off water and sign the inspection tag.
 If the water is cloudy, discolored, or contains sediment, start another five-
second flush; stop; and then continue flushing at five-second intervals until the
water flushes clear. Then sign the inspection tag.
 Ensure the water used for flushing shall be collected in a suitable
container/channel (such as a plumbed drain, bucket, or large rolling waste can). If
any water spill on the floor, dry the area before leaving to prevent a slipping
hazard.
Note: If eyewash station does not run clear after repeated flushings, contact the
Operation department immediately.
4.2. Portable Eye Wash Station:
Cartridge-based eyewash stations use factory-sealed fluid cartridges and do not
require the use of tap water. Some units have a 24-month shelf life if the unit is not
activated. This two-year shelf life is determined by the date of manufacture, and is
more than four times longer than any other primary, portable eyewash station.
Cartridges can be quickly and easily installed in less than five minutes on most
leading models. This means that there is virtually no maintenance with this flushing
solution until the unit is activated.
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MUTUAL AID RESPONSE Revision Date 0
1. Purpose
The purpose of this procedure is to define the outline of instructions which will be
followed by Mutual Aid Partners, while responding to emergencies to any Mutual Aid
Partner site.
2. Scope
This procedure will cover Mutual Aid Partner sites, which includes Nishat Power Limited
(NPL) and Nishat Chunian Power Limited (NCPL).
3. Definitions:
3.1. Mutual Aid

The timely and efficient sharing of capabilities in the form of resources and
services upon request.
3.2. Mutual Aid Partner

The organizations that voluntarily and unconditionally have agreed to give Mutual
Aid in the event of crisis in the respective areas of operation.
3.3. Mutual Aid Agreement

An agreement between Mutual Aid Partners that provide a mechanism to quickly
obtain assistance in the form of personnel, equipment, materials, and other
associated services. The primary objective is to facilitate during, and/or after an
incident for emergency support.
4. Role and Responsibility
4.1. Management of Mutual Aid Partner

Management of Mutual Aid Partner will grant prior permission for the following;
 Coordination and responding to mutual aid emergencies.
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 Security gates opening for Mutual Aid Partner for assistance in an incident
immediately.
 Use of emergency equipment’s, material, resources and services.
4.2. Emergency Coordinator (i.e., Main person to deal emergency)

A) When emergency occurs in own plant:
 Declare emergency situation.
 Will arrange manpower, special rescue equipment and firefighting

appliance/equipment from internal resources and outside Agencies/
Mutual Aid Partner.
 Will communicate with the own emergency team, mutual aid partner
coordinator and other outside agencies as deemed necessary.
 Will provide guidance to outside agencies and other coordinators within

the plant for speedy implementation of Emergency Response Plan.
B) When emergency occurs in mutual aid partner site:
 Will coordinate and mobilize the resources for necessary assistance.
 Will maintain constant liaison with the affected plant and provide any
special assistance on request.
5. Procedure
 For handling emergencies each Mutual Aid Partner will specify their scope,
identifying, equipment, resources and material, which can be shared by Mutual
Aid Partner.
 In order to respond effectively and in minimum time, Mutual Aid Partner will
specify persons by designation who would be responsible & whom shall be
contacted in case of emergency with their phone numbers / mobile numbers.
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 To save time for responding to emergencies, each Mutual Aid Partner will have
prior permission from their management for responding to mutual aid
emergencies.
 Both Mutual Aid Partner will in advance have permission from their management
of security clearance for mutual aid partners for saving time. For this purpose,
Names and designations of each Mutual Aid Partner will be available with
security of each Mutual Aid Partner.
 Mutual Aid Partner will meet annually for discussing, sharing and suggesting of
new ideas, best practices and improvements. Previous mock drills reports will be
reviewed in meeting. The tentative schedule of meeting sessions will be as
under:
 First meeting session – At NPL
 Second meeting session – At NCPL
 Minutes to be issued after each annual meeting between Mutual Aid Partner’s.
 For effective emergency response at Mutual Aid Partner’s site, Mutual Aid
Partner will organize mock drills to get each other familiar with site conditions and
the hazards which may be encountered. The frequency of mock drills would be
every six months, with the following schedule,
 January /February– NPL
 July/August– NCPL
 Mock drill report will be prepared and shared with Mutual Aid Partner’s for taking
necessary measures on observations noted during mock drill.
 Mutual Aid Partner will provide each other with a list of hazardous / toxic
chemicals which can be encountered at each others site with their locations.
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 Each Mutual Aid Partner will have a copy of Emergency Response Procedure for
each Mutual Aid Partner’s site for effective emergency response.
 Mutual Aid Partner will provide replacement for the equipment damaged and
material used during the emergency, with the same specifications or its
reasonable compensation provided by other mutual aid partners responding to
the emergency site.
 When a request for assistance is made by any Mutual Aid Partner’s site, the
Emergency Coordinators will be followed below guidelines;
 Incident site Emergency Coordinator will contact with other Mutual Aid
Partner Emergency Coordinator and will inform about the type of incident, the
type and number of resources being required, current number of resources
assigned to the emergency incident, and the current Emergency Response
Plan (ERP) being utilized.
 Upon receipt of information from incident site Emergency Coordinator, the

Mutual Aid Partner Emergency Coordinator will utilize the following criteria to
determine the level of support that will be provided:
a) What is the incident type and nature?
b) What is the immediate or foreseeable Life Hazard?
c) Has the responsible resources that can be assigned to the

incident? If so, what is their estimated time of arrival at the
incident?
 Mutual Aid Partner does;
 Share only authorized and verified information
 Know what information can and what cannot be shared.
 Keep accurate records and logs of all enquires.
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Revision No 0
 Mutual Aid Partner does not;
 Spread rumours
 Speculate on the causes of an emergency.
 Speculate on the resumption of normal operation.
 Speculate on the outside effects of emergencies.
 Speculate on the value of losses and damages.
 Interfere with the legitimate duties of media representatives.
 Place blame of emergencies.
 Crowd in the affected area (those who have no role assigned in the
emergency plan, should keep away from the emergency area).
6. References:
Emergency Response procedure for NPL.
Emergency Response procedure for NCPL.
Mutual Aid Representative - NPL Mutual Aid Representative - NCPL
Name: Muhammad Akhtar Rasul Name: Muhammad Umar Ul Saqqaf
Designation: Asst. Manager HSE Designation: Manager Electrical
Sign: Sign:
Date: Date:
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Revision No 0
Annexure-1
Contact numbers for Mutual Aid Partners
Sr. No Contact Designation Mutual Aid Site Contact Number
1 Control NPL 049-4388272 Ext. 32061~62

Room/Emergency
Coordinator (Shift
Engineer)
2 Main Gate/Gate NPL 049-4388278 Ext. 32047

Supervisor
3 Control NCPL 049-4388260

Room/Emergency 0316-7770831
Coordinator (Shift
Engineer)
4 Main Gate/Gate NCPL 049-4388265 Ext 520

Supervisor
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Annexure-2
MUTUAL AID GATE ENTRY FORM
Date ……………..
Sr. No. Name Signature Organization
1.
2.
3.
4.
5.
6.
Note: This form is to be filled by Crew entering the gate of Mutual Aid Partner in case of
emergency call
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HSE DOCUMENT AND RECORD Revision No 0
MANAGEMENT Revision Date

1. Purpose
The purpose of this procedure is to ensure that documents and records of HSE management
system are created, accessed, managed and stored in an appropriate manner.
2. Scope
This procedure applies to all documents and records of HSE management system.
3. Definitions
Term Definition
Author The creator of document
Document that will undergo formal review, formal approval,

Controlled document controlled distribution, controlled revision and controlled
storage and access.
The process established in this procedure to define controls
Document control which are needed for the management of HSE management
system documentation.
The number assigned to a document when it is entered into the
document control list/register as a controlled document. This
Document control number number will always be the next sequential number in the
register. This number is to be recorded on the controlled
document in the (e. g. top left corner of the header).
Document control list / A list which identifies all HSE management system documents
register and includes current revision status.
A copy of a controlled document. Uncontrolled documents may
Uncontrolled Document
not be the latest version.
It involves looking at something (a document, report, etc.),
Review
reading it, or studying it (but not changing it).
Revision The action or process of reviewing, editing and amending.
4. Responsibilities
4.1. General Manager Plant
The GM plant is responsible for:
 Ensuring the effective implementation of the document and records management
system.
 The review and final approval of documents for HSE management system.
4.2. Manager HSE
The HSE Manager is responsible for:
 Preparation, approval and implementation of documents.
 Arrangement of resources for providing documents and maintaining the records.
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 Maintaining the document control register.

 Ensuring that only approved latest version of documents are being used.
 Archiving of all obsolete documents and records.
4.3. Plant Staff
Staff is responsible for:
 Obtaining documents from HSE department.
 Not making copies (uncontrolled documents) of documents.
 Participating in reviews of documents as and when required.
5. Procedure
5.1. Document Creation
Manager HSE shall identify the requirement for a new document for HSE management system
and prepare draft document for consultation with HSE committee prior to being approved and
controlled.
The requirement for new or additional documents may be based on, but not limited to:
 Legislative requirements
 Suggestions from staff
 Suggestions from the EHS Committee
 Incident investigation recommendations
 Internal or external audit findings
 Outcomes of workplace inspections and monitoring
 Changes in operational activities and/or structure.
5.2. Document Format
5.2.1. Policies
The following standard format shall be used for HSE Policies:
 Purpose
 Scope
 Responsibilities
Policies shall be approved by GM Plant or Chief Executive Officer.
5.2.2. HSE Procedures
The following standard format shall be used for all HSE Procedures:
 Title
 Purpose/Objective
 Scope
 Definitions
 Responsibilities
 Procedure content
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 Instructions and trainings

 Performance measures (if applicable)
 Appendices (if applicable)
5.2.3. Document Properties
All HSE management system documents shall display the following properties:
 Document title
 Document ID
 Revision number
 Revision date
 Issue date
 Last review date
 Next review date
 Author
 Archive
 Plant/site
Document Id format shall be used as;
1. Procedure, NPL- HSE- A000
2. Procedure relating forms and checklist, NPL- HSE- C000
3. Policy and Plan, NPL- HSE- E000
4. Table of Contents, NPL- HSE- D000
5.3. Consultation and Communication
Consultation on new or revised documents is required prior to approval. This consultation shall
be done through EHS committee meetings.
Evidence of consultation shall be documented through minutes of meeting or emails.
Feedback shall be reviewed and incorporated into draft documents and a final draft prepared
by the Manager HSE for approval.
5.4. Document Approval
New or revised final draft documents shall be approved by the GM Plant.
Once approved, the controlled document shall be shared by the HSE Manager via email or
common share folder on company electronic server system.
5.5. Document Review
All documents of HSE Management System shall be reviewed at least once every three years
in order to ensure it is still up to date.
5.6. Obsolete Documents
Obsolete controlled documents are those which are no longer required or replaced. Obsolete
documents shall be removed from the common share folder and appropriately archived to
prevent unintended use. Archived documents shall be retained and accessible for system
evaluation and legal purposes.
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5.7. Document Control Register

Document control register shall be maintained by Manager HSE for all HSE documents created
or modified.
The Document Control Register shall include the following information:
 Document number
 Document type
 Document title
 Revision number
 Revision date
 Issue date
 Review date
 Next review date
5.8. Records Management
The purpose of Record Management is to ensure that records of inspections, tests and audits
are created and managed in accordance with HSE management system requirements.
Records includes following, but not limited to;
 HSE inspections
 Hazard identification and risk assessments
 Training plans and attendance record
 Incident reports
 EHS Committee meeting agendas and minutes
 Employee/visitor orientation
 Emergency mock drill reports
5.9. Documents and Records Storage
All controlled documents are to be stored in hard or soft form.
The documents records shall be stored on company electronic server system which is regularly
backed up and archived.
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FIRST AID FACILITIES Revision No 0

Revision Date 0
1- Objective
The main objective is to provide immediate basic first aid and illness treatment to victim with
available means at plant.
2- Scope
This procedure shall be applicable to plant staff, visitors and contractor’s staff working inside
plant premises.
3- Definitions
3.1. Risk Assessment
A systematic process of evaluating the potential risks that may be involved in an activity or a
job.
3.2. First Aid
The immediate care given to someone who gets ill or injured until more advanced care is
provided by a certified physician.
3.3. First Aider
A person who has successfully completed the training that has given him the competency
required to administer first aid.
3.4. First Aid Equipment
First aid boxes containing kits, medicines and other equipment used to treat burn, injuries and
illnesses.
4- Responsibilities
4.1. Plant Staff
Plant staff shall,
 Take reasonable care and comply with all instructions and procedures for their and other
persons health and safety at the workplace.
 Identify, report and control hazards and their risks at workplace if observed before or
during work.
 Record any item used from first aid box in the log sheet and the purpose of using that
item.
 Report the detail of injury to shift engineer and manager HSE.
4.2. Emergency Response Team (ERT)
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Revision Date 0

ERT shall,
 Provide first aid to victim until the person recovers or medical assistance in hospital is
provided.
 Take reasonable care and proper precautionary measures of personal safety while
performing first aid to control the infections that may occur during first aid activities
 Follow first aid protocols and procedures.
 Record any item used from first aid box in the log sheet and the purpose of using that
item.
4.3. HSE Manager
HSE Manager shall,
 Assess the first aid requirements at plant with guidance of company doctor and maintain
record of all first aid cases.
 Ensure the availability of medicine and equipment in first aid boxes.
 Discuss all reported first aid cases in EHS committee meeting and suggest necessary
actions.
 Organize first aid training programs and ensure that adequate number of workers are
trained as first aid administer.
5- Procedure
5.1. First Aid Equipment and Facilities
Hazard Identification and Risk Assessment (HIRA) is performed to evaluate the needs and
scope of first aid treatment at site.
5.1.1 First Aid Boxes / Kits
Three number of first aid boxes are kept at following prominent and accessible locations.
1. Admin Building
2. Control Room
3. Workshop
5.1.2 Contents
The contents of first aid kit / box are based on risk identified in HIRA. First aid box provides
the basic tools, equipment and medicine for first aid treatment to injured or sick person in
following conditions;
 Cuts, scratches, punctures, grazes and splinters
 Muscular sprains and strains
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 Minor burns
 Amputations and/or major bleeding wounds
 Broken bones
 Eye injuries
 Headache, muscle fatigue
 Stomach disorder, vomiting
 Allergy
The recommended contents of a first aid box are mentioned in First Aid Box Inspection
Checklist Form.
5.1.3 Restocking and Maintaining of Box
EHS department shall inspect the first aid boxes on monthly basis.
During inspection, it will be ensured that;
 All items (medicines, equipment’s etc.) in first aid box are in working order, have not
deteriorated, are within their expiry dates and sterile products are sealed. Expired,
deteriorated and open seal items will be removed.
 Top up quantity of box items as and when required.
5.1.4 Record Keeping of Items Used
Items used from the first aid box shall be logged in “Use of First Aid Box Log Sheet.
5.2. Emergency Eye Wash and Body Shower Facilities
Emergency eye wash and body shower stations are provided near hazardous chemicals areas.
Three emergency eye wash and six body shower stations are provided at following plant
locations.
 Fuel treatment house
 Chemical store yard
 Chemical dosing area at cooling towers
 Engine hall A and B
 Workshop
Portable, self-contained eye and body wash units are provided in chemical labs which have
their own flushing fluid to flush chemicals, foreign objects or substances from the eyes and
body.
All emergency eye wash and body shower facilities are inspected on monthly basis.
5.3. Ambulance Van
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Fully equipped ambulance van is available 24/7 at site for transferring the victim to nearest
health care center or hospital. Inspection of ambulance van and emergency equipment is
performed on regular basis.
6- First Aid Trainings
The training of first aid personnel is the single most important factor to determine the
effectiveness of organized first aid. Each staff member must take basic first aid training.
Emergency response team (ERT) members shall also take advance course of first aid training
from external trainers or National Rescue service 1122 etc.
The main objective of training is to provide basic knowledge of first aid. At the basic level, this
includes the treatment of;
 Wounds
 Bleeding
 Fractured bones or joints
 Crushing injuries (e.g., to the thorax or abdomen)
 Unconsciousness, especially if accompanied by respiratory difficulties or arrest
 Eye injuries
 Burns
 Low blood pressure, or shock
 Personal hygiene in dealing with wounds
 Care of amputated digits.
The general tasks in basic training are;
 How first aid is organized?
 How to assess the situation, the magnitude and severity of the injuries and the need for
additional medical help?
 How to protect the casualty against further injury without creating a risk for oneself; the
location and use of the rescue equipment?
 How to observe and interpret the victim's general condition (e.g., unconsciousness,
respiratory and cardiovascular distress, bleeding etc.)?
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HSE VISIT AND AUDIT Revision Date
1. Purpose
This procedure is prepared to check and monitor compliance level for all parameters defined
in the HSE visit and audit checklist.
2. Scope
This procedure is applicable on plant premises for conducting HSE visit and audits.
3. Responsibility
3.1. Manager HSE will visit for audits and /or follow-ups and send audit/ observations report
to all concerned for necessary corrective measure.
3.2. Concerned HODs will take necessary corrective measures to ensure removal of
deficiencies related to his department within the given target time.
4. Procedure
4.1. Types of HSE Audit
Audit shall be done to ensure the health and safety of workers those are working on at
plant. There are two types of audits are mention below;
4.1.1 Internal Audit / Visit
 Internal Audit shall be conducted for onsite Operations and HSE Manager will conduct
the HSE Audit.
 HSE audits are based on surprise visits and are conducted company wide, activities at
NPL; each area of plant is covered at least once in every month.
 HSE manager will conduct meeting with the concerned dept. head or subordinate and
will discuss the observations related to his department. If necessary, then report of
audit / visit will be generated and forward to concerned department.
 Follow-up of all previously raised NCs/observations are made during visit of particular
area.
 Audit / visit report on the prescribed formats is sent to the concerned dept. head.
 Summary report is also circulated to the concerned management through e-mail.
 A summary of HSE audits / visits containing dept. wise summary statistics, actual
description and status of NCs/observations raised in all the previous audits is also
circulated to concerned HOD.
 Record of all HSE audits / visits is maintained in HSE office.
4.1.2 External Audit
 External Audit may be conducted by independent consultant / auditor / surveyor.
 Scope of audit will be shared with HSE department.
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DOC ID NPL/HSE/A033
REV 0
HSE AUDIT / VISIT ISSUE DATE
LAST REVIEW
NEXT REVIEW
Plant NPL Author Manager HSE ARCHIEVE SITE ARCHIEVE STATUS FINALIZED
 Audit team will conduct kick off meeting with the HSE department.
 Status of all pending observations will be discussed during kick off meeting.
 Audit team will visit the site for audit as per predefined scope.
 Closing meeting will be held with department after completion of site visit for
correction, recommendation and improvement in draft audit report.
 After closing meeting final audit report will be distributed with HSE department and
plant management.
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CONTRACTOR SAFETY Revision No 0
Revision Date

1. General HSE Guidelines
Contractor shall follow below mentioned HSE guidelines;
1. Safety orientation of contractor staff shall be performed by HSE representative before site
visit and start of work. Emergency Response Plan, smoking policy and HSE guidelines shall
be explained to the contractor.
2. After orientation, contractor will contact relevant department for execution of work.
3. All jobs shall be carried out in supervision and coordination of relevant department.
4. Necessary Work Permit will be taken by the relevant department before allowing contractor
to start the work.
5. Contractor shall acknowledge the work permit before starting of work and ensure the work
permit guidelines during work execution.
6. Contractor shall comply with PPE procedure.
7. Contractor shall ensure that electric cords and plugs of power actuated tools are in workable
condition.
8. Contractor shall use certified and calibrated lifting equipment and healthy tools, equipment
and access equipment during execution of work.
9. Emergency Response Plan (ERP) plan, smoking policy and HSE guidelines of site shall be
followed by contractor.
10. All underground utilities lines shall be protected from damage during excavation work.
11. Contractor shall avoid to produce environmental (water, air, land etc.) pollution.
12. Contractor shall follow housekeeping guidelines during and after completion of work.
13. Vehicle movement and parking shall be done as per site vehicle safety procedure.
14. Contractor shall be responsible for the safety of his staff.

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HSE SIGNS, PIPELINE COLOUR Revision No 0
CODING AND BARRICADE Revision Date 0
Plant NPL Author Manager HSE Archive Site Archive Status Draft

1. Objective
The objective of this procedure is effectively use of HSE signs, pipeline colour coding,
barricades and information boards in hazardous area.
2. Scope
This procedure shall be applied on operations, maintenance and construction process at
plant.
3. Definitions
3.1. HSE Sign
HSE sign is an information or instruction about health and safety at work on a signboard, a
color, an illuminated sign or acoustic signal and a verbal communication.
3.2. Solid Barricading
A barricade is a temporary fence or hand railing consisting of rigid vertical and horizontal
pipes.
4. Responsibilities
1. HOD shall ensure that all employees understand and comply this procedure during routine
jobs.
2. HSE Manager shall ensure that HSE signs and barricades are placed in hazardous area
and employees are familiar with their meanings and use.
3. Craft person shall place or erect signs and barricade hazardous area and keep these
signs and barricades in proper condition.
5. Procedure
5.1. Safety signs
5.1.1 General
 The standardization of HSE signs at plant is necessary so that wherever a particular HSE
sign is seen it provides the same warning or information message to all personnel.
 HSE signs are not a substitute of other risk controlling methods such as engineering
control, safe work practices etc.
 Warning signs shall be displayed at prominent places on walls for fire hazards, electrical
equipment, openings, overhead working, noisy areas and other such hazards.
 Mandatory signs shall be provided for enforcing the use of personal protective clothing and
equipment and providing specific instructions appropriate to the task or condition.
 Prohibition signs will be displayed for restricting access or entry, no smoking areas, no
parking and any other unauthorized acts.
 Fire signs shall be provided at areas where fire equipment has been sited e.g., fire
extinguishers, fire hydrant, fire blankets, etc.
 Barriers and warning/ barricade tape will be provided as appropriate, only fixed and solid
barriers will be used for edge protection on excavations, floor openings and penetrations.
 All emergency exits passageways, fire extinguishers and boxes, first aid stations, eye
wash stations, emergency muster points shall be highlighted with safety signs.
 These instructions shall be applied equally to office, workshop, engine halls, FT house and
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other plant locations.
5.1.2 Specifications
The signs can be grouped as follows:
 Prohibition
 Mandatory
 Warning
 Emergency escape and first aid
 Firefighting
Prohibition Signs:
Round Shape - Background color shall be white with black symbol, centrally placed and
red circular band and crossbar.
Mandatory Signs:
Round Shape - Background color shall be blue, with a white symbol or text centrally placed.
Warning Signs:
Triangular Shape - Background color shall be yellow with a triangular warning symbol
edged with a black band. The text or symbol will be in black and centrally located.
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Emergency Escape and First Aid Signs:

Rectangular or Square Shape - Background color shall be green with white symbol or text
green.
Fire Fighting Signs:

Rectangular or Square Shape - Background color shall be red with white symbol or text. The
shape of the sign shall be square or oblong.
5.1.3 Size and Position of HSE Signs

The size of sign shall be suitable for being seen and read easily by the staff.
Signs will be affixed at obstruction free prominent places on walls or erected in working area.
Where practicable signs will be erected at road side areas with the following signs;
 Authorized personnel only.
 PPEs need to worn.
 Parking
 Safety First
 Equipment Safety
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 Speed Limit (km/hr)
Inspection of all signs shall be made on regular basis.
5.2. Pipeline Color Coding
Pipeline will be painted or marked with conspicuous color according to the following standard
coding scheme;
Pipeline Colour
Diesel Beige
HFO Dark Chocolate
Sludge Terra-cotta
LT Water Leaf green
HT Water Leaf green
Air Light Blue
Fire Water Red
Water Sea Green
5.3. Barricade
 Safety barricade is required to protect personnel which are exposed to following dangers,
 Being struck by falling objects, moving material or tools.
 Falling into excavations, holes, openings and elevated platforms
 Exposure to hazardous substances, process or activities.
 Effective use and compliance of safety barricade will isolate and reduce the risk of
exposure to hazards.
 Hard barricade includes nylon rope, wire rope, guardrails and grid netting shall be use at
the edge and opening of elevated platforms or excavations.
 Soft barricade includes highly visible coloured barricading tapes shall be used to alter and
stop movement of unnecessary staff and vehicles in or under the working area.
 Caution, warning or danger signs shall be attached with barricade to alert the associate
hazards.
 Inspections shall be made on regular basis to ensure that barricades, signs and warning
tags are still present in appropriate condition.
 Barricades shall not be crossed unless permission has been obtained by the craft person
which are responsible for this barricade.
 Disciplinary action shall be taken when;
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 Someone enters into a barricade area or remove barricade or warning tag
without permission.
 Work is completed but barricade and warning tag are not removed.
6. Training
Training sessions shall be arranged to educate the plant staff about;
 HSE signs and instructions meaning and use.

 Proper use of barricades
 Pipeline colour coding use and benefits.
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Revision No 0
TRAINING PROGRAM Revision Date
1. Purpose
The purpose of this procedure is to define how HSE and technical trainings will be
planned, delivered and recorded.
2. Scope
This procedure shall be applicable to plant staff and regular contractor staff during working
inside the plant premises.
3. Definitions
3.1 Training is a planned activity designed to impart knowledge and skills to a person, to
help reach a desired level of performance. Training can be taken in different means. For
example, through instructions, online training, coaching, briefings and classroom sessions.
4. Responsibilities
4.1 Head of Department (HOD)

HOD shall be responsible to;
• Ensure that department staff is technically trained for safe execution of job.
• Analyze the need of trainings and prepare task specific annual training plan.
• Conduct trainings as per plan and ensure maximum participation of staff in training
sessions.
• Allocate budget for technical trainings.
4.2 HSE Manager
HSE Manager shall be responsible to;
• Prepare and execute HSE annual training plan and maintain the record of training
sessions.
• Ensure that plant staff is properly trained in health, safety and environment practices
and aware of hazards involved in their work.
• Prepare and deliver the training material (slides, notes etc.) To plant staff where ever
required.
• Ensure the effectiveness of training and need for further refresher courses.
• Manage external HSE training sessions as and when required.
• Allocate budget for HSE trainings.
4.3 Admin Department
Admin will be responsible to;
• Collect the annual training plans from all departments and compile in a file.
• Follow up with departments for monthly training plan and maintain the attendance
record.
5. Procedure
5.1 Training Needs Analysis
This analysis shall be done in consultation with department team leaders and EHS
committee. Analysis shall cover;
• The training requirements considering HSE and OEM manuals.
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TRAINING PROGRAM Revision Date
• Any other risk or technical requirement that may be identified during consultation.
• An incident outcomes and necessary corrective measures.
• Any new legislative requirement.
5.2 Annual Training Plan
• Training plan shall be developed by considering training needs analysis, training
providers and previous training plan.
• Training will be conducted in-house or by inviting external faculty or trainer.
• All departments will prepare annual training plan and share with admin department.
• HSE and admin department shall circulate monthly training schedule as per annual
training plan.
5.3 Training Record
The attendance records shall cover;
• Name of participants.
• Date and venue.
• Name of trainer.
• Training subject.
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Issue Date 20- 01- 2022
Revision No 0
VEHICLE SAFETY Revision Date 0
1. Objective
This procedure provides guidelines to drive vehicles inside the plant premises in order to
comply with the safe driving requirements and follow road safety practices.
The primary objective is to avoid the risk of vehicle accidents and injuries.
2. Scope
This procedure will be applicable on all types of vehicles operated by employees, contractors
and visitors inside the plant premises.
3. Responsibilities
3.1. Admin Department
Admin department will;
• Ensure the implementation of the procedure.
• Check the condition of vehicles and driving license at plant main gate.
• Inspect the condition and fitness of plant staff’s vans on quarterly basis.
• Take necessary action on observations noted during vehicle inspection process.
3.2. Vehicle Driver
• Driver will comply with the procedure and follow all local, national and plant traffic and
safety rules inside and outside the plant.
4. General
• The vehicle driver must possess a valid driving license that covers the type of vehicle
being driven.
• A vehicle should be mounted with all mandatory attachments required legally and for
safety.
• The driver must wear safety helmet while driving motor cycle.
5. Procedure
• Company vehicles must be periodically inspected and maintained as per OEM
guidelines.
• Persons abusing vehicles or drive in a reckless manner will be subjected to
disciplinary action.
• The speed limit will be 20 Km/h inside the plant premises.
• Seat belts must be maintained in proper working condition and must be worn by the
driver and the person seated at front seat.
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VEHICLE SAFETY Revision Date 0
• While reversing the vehicle, the driver must view rear area of the vehicle to ensure
area is clear. Driver should not rely solely on back view mirror or camera.
• Equipment such as tools, toolboxes, etc., should not be placed in the driving
compartment of vehicle. These items must be placed in trunk or separate
compartment of vehicle. Vehicle dashboard should be clear from objects.
• Drivers of company vehicles are not allowed to carry unauthorized passengers.
• Use of cell phone is prohibited while driving.
• Drivers must ensure that the spare tire, car jack and tools are maintained in good
condition.
• Drivers will report operational problems and defects as soon as possible. The vehicle
is to be checked for damage or any other problems daily.
• Personnel never go a vehicle that is supported only by a vehicle jack. Safe support for
the vehicle is to be used.
• All company vehicles and staff van are to be equipped with tool kits and a small first
aid kit.
• All vehicle accidents shall be reported immediately.
• Driver shall not drive while under the influence of alcohol or other drugs, including
medication that may cause drowsiness or impair judgment.
• Company cars, staff vans and visitor vehicles should be parked only at designed
parking areas.
• Fuel tanker lorries should be parked on weigh bridge road, fuel decanting station and
tanker lorry parking area.
• To avoid any accident, the drivers shall always drive with full attention and shall not
take any risk while over taking. If someone is found in horseplay, disciplinary action
shall be taken.
• Always maintain safe following distance to avoid collision in case the vehicle ahead of
you stops suddenly.
• Drive slowly when approaching intersection, pedestrian crossing or road corners.
• All movement of the vehicle must be recorded in the vehicle logbook.
• Inspection forms to be retained at admin department.
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Revision No 0
HSE TEAM Revision Date
1. Role and Responsibilities

The role and responsibilities of HSE Team at site are as follows;
1. Implementation of HSE initiatives, programs and procedures.
2. Prepare, implement and review the company HSE manual in line with standards,
applicable legal regulations and codes.
3. Conduct HSE Management Committee Meetings for the review of HSE related
matters.
4. Conduct HSE related inspections, testing and audits as per HSE manual guidelines
and take necessary corrective measures.
5. Conduct Hazards Identification and Risk Assessment (HIRA) at site.
6. arrange environmental monitoring and submit quarterly monitoring and CSR reports to
EPA department.
7. Prepare annual HSE budget and follow up budget utilization.
8. Conduct planned and unplanned mock drills to evaluate the effectiveness of
Emergency Response Plan.
9. Conduct annual HSE training program for plant staff and safety orientation for visitors,
contractor and new employees.
10. Review the HSE related incident report and suggest necessary action for prevention
of similar incident in future.
11. Maintain the level of PPEs for plant staff and visitors.
12. Prepare monthly, annual and agreement year HSE performance reports.
13. Monitor the third-party inspection, testing and calibration of lifting equipment’s and
gears, other pneumatic, hydraulic, electrical tools and instruments as per HSE manual
guidelines.
14. Monitor the collection and disposal of plant wastes as per company waste
management procedure.
15. Monitor the proper operation of effluent water treatment facilitates and confirm that
parameters of waste water releases into the main drain channel are well within PEQS
limits.
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Revision No 01
ELECTRICAL SAFETY Revision Date 21-06-2022
1. Objective
This procedure provides guidelines for safe practices when dealing with electrical
equipment’s and systems at the plant.
2. Scope
This procedure applies on all activities performed on electrical systems which may directly
affect the quality of working at plant.
3. Responsibility
Head of department;
HOD is responsible for;
• Implementing and execution of the procedure.
• Emphasize on safe work practices considering HSE manual.
• Technical training of employees as per OEM guidelines and standard engineering
practices.
• Take necessary measures against unsafe work practices.
Employees
Employees are responsible for;
• personal and safety of team members as well as of individuals in the vicinity of the
work.
• ensure safe work practices while working with power tools and electrical systems.
• Immediate report unsafe work conditions to HOD, HSE manager and co-workers.
• Capable of handling electrical emergency.
4. Definitions
Low Voltage 50 to 1000 V
Medium Voltage 1 kV to 35 kV
High Voltage 35 kV to 230 kV
EHV Voltage 230 kV to 765 kV
5. Procedure
1. Treat all electrical circuits as live until their condition is known certainly. Low voltages
shall also be treated as dangerous.
2. Qualified persons shall participate in the construction, maintenance or operation of
electrical equipment. A qualified person is one who is specially trained on the equipment
and the hazards involved.
3. Conditions related to the safety of the work to be performed shall be determined prior to
work on or near electric devices or before startup of equipment.
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Revision No 01
4. Refit the guards and protective items removed during the repair of electrical equipment
immediately after completion of job.
5. When using electrical extension cords, take the following precautions:
5.1 Use only standard outlets and connections.
5.2 Make sure the cord is properly connected, grounded and protected from traffic.
5.3 Prevent the cord from being wrapped around any part of working personnel body.
5.4 Repair or replace defective cords immediately.
5.5 Never remove a grounding pin from a receptacle.
5.6 Always use the cord with protected sheath.
6. Use only standard lighting when working in confined spaces (vessels, boilers, etc.) or
other hazardous areas.
7. All portable electrical tools shall be grounded with grounding wire. Use non-arcing or
explosion-proof tools in hazardous areas.
8. Under no circumstances, circuits shall be protected with over rated fuses or circuit
breakers.
9. Always use appropriate fuse puller when removing cartridge fuses.
10. When electrically operated equipment is being repaired or service, it is essential that:
10.1 Both the safety switch and/or circuit breaker are in the “OFF” position.
10.2 Portable electrical appliances shall be plugged out from receptacles.
10.3 Make sure that the equipment has become stationary.
11. Electric panel doors should be closed and locked when no work is being done.
12. Switches should be fully opened or closed. Make sure that switches are not left in partially
open position which may cause arc or heating of the contacts.
13. Hazardous working area shall be marked off with barricade tape to alert personnel for
potential hazards.
14. The PTW and LOTO (lockout/tagout) procedure shall be followed when repairing and
maintenance of electrical equipment’s is being carried out.
15. Disconnect the circuit before changing faulty bulbs or tube lights.
16. Special attention should be given to electric safety rubber gloves. It must be in good
condition and inspected prior to each use. Gloves must be dielectric tested before first
issue and every six months thereafter or when showing any signs of defects upon
inspection. Write the date of first issue and next re-testing on the gloves pair with
permanent marker. The "First issue" mean when the new gloves are removed from their
original, manufacturer's packaging
17. Defective or worn safety belts, full body harness and climber shall be immediately
replaced.
18. While operation do not look directly at exposed Isolators / disconnects or switches for
safety of eyes from arc light.
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Revision No 01
19. Install generators, motors, control equipment and conductors in such a manner that
exposed live parts are either properly guarded or insulated to provide adequate protection
for all operating personnel.
20. Provide sufficient space for safe inspection, repair or replacement when installing
electrical equipment.
21. Do not wear any metal watch or conductive jewelry while working on electrical
equipment’s.
22. Metal measuring tapes, steel rules or scales or wire-reinforced hoses shall not be used
when working on or near energized equipment or lines.
23. Always use standard electrical tools and equipment.
24. Use only approved brushes, wipers or dusters equipped with insulated handles for
cleaning switchboards, switches or any other electrical equipment.
6. Pre-work Briefing
Electrical team leader will brief his team members about Job safety before startup of work.
The briefing must cover the hazards associated with the job, work procedures, special
precautions, energy source controls and requirement of personal protective equipment
(PPE’s).
The primary hazards of electricity are:
• Shock
• Burns
• Arc –Blast
• Explosions
• Fires
7. Respond and Report an Accident
7.1. In case of personnel injury:
If a person gets electrical shock and remains in contact with an electrical supply then,
• Immediately disconnect the electric supply source. If it is not possible, stand on dry
area, then use a non-conducting material (dry cloth, wood, etc.), looping it over
victim’s feet, hand or head and drag him to safe area.
• Inform duty shift engineer in control room immediately.
• Electric shock may completely stop all bodily functions. In these instances, well-
administrated first aid may prevent a fatality.
• Considering victim condition send him to hospital for further treatment.
• Inform to concerned HOD and HSE Manager.
7.2. In case of an electrical fire:
• Using manual call point/break glass unit, activate the fire alarm system.
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Revision No 01
• Alert everyone in the area for evacuation.

• Use CO2 or dry chemical powder fire extinguishers.
• Do not use a Type A (water) for fire extinguisher.
• If you are not trained to use a fire extinguisher, leave the area immediately.
• Wait for the emergency response team (ERT) to arrive.
8. Training
Electrical team working on or near exposed energized parts shall be trained and familiar
with the following:
• The skills necessary to distinguish exposed live parts from other parts of electric
equipment.
• The skills necessary to determine the nominal voltage of exposed live parts.
• The proper use of precautionary techniques, personal protective equipment, insulating
and shielding equipment, insulating and shielding materials and insulated tools for
working on or near exposed energized parts of equipment.
319
Part-III
HSE Policies
and
Management Plans
320
Document ID NPL-HSE-E001
SMOKING POLICY Revision No 0

Revision Date 0

Statement:
Nishat Power Limited is committed to providing a healthy, comfortable workplace and to promoting
the health and wellbeing of its all employees.
Health hazards due to smoking has impact on both the smoker and the non-smoker who is exposed
to second hand smoke. Therefore, Nishat Power Limited urge to all its employee and visitor to stop
or reduce the smoking to provide a smoke-free workplace for its employees and visitors.
“Smoking is injurious to Health”
Purpose:
• To protect the health of its employees from smoking hazards in the workplace.
• To provide a smoke-free working environment in all plant areas (buildings, office, work places,
parking and grounds etc.) except smoking designated areas.
• To minimize the fire risk to NPL property attributable to smoking
• To encourage a smoke-free workforce
Scope:
This policy is applicable to all NPL employees, visitors, contractors and all others accessing inside
the NPL boundaries.
Policy:
Smoking by staff, contractors and visitors is prohibited at any site within the boundaries of NPL
except Smoking designated areas.
NPL will not accept or promote sponsorship from any tobacco company or company affiliated to the
tobacco industry.
Smoking Designated Area:
Following Five (5) areas at plant is declared for smoking:
1. Outside main gate office
2. Outside admin building.
3. Outside staff and driver rest rooms nearby decanting station
4. Emergency door side platform outside control room
5. Open area behind washing shed
321

Revision Date 0

Effective Date:
__________Policy will be immediate implemented after management approval and getting signature
of acknowledgement from all employees.
Enforcement:
It is expected that all employees, visitors, contractors should respect this policy. Failure to adhere to
any and all aspects of this policy may result in disciplinary actions.
• Employees who violate this policy frequently or cause severe problems (e.g. fires) may face
consequences like counseling, fine, warning etc.
NOTE: Remains of cigarettes are to be put inside designated ash trays.
322

Revision Date 0

Statement of Understanding
I have read and fully understand the terms of this policy.
Employees Acknowledgement:
Sr. E-Code Employee Name Designation Department Signature Date

No
1 1001 Muhammad Nawaz General Manager Operation
2 1006 Munawar Ali Civil Engineer Civil
3 1008 Muhammad Yousaf Driver Admin
4 1010 Muhammad Abrar Peon Admin
5 1012 Shoaib Hashim Chishti Manager Admin & Admin

Security
6 1015 Abdul Rauf Assistant Manager Store
7 1019 Irfan Shafiq Assistant Manager IT
8 1020 Javed Akbar Shaheen Gate Supervisor Admin
9 1023 Muhammad Ali Decanting Helper Mechanical
10 1024 Muhammad Ayaz Dy. Manager Store
11 1029 Muhammad Fayyaz Cook Admin
12 1033 Ashraf Ali Decanting Helper Mechanical
13 1034 Atif Khan Gate Clerk Admin
14 1035 Ashfaq Ahmad Decanting Helper Mechanical
15 1037 Gulzar Ahmad Gate Clerk Admin
16 1041 Muhammad Javed Helper Cook Admin
17 1046 Muhammad Qasim Security Guard Admin
18 1047 Talib Hussain Security Guard Admin
323

Revision Date 0

19 1048 M. Afsar Khan Security Guard Admin
20 1054 Abdul Sattar Security Guard Admin
21 1055 Muhammad Yousaf Security Guard Admin
22 1056 Abdul Sattar Security Guard Admin
23 1058 Zafar Iqbal Security Guard Admin
24 1059 Zia Ullah Security Guard Admin
25 1062 Raonaq Ali Security Guard Admin
26 1068 Muhammad Anwar Security Guard Admin
27 1069 Basit Ali Gardener Admin
28 1070 Muhammad Asif Gardener Admin
29 1074 Muhammad Zahoor Security Guard Admin
30 1077 Farzand Ali Security Guard Admin
31 1078 Younus Masih Security Guard Admin
32 1088 Shahid Mehmood Security Guard Admin

Raja
33 1091 Muhammad Farooq Security Guard Admin
34 1095 Muhammad Akram Security Guard Admin
35 1105 Basharat Ali Driver Admin
36 1110 Waqas Ahmad Lab Chemist Operation
37 1113 Tanveer Ahmed Asst. Lab Chemist Operation
38 1120 Ghulam Mohi Ud Din Security Guard Admin
39 1122 Tahir Mahmood Malik Manager Mechanical Mechanical
40 1136 Saad Amjad Assistant Manager Electrical
324

Revision Date 0

41 1138 Muhammad Suleman Security Guard Admin
42 1140 Abdul Ghaffar Security Supervisor Admin
43 1141 Gul Nawaz Security Supervisor Admin
44 1142 M. Mohsin Aslam Asst. Electrical Electrical

Engineer
45 1144 Muhammad Sarwar Security Guard Admin
46 1147 Uzair Ahmad Electrical Helper Electrical
47 1149 Muhammad Irfan Assistant Manager Operation

Hafeez
48 1150 Faran Mudassir Shah Mechanical Helper Mechanical
49 1151 Muhammad Ashraf Assistant Store Keeper Store
50 1154 Syed Waqar Ul Hassan Mechanic Mechanical
51 1155 Muhammad Saleem Mechanic Mechanical
52 1156 Muhammad Ashraf Manager Maintenance Mechanical
53 1157 Ali Raza Maintenance Engineer Mechanical
54 1158 Muhammad Idrees Assistant Maintenance Mechanical

Engineer
55 1159 Majid Saleem Machinist Mechanical
56 1161 Muhammad Noman Mechanic Mechanical

Zafar
57 1162 Asad Rasheed Assistant Mechanic Mechanical
58 1163 Shehzad Humayun Sr. Mechanic Mechanical
59 1164 Umer Draz Assistant Mechanic Mechanical
60 1166 Zohaib Sohail Mechanic Mechanical
61 1167 Muhammad Asif Mechanic Mechanical
62 1168 Waqas Pervaiz Assistant Mechanic Mechanical
325

Revision Date 0

63 1169 Abid Ali Mechanic Mechanical
64 1170 Abdul Waheed Mechanic Mechanical
65 1171 Abrar Hussain Khan Mechanic Mechanical
66 1172 Ejaz Anjum Mechanic Mechanical
67 1172 Arshad Mehboob Mechanic Mechanical
68 1173 Ghulam Farid Sr. Welder Mechanical
69 1174 Muhammad Nouman Assistant Mechanic Mechanical
70 1175 Basharat Ali Storekeeper Store
71 1176 Saqib Akram Mechanic Mechanical
72 1177 Imtiaz Hussain D. Mng. Maintenance Mechanical
73 1178 Muhammad Imtinan Planning Engineer Operation

Ul Haq
74 1179 Sajid Hussain Shah Operation Manager Operation
75 1180 Muhammad Ishaq CRO Operation
76 1181 Muhammad Amir ERO Operation
77 1182 Hafiz Muhammad Boiler Operator Operation

Dawood
78 1183 Aamer Rashid Assistant ERO Operation
79 1184 Syed Iram Sajjad Boiler Engineer Operation

Jaffery
80 1185 Junaid Mehboob ERO Operation
81 1186 Khalid Mehmood Shift Engineer Operation

Saleemi
82 1187 Muhammad Mansha Sr. ERO Operation
83 1188 Amanat Ali Boiler Operator Operation
84 1189 Khalid Mehmood Boiler Engineer Operation

Shaheen
326

Revision Date 0

85 1190 Imtiaz Haider Assistant ERO Operation
86 1191 Muhammad Usman Shift Engineer Operation
87 1192 Abid Mehmood Asst. Shift Engineer Operation
88 1193 Rashid Saleem Assistant ERO Operation
89 1194 Muhammad Arshad Mechanic Mechanical
90 1195 Mumtaz Ahmed Assistant ERO Operation
91 1196 Muhammad Rafiq Asst. Decanting Operation

Supervisor
92 1197 Shabbir Ahmed Decanting Supervisor Operation
93 1198 Shahid Hussain Lab Chemist Operation
94 1200 Muhammad Javaid Manager Electrical Electrical

Iqbal
95 1201 Tariq Shehzad Electrical Engineer Electrical
96 1202 Abdul Ghaffar Asst. Decanting Operation

Supervisor
97 1203 Nadir Sher Asst. Decanting Operation
Supervisor
98 1204 M. Inam Ur Rehman Boiler Engineer Operation
99 1205 Munawar Hussain Chief Chemist Operation
100 1207 Rana Ishtiaq Nisar Assistant Admin Officer Admin
101 1208 Rehmat Masih Housekeeping Admin

Supervisor
102 1209 Syed Azam Ali Zaidi Electrician Electrical
103 1211 M. Arshad Mehmood Sr. Electrician Electrical

104 1212 Muhammad Ejaz Electrician Electrical
105 1213 Naveed Ashraf Assistant Electrician Electrical
106 1214 Muzamil Hussain Assistant Electrician Electrical
327

Revision Date 0

107 1215 Shakeel Ahmed Electrician Electrical
108 1216 Ashraf Ali Asst. Electrical Electrical

Engineer
109 1217 M. Aamir Saddique Electrician Electrical
110 1218 M. Usman Maqsood A.C Technician Electrical
111 1219 Muhammad Usman Electrical Engineer Electrical
112 1220 Waqas Ahmed Sr. Electrician Electrical
113 1221 Nouman Ahmed Sr. Electrician Electrical
114 1222 Muhammad Zahid Electrical Supervisor Electrical

Islam
115 1223 Majid Ali Admin Officer Admin
116 1225 Muhammad Zahid Boiler Engineer Operation
117 1226 Muhammad Zafar CRO Operation
118 1227 Malik Zaheer Akbar Assistant Boiler Operation

Operator
119 1229 Muhammad Zaheer ERO Operation
120 1230 Rai Khalid Mehmood ERO Operation
121 1231 Khalid Mehmood Sr. ERO Operation
122 1233 Muhammad Nawaz Shift Engineer Operation
123 1234 Shahid Javeed Assistant ERO Operation
124 1235 Safdar Hussain Boiler Operator Operation
125 1236 Shahzad Ali Asst. Boiler Engineer Operation
126 1237 Muhammad Kamran CRO Operation
127 1238 Abid Rauf ERO Operation
128 1239 Badar uz Zaman Mechanic Mechanical
328

Revision Date 0

129 1241 Awais Ali Assistant Electrician Electrical
130 1242 Liaquat Ali Sr. Mechanic Mechanical
131 1243 Muddassar Rafiqe Operations Helper Operation
132 1244 Sakhawat Mushtaq Sr. Mechanic Mechanical
133 1245 Amraiz Khan CRO Operation
134 1246 Syed Jamal Shah Operations Officer Admin
135 1246 Syed Jamal Shah Operation Officer Admin
136 1247 Altaf Hussain Sr. Shift Engineer Operation
137 1248 Hafiz Hamza Basit Trainee Engineer Mechanical
138 1250 Mazhar Hussain Driver Admin
139 1252 Kashif Malik Maintenance Engineer Mechanical
140 1254 Abdul Hameed Security Guard Admin
141 1259 Kashif Naveed Operation Helper Electrical
142 1260 Saddam Hussain Electrical Helper Electrical
143 1261 Babar Khan Assistant Electrician Electrical
144 1262 Mohsin Munir Helper Operation
145 1264 Tariq Mahmood Sr. Electrician Electrical
146 1265 Tariq Mahmood Assistant Electrician Electrical
147 1266 Owais Abdullah Asst. Mechanic Mechanical
148 1267 Zeeshan Aslam Mechanic Mechanical
149 1269 Sarfraz Anwar Sr. Mechanic Mechanical
150 1273 Afzal Rahmat Asst. Mechanic Mechanical
329

Revision Date 0

151 1274 Attiq Ur Rehman Asst. Mechanic Mechanical
152 1276 Muneeb Amin Trainee Engineer Electrical
153 1277 Tayyab Abbas Mechanic Mechanical
154 1278 Azahar Khan Trainee Engineer Mechanical
155 1279 Zafar Iqbal CRO. Electrical Electrical
156 1280 Muhammad Ansar Helper Operation
157 1286 Hassan Azhar Electrical Engineer Electrical
158 1286 Nishan- E - Haider Trainee Engineer Mechanical
159 1286 Muhammad Usman Asst. Boiler Mechanic Mechanical
160 1286 Yasim Javaid Asst. Electrical Electrical

Engineer
161 1286 Naveed Aslam Boiler Engineer Mechanical
330

Revision Date 0

331
Smoking Points at Plant
Lawn
Fuel Testing
Elect. Shop
Lab
Road
Water Testing Lab
Toilets Change
Ware Room
Grid Station House # 01 → →
Toilets Behind washing
↑ MM office
Shed
EM Office
5- Smoking Area
Road
Workshop Fuel shop
Tool store Washing
Elect. Wshop Shed
4-Smoking Area Grid Station Road
(Upper platform)
Control
Engine Hall "A" Engine Hall "B"
Room
Drain
HRSG & Cooling Tower Area
Cooling Tower Road
FT House
Road
Day Tank Yard Main Tank Yard

Road
Drain
Decanting Area
3- Smoking
area
Admin Building
Driver and Gardner Room

2- Smoking
area
Project Gate
Building Office
332
333
1- Smoking
area
Document ID NPL/HSE/E002
ENVIRONMENTAL Revision No 0
MANAGEMENT PLAN Revision Date 0
1. Purpose
The purpose of this plan is to reduce adverse impact to sensitive environmental resources and
to minimize disturbance for neighbourhood.
2. Scope
This plan will be applicable on plant operational and maintenance activities that may have
adverse impacts on environment and community.
3. Definition
Environmental Management Plan (EMP) is defined as;
“EMP describes the processes that an organization will follow to maximize its compliance and
minimize harm to the environment.”
4. Environmental Policy
Nishat Power Limited (NPL) considers environment protection to be one of its basic
responsibilities and accordingly NPL undertakes to minimize the hazards in all aspects of its
work and highlights the safe working procedures to protect the property and natural
environment.
Environmental Policy is reliable, safe, efficient and compliant with applicable legal
requirements and regulations.
To achieve environmental policy objectives, NPL is committed to;
1. continually improve performance and reduce adverse environmental impact.
2. provide adequate instructions, training and supervision of work practices.
3. prepare and implement necessary procedures to deal with emergencies, incidents, safe
work, health and environmental protection.
5. Environmental Management Plan
5.1. Following areas are covered in this plan;
• Procurement of good quality fuel.
• Safe transportation of fuel.
• Traffic management of fuel vehicles inside and outside the plant.
• Fuel treatment.
• Compliance of exhaust gas emission standards.
334
• Compliance of ambient air quality standards.

• Treatment of effluent water.
• Maintenance of pollution control equipment
• Collection, storage and disposal of hazardous and non-hazardous wastes.
• Environmental management trainings.
• Monitoring and reporting of environmental parameters.
• Corporate social responsibility (CSR)
• Follow up for compliance of environmental regulations
5.2. EMP defines roles and responsibilities for HODs and describes environmental related
inspections and maintenance practices.
Environmental Management Plan (EMP)
Sr. No. Activities Responsibility
1 Safe transportation of fuel Contractor and Manager

Purchase
2 Assurance of good quality of fuel Manager Supply Chain
and Manager Operation
3 Safe decanting of fuel Manager Operation
4 Safe storage of fuel Manager Operation
5 Check on fuel spillage in storage area Manager Operation
6 Reporting of fuel leakage in operational area Manager Operation and

Manager HSE
7 Safe handling of fuel leakage incident Manager Operation
Air Pollution
8 Emission of SO2, NOx and PM within NEQS Manager Operation and
limits and record keeping. Manager HSE
Hazardous and Non-Hazardous Waste
335
9 Separate collection and storage of hazardous Relevant HODs

waste like tins, mercury bulbs, batteries, resins,
paints, lubricant empty containers, cotton rags
and sludge
10 Proper storage and disposal of hazardous waste Manager Admin &
to EPA approved contractor Security and Manager
HSE
11 Collection and storage of solid waste in separate Manager Admin &
bins/containers Security
12 Segregation of recyclable waste from solid waste Manager Admin &
and disposed off through contractor in eco- Security
friendly manner.
13 Training of workers for handling of hazardous Manager HSE
materials
Water and Waste Water
14 Conservation of water through in house good Manager Operation

operation practices.
15 Ensure compliance of NEQS for effluent water Manager Operation and

Manager HSE
16 Operation of treatment units (oily water and Manager Operation
effluent settling ponds).
Noise
17 Ensure compliance NEQS limits for noise Manger Operation and
Manager HSE
18 Protection of workers from high noise in engine Manager HSE
hall through wearing of PPEs
Tree Plantation Plan

19 Calculation and reduction of carbon foot prints GM, Manager Admin &
through tree plantation. Security and Manager
HSE
20 Looking after of trees inside the plant premises Manager Admin &
Security
Health and Safety
21 Installation of proper safety equipment, signs and Manager HSE

instruction boards to avert form accidents
336
22 Provision of PPE to plant staff and ensure its Manager HSE

compliance
23 Prepare and implement emergency response Manager HSE
plan and conduct mock drills
24 Inspection, testing and maintenance of fire Manager Electrical and
protection system. Manager HSE
25 Display emergency contact numbers at visible Manager HSE
locations.
26 Ensure the compliance of HSE management EHS Committee
system for safe execution of work.
27 Conduct plant staff training on HSE management Manager HSE
system.
Community Development and Social Responsibility
28 Prepare and implement corporate social Plant Management

responsibility plan for local people of the Project
area.
29 Allocation of sufficient funds for CSR Plant Management
Compliance of Environmental Regulations
30 Prepare environmental policy EHS Committee
31 Environment parameters monitoring from Manager HSE

certified lab and report the results to EPA Punjab
32 Suggest necessary measures for compliance of EHS Committee

NEQS.
33 Budget for EMP implementation Plant Management
34 Review of EMP implementation as and when EHS Committee

required.
337
Part-IV
HSE Forms
and
Checklists
338
Document ID NPL-HSE- C002/01
EMPLOYEE SAFETY ORIENTATION Revision No 02
FORM Revision Date 23-07-2019

Employee Name: _______________________ Employee Id: ________________
Designation & Dept.: ________________________ Orientation Date: _____________
The orientation covered the following in brief: employee
Covered (Yes / No /
Sr. No. Particular
NA)
1 Site General Safety Rules
2 Personal Protective Equipment (PPEs)
3 Eye Protection
4 Hearing Protection
5 Foot Protection
6 Head Protection
7 Hand Protection
8 Slip, Trip and Fall Protection
9 Housekeeping
10 Safe Use of Lifting Equipment’s
11 Tools and Equipment Safety
12 Welding, Cutting & Grinding Safety
13 Electrical Safety
14 Fire Prevention and Safety
15 PTW and LOTO
16 Entry into Confined Space
17 Emergency Preparedness and Response Plan
18 Environmental Management System (EMS)
Occupational Health & Safety Management System
19
(OH&SMS)
Employee’s Signature HSE Manager’s Signature
339
VISITOR SAFETY ORIENTATION Revision No 01

Visitor Name: _______________________ Company Name: __________________
Host Dept.: _________________________ Visit Date: _______________________
Purpose of Visit: _________________________
The orientation covered the following tropics and understood by me:
Sr.No. Particular Covered (Yes / No / NA)

1 Site General Safety Rules
2 Personal Protective Equipment (PPEs)
3 Slips, Falls, Trips
4 Fire Prevention & Safety
5 Lockout/Tagout
6 Vehicle Driving / Parking Areas
7 Spill prevention plan
8 Emergency Evacuation Plan
9 Safe use of Lifting and Access Equipment
10 Confined Space Entry
11 Hot Work
_________________________ ______________________
Visitor’s Signature HSE Manager’s Signature
340
Revision No 01
HSE COMMITTEE MEETING MOM Revision Date 22-12-2019
Plant NPL Status Manager HSE Archive Site Archive Status Finalized
Date: Time: Place: Ref:
Subject:
EHS Committee Meeting
Participants:
Minutes:
Review of previous meeting memo:
Initiation
Sr. No. Particular Discussed Status / Further action required Responsibility Target Date
Date
New Point Discussed and Agree upon:
Initiation
Sr. No. Particular Discussed Status / Further action required Responsibility Target Date
Date
Nishat Power Limited

66-km Lahore Multan road near
Jambar Kalan,
Tehsile Pattoki, Distt. Kasur
Pakistan
341
4- MOM of Meeting
342
Document ID NPL/HSE/C004/02
Revision No 02
MONTHLY SAFETY REPORT Revision Date 07-03-2021
PLANT COD DATE: MONTH: YEAR: REPORT NO:
1. REACTIVE INDICATORS
Recordable Cases
Classification / Type This month Year to date Project inception
Fatalities of General Public member involving Licensee Operations
Fatalities of NPL Employee
Fatalities of Contractor Employee
Fatalities Incident Notification submitted to NEPRA
Injury/Illness of General Public member involving Licensee Operations
Lost Time Injuries (LTI) or Illness of NPL Employee
Lost Time Injuries (LTI) or Illness of Contractor Employee
Restricted Work Injury (RWI) of NPL Employee
Restricted Work Injury (RWI) of NPL Employee
Medical Treatment Injury (MTI) of NPL Employee
Medical Treatment Injury (MTI) of Contractor Employee
First Aid Cases (FAC) of NPL Employee
First Aid Cases (FAC) of Contractor Employee
Fire Incident
Others
Near Misses
Crane / Heavy Equipment / Asset damage Incident
Spillage / Environmental Incidents
Page 1 of 6
343
Revision No 02
2. STATISTICS 3. EHS PERFORMANCE – INJURY SUMMARY

This Year to Project
Description
month date inception
Total Man Hours Worked (NPL Staff)
Fatality/ LTI 1
Total Man Hours Worked (Contr. 0
Staff)
0 Restricted Work Injury 10
Man-hours since last LTI (NPL Staff)
Man-hours since last LTI (Contr. Staff) Medical Treatment 30

0
Injury
Total no. of lost workdays (NPL Staff)
Total no. of lost workdays (Contr. 0 First Aid 300
Staff)
Total no. of restricted workdays (NPL Near-miss 600
0
Staff)
Total no. of restricted workdays (NPL
Staff)
Recordable Incident Rate (RIFR*) NPL Staff Status Injury Triangle
(NPL Staff)
Recordable Incident Rate (RIFR*)
(NPL Staff)
*RIR = Total recordable cases x 200,000
Man-hours from COD
Page 2 of 6
344
Revision No 02
4. PROACTIVE INDICATORS
This month Year to date Plant inception
No. Man hours No. Man hours No. Man hours
Site Induction/Orientation
HSE Training (sessions)
HSE Meetings
Emergency Drills
Safety Walks
Housekeeping Walk
Tool Box Talk
HSE Inspections
Page 3 of 6
345
Revision No 02
5. EHS TRAINING
Attendees
Sr. # Topic Duration (Hrs) Man hours
(No’s)
Page 4 of 6
346
Revision No 02
6. PROACTIVE HSE MEASURES

Events Type Lead Date Remarks
1. Inspections
2. Audits
3. Other
initiatives
Page 5 of 6
347
Revision No 02
7. HSE OFFICER COMMENTS

Summary
Major issues:
Achievements / Milestones
Prepared by: Endorsed by:
Asst. Manager HSE General Manager

Date:
Attachments:
1. Incident Report
2. Monthly Inspection
3. Safety/Housekeeping Walk
Page 6 of 6
348
SAFETY WALK REPORT Revision No 01
Revision Date 22-12-2019
Date: _________________ Area: ______________________________
Participants: ______________________________
Sr. No Nearmiss/Observations Area Concern Corrective/ Preventive Action

Department
349
ANNUAL SAFETY WALK PLAN Revision No 0

Revision Date 0
Year: _____________________
1st Quarter 2nd Quarter 3rd Quarter 4th Quarter

Sr.
Plant Area
No January~ March April ~June July ~September October ~December
Note:
1. Date and Timings for walk will be decided by EHS Committee.
2. Safety walks shall be led by General Manager.
Prepared By: Endorsed By:

AM HSE GM Plant
350
ANNUAL HSE COMMITTEE MEETING Revision No 0
PLAN Revision Date 0
Year: _____________________
Sr.
January February March April May June July August September October November December
No
1
2
3
4
5
6
7
8
9
10
11
12
Note:
1. Date and timings for meeting will be decided by EHS Committee mostly it will be conducted in last week of month.
2. Extra meeting session will be conducted as and when required.
3. Meeting shall be led by General Manager.
Prepared By: Endorsed By:

AM HSE GM Plant
351
INCIDENT REPORT FORM Revision No 02

This report must be completed for each incident. (To be completed within 24 hours)
An incident is defined as an unplanned event or chain of events, which has (Accident) or could have (Near-Miss) caused
injury or Illness and/or damage to third parties, to Assets (material/production) or to the Environment.
Date & Time Report No
Type of Incident
Injury: Restricted Work Injury Case First Aid/Medical Treatment Case Lose Time Injury
Environment Damage: Fire Chemical/Oil Spillage Other: …………….
Location of Incident Incident Date & Time
Person Involved
INCIDENT DESCRIPTION
(name and designation)

Describe: Operation in progress, Number and extent of injuries, Equipment damaged, Actions taken,
Recommendations.
Description:
Immediate Action Taken:
Reported By: Designation

(name & Sign)
TO BE COMPLETED WITHIN 7 WORKING DAYS AFTER THE INCIDENT
352

Immediate Cause Precise the Immediate Cause of the Incident in the following table
Slip, Trip Fall from Height

Struck By Oil or Chemical Leaks/spillage
Caught Between Explosion or Burns
Struck With Gas Release
Electrocution Other
Cause Factors Identify factors (underlying causes) contributing to the Immediate cause, tick all that
apply
Unsafe Practices Unsafe Conditions

Operating without authority Inadequate guards or barriers
Failure to notify / make safe Defective tools, equipment, substances
Operating or working at improper speed Inadequate tools, equipment, substances
Defeating or removing a safety device Poor access
Using inappropriate equipment/tools Inadequate warning system or notice
Using equipment improperly Fire and explosion hazards
INCIDENT ANALYSIS
Failure to use P.P.E. properly Substandard housekeeping

Improper loading or positioning Hazardous gases, dust, fumes, vapour
Improper lifting Excessive noise
Improper position for task Radiation exposures
Servicing equipment in operation Inadequate ventilation
Failure to comply with procedure/instruction/permit Inadequate design
Horseplay Substandard inspection/ maintenance
Other Uneven walk ways
Other
Main Cause Determine the Fundamental Causes of the Incident in the following table and select the
Main Cause
1-Respect of Laws and Regulations 8-Competence and Training of
Fundamentals Causes
Personnel
Fundamentals Causes
2-Responsibilities of Management 9-Emergency Preparedness &

Response
Main Cause
Main Cause
3-Operational Responsibility 10-Incident Analysis

4-Risk Evaluation and Management 11-Audit and Inspections
5-Respect for the Environment 12-Performance Improvement
6-Safeguarding of Health 13-Criminal Act / Delinquency / Ill Will
7-Control of Contractors and 14-Other Causes
Suppliers
Comments :
353

Please tick one box in each of the six columns of the matrix to indicate actual and
Severity potential severity based on the definitions provided.
Consequences Human Real Pot Environment Real Pot

Response means locally
1. Minor None or Minor Injury available (Tier 1) ≤1bbl
spilled
Medical Treatment or Locally available (Tier 1)
2. Moderate
work restricted injury or −1000 bbl spilled
Single LTI with Locally assistance (Tier
INCIDENT ANALYSIS
3. Serious Disability or Multiple 2) 1000- 10000-bbl

LTI’s spilled
Single Fatality or
External assistance (Tier
4. Major Multiple LTI’s with
3) or10,000bbl spilled
Disabilities
External assistance (Tier

5. Catastrophic Multiple Fatalities
3) or 100,000 bbl spilled
- Pot. is an abbreviation of potential
Damage / Loss (Human, Property, Environment):
Further recommended actions to

CORRECTIVE ACTIONS ENDORSEMENT
To be completed by the Investigation Team prevent recurrence

Action(s) identified Action by Target Date
354

Any suggestion/recommendation by General Manager
Date____________________ Signature:_______________________
Note:
a) Attach all photos, witness statements and sketches.

b) Copy distribution : OM / MM / SHE Officer / AM
355
NEARMISS & UNSAFE ACT Revision No 02
/CONDITION REPORT FORM Revision Date 20-12-2021

Date: Reported By (Optional)
Please tick the appropriate

Near Miss Unsafe Act/Unsafe Condition Suggestion
Description of the Observation or Event
Immediate Action taken/Improvement Proposal
Signature: ______________
HOD Remarks
Name & Sign: _________________
Target Date for Action Closed Date
HSE Manager (Name &

Sign)
356
MOBILE CRANE PRE-USE CHECKLIST Revision No 01

06-07-2018
Revision Date
Inspected By: __________________________________ Visited Date: _______________________________

Capacity of Crane: ______________________________ Crane Model & Vehicle No: _____________________
Sr. Items Status Remarks

No
A. Mobile Crane Approved For Use Yes No N/A
1 Is crane approved by MOM?
2 Is crane has a valid Lifting Machine (LM)
inspection and test certificate (issued less than
12 months ago)?
B. General Requirements
3 Is crane provided with markings of the Safe
Working Load (SWL) and LM number?
4 Are safe access and egress provided to the
crane operator?
5 Is a load capacity chart displayed in the
operator cabin?
6 Is operator crane cabin provided with a locking
mechanism?
7 Is fire extinguisher fit for use and provided in
the operator cabin?
8 Is an updated OEM log book available in the
operator cabin?
9 Is OEM Manual made available?
C. Other Visual Checks

10 Are load charts and other symbols available and
visible?
11 Is hydraulic fluid level sufficient?
12 Is slewing oil level sufficient?

13 Are all mounting bolts in good condition?
14 Is hydraulic system free of leaks?
15 Are boom sections free of cracks or dents?
16 Are main and auxiliary wire ropes well

lubricated and no visible defects such as broken
wires, kinks, excess wear, crushing etc.?
Page
357 1 of 2
MOBILE CRANE PRE-USE CHECKLIST Revision No 01

06-07-2018
Revision Date
17 Are winches, pulleys and wire ropes in good

working condition?
18 Is crane hook provided with a safety catch to
prevent displacement of the sling or load from
the hook?
D. Safety and Operational Devices
19 Is a load radius indicator with warning alarm
installed?
20 Are an effective hoist and derricking braking
mechanism maintained?
21 Is a swing lock or swing brake capable of
preventing unintended rotation functional?
22 Is limit switch to prevent over-hoisting of the
hook (i.e. anti-two block device) functional?
23 Is Limit switch to prevent over-derricking of
boom functional?
24 Is Load Moment Limiter to prevent over-turning
moment functional?
E. Rigging
25 Are the full sling details (include SWL and
Factor of Safety) checked?
26 Is lifting gear certificate for selected rigging
valid?
27 Is spreader type, length and SWL suitable for
the lift?
28 Are shackles size, type and SWL suitable for the
lift?
29 Is sketch of rigging method provided?
Additional Remarks:
Page
358 2 of 2
PORTABLE HAND AND POWER TOOLS / Revision No 01
EQUIPMENT INSPECTION FORM Revision Date 13-10-2018
Inspected By: ____________________ Inspection Date: ___________________
INSPECTION ITEM Yes No N/A COMMENTS

Are the handles on all hand tools such as, but not limited to, hammers, awls,
screwdrivers, files, and knives secured tightly to the tool?
Are the handles on all hand tools free from cracks, breaks, splinters, bends, sharp
edges, and makeshift repairs (like taped cracks)?
Are the handles of all hand tools free of oil, grease, lubricant, and/or any other
material that could cause the user’s hand to slip / lose their grip on the tool?
Are the handles on all hand tools used in close proximity to electricity made of the
proper material for the job being performed (such as rubber or other insulating
material)?
Are the heads of all hand-held impact tools such as hammers firmly attached to their
handle?
Are the tips of all hand-held impact tools such as chisels or center-punches relatively
sharp, and their heads free from burrs and/or a “mushroomed” head?
Are the tips of hand tools such as screwdrivers free of chips, breaks, bends, and/or
twists?
Are the jaws on hand tools such as wrenches, pipe wrenches, regular wrenches,
channel locks, and pliers free of excessive wear and, where applicable, securely
attached?
Are all socket wrenches and attachments (such as sockets, extensions, swivels . . .)
free of cracks, worn attachment points, and/or worn gripping surfaces?
Are the blades on all hand-held cutting tools such as knifes, box-cutters, and scissors
relatively sharp and free of beaks, chips, and/or twists?
Do retractable blades / self-sheathing blades on hand-held cutting devices such as
box-cutters operate smoothly and properly?
359
PORTABLE HAND AND POWER TOOLS / Revision No 01
EQUIPMENT INSPECTION FORM Revision Date 13-10-2018
Is the hand tool user provided with and using all necessary personal protective
equipment (e.g.: safety glasses, face shield, hearing protection, proper type and size
of gloves . . .)?
OTHER OBSERVATIONS:
360
Document ID NPL-HSE-C010/01
Issue Date 01/01/2016
NEW PPE ISSUANCE AGAINST Revision No 01

13-10-2018
DAMAGE/MISSING PPE FORM Revision Date
Plant NPL Author Manager HSE Archive Site Archive Status FINALIZED
Employee Name: Employee Code:
□ Damage PPE □ Missing PPE
Description of PPE:
Reason for Damage/Missing:
Employee Signature
HOD Remarks:
HOD Signature
HSE Officer Remarks:
HSE Manager Signature

PPE issuance status for the year…………………….
PPE Type Recommended Issued

Safety Shoes
Boiler Suit
Ear Muff
Helmet
361
Revision No 1
FIRE EXTINGUISHER MONTHLY INSPECTION FORM Revision Date 01/01/2018
Last Review 02/12/2021
Next Review 02/12/2024
Date of Inspection: Inspected By:
Operation
Body free from Hose Pipe Inspection Tag
F. Ext. Application for Placed at marked External cleaning Seal in place Instruction
Location Type Capacity rust, burrs & Condition attached Remarks
No. class of fire location (Yes/No) done (Yes/No) (Yes/No) placed
damage (Yes/No) (Yes/No) (Yes/No)
(Yes/No)
362
FIRE HYDRANT AND HOSE BOX MONTHLY Revision No 1
INSPECTION FORM Revision Date 01/01/2018

Inspected By: Inspection Date:
Fire Hose / Reel Box

Box Condition
Sr. No. Location Hose box No. Hose Nozzle Coupling F. Key Remarks
(Ok/Not ok)
Fire Hydrant Valves/ Point

Valve Spindle
Any part Hydrant Cap
Sr. No. Location Hydrant No. operation greasing/ Coupling Seals Remarks
missing in Place
free oiling done
363
Remarks:
364
Revision No 1
FIRE WATER LINE VALVE INSPECTION FORM
Inspection Date:_______________ Inspected By:_______________ Checked by Name/Sign_______________
Sr. Status Equip. status Equip. status as Activity OK/Not

PPS Code Equipment Description Location Remarks
No should be as found left (open/close) OK
365
FIRE FOAM TROLLEY MONTHLY INSPECTION Revision No 1
Inspection Date:_______________ Inspected By:_______________
Condition of Nozzel Condition Venture Tube Trolley Tyre Ratio Adjustment

Sr.
Location Code Hose (okay/not (okay/not okay) Condition Condition V/V (okay/not Remarks
No
okay) (okay/not okay) (okay/not okay) okay)
1
366
Revision No 01
FIRE HOSE HYDRAULIC TEST FORM
Date of Hoses Test: ____________ Service Test Pressure (Bar):__________________
Test Performed By: _________
Coupling &
Size Test Gasket
Length Corrective Action (Repairing Completion
Hose No (Dia) (Ok/Not Condition Reason of test failed Target Date
(m) and Maintenance) Date
Inches Ok) (Ok/ Not Ok)
367
FIRE PUMPS WEEKLY CHECK Revision No 01
AND TEST FORM Revision Date 06-07-2018

Engine Motor
Sr. No Description
driven pump driven pump
1 Pump room heat is adequate (>40oF) and ventilation
louvers are clean and free to operate
2 Note Down water Level in Fire Water Tank
3 Fuel tank is 2/3 full & Oil Level Checked N/A
4 Valves open (Suction, Discharge, & By-pass)
5 Pump Start- MANUAL (on switch)
6 Pump start- AUTOMATIC –Start by pressure drop
7 Pump Stop- MANUAL (off switch)
8 Time controller is on first step (reduced voltage or reduced

N/A
current starting)
9 Pump Start pressure on AUTOMATIC
10 Suction and Discharge Pressure
11 Start Time & End Time (Hrs)
12 Pump run (30 minutes for engine driven and 10 minutes

electric driven)
13 Pump packing showing slight discharge
14 Casing relief valve flows to drain while fire pump is running

15 Casing relief valve stops flowing when fire pump shuts off
16 Pump free from unusual vibration
17 Packing’s, bearings, casings not overheating
18 Circulating relief valve working

19 Heat Exchanger Cooling Water Discharge OK N/A
20 Engine Speed Adequate (RPM) N/A
21 Engine Oil Pressure in Normal Range N/A
22 Engine Water Temperature in Normal Range N/A
23 Battery Charging Rate in Normal Range N/A
24 Battery Terminals Corrosion Free N/A
25 Battery electrolyte level is normal N/A
26 Controller power & Transfer switch normal pilot light on
illuminated
27 Pump running meter reading (in Hrs) N/A
28 Facilities notified for deficiencies
Page 1 of 2
368
FIRE PUMPS WEEKLY CHECK Revision No 01
AND TEST FORM Revision Date 06-07-2018

29 Alarm received at WOIS and container light illuminated.

30 Test Acceptable
REMARKS:
Name & Signature of Operator Name & Signature of Shift Engineer
Page 2 of 2
369
FIRE FOAM SYSTEM INSPECTION AND Revision No 01
TEST FORM Revision Date 06-07-2018
Inspection Date: ______________ Inspected By: _______________

Area/ Location: _________________________________________________________
Monthly Inspection & Test:

Sr. # Items Yes No N/A
1 Are all valves position verified (Open/Close) and found okay?
2 Are all valves move freely? Greasing carried out?
3 Are all valve easily accessible and free from external leakage?
4 Are all valves provided with appropriate identification?
5 Are drain valves operating properly?
6 Is adequate foam concentrate for design?
7 Is concentrate foam tank free from corrosion?
8 Is foam tank pressure vacuum vent operational?
9 Is foam concentrate pump operational?
10 Is gauge at concentrate pump is in good condition?
11 Is F Key/ Wrench available for open the valve?
Remarks:
Annual Inspection & Test: (in addition with above items)

Sr. # Items Yes No N/A
1 Is foam water discharge sprinkler place in proper direction?
2 Is pipe & fitting free from damage, corrosion, misalignment?
3 Is low point drain are okay?
4 Foam concentrate sample is submitted for lab quality test?
5 Operation Test Perform?
1- Discharge devices properly located?
2- Discharge devices no impeded?
3- Concentrate strainer, basket clean after each test?
4- Response time………., discharge time………
5- Foam solution concentrations are acceptable?
6 All control valves through full range and return to normal position?
Remarks:
370
WET PIPE SPRINKLER SYSTEM Revision No 01
INSPECTION AND TESTING Revision Date 06-07-2018
FORM Last Review 18-12-2021
Location: Inspection/Test Date: __________________

Inspected by (Name & Signature): _______________________________________________
This Report Covers (Inspection & Test):
Monthly Quarterly Annual
Three-Year Five-Year
Inspections:
1- Monthly
Sr. No Description Yes No NA Comments (Corrective Action)
1 Gauges—normal water pressure
maintained
Control Valves
1 In the correct (open or closed) position
2 Sealed, locked, or supervised

3 Accessible
4 Free from damage or leaks
5 Proper signage
Alarm Valves
1 Free of damage
2 Accessible
3 Retard chamber/alarm drains not leaking
2- Quarterly
1 Alarm devices—free of damage
2 Hydraulic data nameplate—securely

attached to riser/legible
Pressure Reducing Valve
1 In the open position/not leaking
2 Maintaining downstream pressure
3 In good condition
3- Annually
Sprinklers (visible)
1 No damage or leaks
2 Free of corrosion, foreign material, or paint
3 Installed in proper orientation
4 Fluid in glass bulbs
Page 1 of 3
371
5 Spare sprinklers—proper number and type.

Complete with wrench?
6 Hangers and seismic bracing—not
damaged or loose
Pipes and Fittings (visible)
1 In good condition/no external corrosion
2 No leaks or mechanical damage
3 Correct alignment—no external loads
4- Five Year
1 Alarm valve interior including strainers,

filters, and restriction orifice
2 Check valve—internal moves freely, in good
condition
3 Obstruction inspection—no foreign or
obstructing material found
Test:
1- Quarterly
1 Alarm devices—water motor gong
2 Main drain test—if the sole supply is through
a backflow preventer.
Static (Bar)__________
Residual (Bar)_____________
3 Do results differ by more than 10% from

previous test?
2- Semi-annual
1 Supervisory switch functions
Alarm devices—inspectors test or bypass
opened/obstructed water flow
2 Alarm devices—inspectors test or bypass
opened/obstructed water flow
3- Annual
1 Main drain test. Static (Bar)__________
Residual (Bar)_____________
2 Do results differ by more than 10% from

previous test?
3 All control valves operated through full
range of motion and returned to normal
position.
4 Specific gravity or anti-freeze system (if
present)
5 Backflow preventer—test
Page 2 of 3
372
6 Backflow preventer—flow test
4- Five Year
1 Gauges tested or replaced
2 Pressure reducing valve—flow test and
comparable to previous results
Remarks:
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Page 3 of 3
373
FIRE DETECTION SYSTEM Issue Date 01-01-2016
Revision No 01
QUARTERLY INSPECTION, TEST AND
MAINTENANCE FORM Last Review 18-12-2021
Inspection Date: _________________________________ _____ Device & Location: _______________________________________

Loop Connection Status: ________________________________ Panels Batteries Status: ___________________________________
Inspection Performed By: _______________________________ Job Verified By: _____________________________________________
Testing
Loop Zone Device Analog Alert Alarm Visual
Device Type Cleaning (flame/ Remarks
No No No Value Level Level Inspection
heat)
374
FIRE FOAM PROPORTIONATE Revision No 0
TEST REPORT Revision Date 0

EXECUTIVE SUMMARY
1. Objective:
2. Apparatus
3. Procedure
4. Results
5. Conclusions
Page 1 of 1
375
FIRE SUPPRESSION SYSTEM Revision No 0
COMMISSIONING CHECKLIST Revision Date 0
Location: ____________________ Area: ________________________________
Type of Suppression System: _____________________________________________
Inspection/Test Status: Okay/Not Okay Inspection/Test Date: _____________________
Inspected by (Name & Signature): ______________________________________________
Checklist legend: OK = No problems N = Need to fix and retest N/A = not applicable
1 System Installation Ok N N/A
1.1 Piping installed per plans
Prior to system being hooked up, perform an underground

1.2 flush.
Hangers and end of line restraints per plans. minimum 1
1.3
hanger per pipe section.
1.4 Inspector’s test valve at end of line.
1.5 Fire connection shall be installed no higher than 18” - 48”.
Fire connection must be visible, accessible, couplings swivel,

1.6 caps in place, ID signs in place, check valve not leaking.
Standard spacing from the wall for upright and pendent
1.7 sprinkler should be 4”. Max space of heads=15’,
unless otherwise specified.
Standard spacing from the ceiling for side wall sprinkler
1.8
should be 4-6.” .
Pressure water gauges should be provided on each side of
1.9 the water supply when an alarm check valve is installed
Caution signs shall be attached to all valves controlling
1.10 sprinklers. Control, drain, test connection valves shall also
be identified.
2” main drain must be opened until system pressure
1.11 stabilizes.
Static Pressure: Residual Pressure:__________
All exposed sprinkler system piping shall be protected
1.12 against freezing (40°F)
System valves and gauges shall be accessible for operation,
1.13 inspection, tests, and maintenance.
2 Wet Sprinkler System

Modifications affecting more than 20 sprinklers will require
2.1 testing. (20 or fewer sprinklers shall not require testing in
excess of system working pressure).
376
All piping and attached accessories subjected to system

working pressure shall be hydrostatically tested at 200 psi
2.2 (13.7 bar) and shall maintain that pressure without loss for 2
hours.
Test pressure read from gauge located at the low elevation
2.3 point of the system or portion being tested.
Record Initial Pressure: ____________
2.4 Date: Time: ______
Return in 2 hours; determine if there is any gauge pressure
2.5 loss or visual leakage
Record Final Pressure: _________
2.6 Date:___________ Time:______
Witness system drain/Gauge must drop as system drains.
2.7
3 Sprinkler Final
Are all of the valves open to allow water to flow into system?
3.1
Is there pressure on the gauges?
3.2
There should be spare sprinkler heads on the premises, as
3.3 well as a sprinkler wrench.
Inspect sprinkler heads for dirt, damage, paint, and

3.4 obstruction.
Sprinkler heads that are damaged or painted over must be
3.5 replaced.
Sprinklers shall be installed under fixed obstruction over 4 ft.
wide such as ducts, decks, open grate flooring, cutting
3.6
tables, and overhead doors.
The proper type and temperature sprinklers are used and
3.7 match plans.
Check that sprinkler head and location match the type
3.8 indicated on the plans.
Hydraulic plates shall identify location of design
area(s), discharge densities over design area(s), required
flow & residual pressure demand at base of riser, occupancy
3.9 or commodity classification & max permitted storage height,
hose stream demand in addition to sprinkler demand.
4 Main Drain Test:

Is the system being monitored for fire alarms? Check that
4.1 flowing water will alert the fire department and alarm
company.
4.2 Is there a Hydraulic calculation plate? (Note the pressure on
the plate)
377
4.3 The main drain should be able to be fully opened without

causing water damage.
Open the drain valve and let it run. When the pressure
stabilizes, note whether the pressure dropped and stayed
4.4 below the residual pressure on the calculation plate or as per
design. If it does, there is a problem with the system.
5 Flow Test:
Is the system being monitored for fire alarms? Check that
5.1 flowing water will alert the Control Room staff (CRO, Shift
Engineer etc.)
Open the inspectors test valve at the end of the system or
5.2 the alarm valve at the system riser. Did alarm go off when the
system flowed?
5.3 Sprinkler rapture test: Is sprinkler heads/blub are burst at
design temperature and cover the designed flooded area.
Additional Comments:
378
FORK LIFTER INSPECTION Revision No 01

MONTHLY FORKLIFT INSPECTION CHECKLIST
Inspection Date: _____________
Sr. Inspection Item Current Status

No Okay Not Okay
1 Manufacturer’s data plate is clean and readable?
2 Weight capacity signs on both sides of the truck are legible?
3 Reverse alarm or warning light is operational?
4 Forks are not distorted or cracked?
5 Lift chains have equal tension and no broken pins or extra wear?
6 No loose bolts or cracks on overhead guard and backrest?
7 No loose lock nuts on tilt cylinders?
8 No signs of fluid leaks under forklift?
9 Adequate fluid (brake, engine oil, hydraulic oil, and coolant) levels?
10 Rubber tyres are not cracked or worn excessively?
11 Lug nuts on wheels are tight?
12 Air pressure in inflatable tyres meets manufacturer’s specs?
13 Dashboard gauges give proper reading when forklift is in service?
14 Horns sound properly?
15 Parking brake functions correctly?
16 Adequate tension and free play in steering wheel?
17 Mast and forks raise, lower, and tilt smoothly?
18 Clutch engages properly?
19 Engine Exhaust
20 Fuel Leakage
21 Noise
Comments/Corrective Actions:
Workshop Supervisor Signature’s HSE Manager Signature’s
379
CIVIL WORK PERMIT Revision No 0

1. CWP No: __________________PTW No (if any): __________________Date: _____ ____ ______
2. Job Description : ___________ ______________________ ___ _ _

______________________________________________________________________________ ___
Area: ____________________________________________________________________________________
3. Underground Utilities: Electrical Appliance Pipelines IT Appliance Other_________
Safety Measures (if any):
4. Adjacent Area Protection Measures: ___________________________________________________________
5. Related Work Permits: HWP: Yes #_____ No WAHP: Yes #_____No CSEP: Yes #_____No
SEDP: Yes #_____ No
6. Hazards and Precautions:
Description Y/N/NA Description Y/N/NA

Control and protective measures are Utility location and drawings to be reviewed
appropriate for the work activity and necessary precautions have been taken
Tools and work equipment are suitable for Utilities crossing the excavation to be
the work activity supported/ protected from falling objects
Employees protected from Cave-in/loose soil Precaution taken to protect employees from
that could roll into excavation water accumulation (Dewatering)
Air in excavation to be tested for oxygen Spoils, materials to be placed at least “2”
deficiency, combustible & other meters away from edge of excavation
contaminants.
Adequate sign posted and area barricaded in Safety Harness or life line need to used
working area
Ladder secured and extend above “3” feet Exit ladder not more than “25” feet away
from edge of excavation from any employee working in excavation
7. Personal Protective Equipment’s
Hand Protection Face Protection Respiratory Protection Foot Protection Body/Head protection Ear/ Fall Protection
Welding Gloves Goggles Dust Mask Gum Shoes Boiler Suit Ear Muff
Cotton Gloves Face Shield Face Mask Safety Shoes Chemical Suit Ear Plug
Welding Full body
Leather Gloves SCBA HV Shoes Hard Hat/Helmet
Shield harness
8. Verification done by: (Craft Person name and sign)_____________________Date: ___________ Time: ___________
9. Shift Engineer Approval and Authorization:
Name and Signature: _____________________________________Date: ___________Time: ____________

10. Craft Person Acceptance and Release (Print name along with signature)
Accept Release
Name / Signature Date / Time Name / Signature Date / Time
11. Area House Keeping (Craft Person name and sign):____________________________________________

12. Completion:
Shift Engineer (Name and Signature):____ ___________ Date: ____________Time:______________
380
HOT WORK PERMIT Revision No 02

1. HWP No: ________________PTW No (if any): __________________Date: __________ ______
2. Equipment Code: __________________Area: ___________________F. Extinguisher No:__ _

Equipment Description (if any):___________________________________________________________
Job Description: _______________________________________________________________________
_______________________________________________________________________________
3. Equipment to be used: Welding Machine Grinder Gas Torch Drill Other_____
4. Fire Attend Name & Sign:__ __________ _
5. Hazards and Precautions
Precautions within 10 meters (35 feet) Yes No N/A

Suitable fire extinguisher or Fire hose or reels are immediately available and operative
Fire watcher available & trained for using fire extinguisher and knows ERP procedure.
Hot work area ventilated, isolated and barricaded.
Combustible/Flammable materials (solids, liquids, gases) removed and adjacent area is safe.
Immovable Combustible/Flammable materials protected by fire blankets or hard sheet.
Combustible floors have been protected by non-combustible materials (wetted liquid or sand etc.)
Floors have been swept clean, holes & other openings in walls have been protected.
Equipment for hot work checked and found okay
Electrocution
Gas cylinders are sited at least 3 meters from the source and secured properly in vertical position with
regulator & flash back arrestor
Enclosed/confined spaces have been emptied or tested, or known to be free of flammable vapors.
Is explosimeter/Gas analyzer tests required and has been taken?
Oxygen: __________ LEL:_________ H2 _________ Signature of Tester : ____________

Hand Protection Face Protection Respiratory Protection Foot Protection Body Protection Ear Protection
Leather Gloves Welding SCBA HV Shoes Fire Suit
Shield
7. Verification done by:_______________ ____________ ______Date: ___________ Time: ____________

(Print Name along with signature)
Name and Signature: _______________________________ ______Date: ___________Time: ____________
Accept Release
10. Is the JHA for the activity appropriate? Yes NO if No pleases Comment:
Special Comments/Suggestion (if any):
10. Completion: Shift Engineer Name and Signature: _____________________________
Date: _____________Time: ______________

381
DAILY HIRA CHECKLIST FOR HOT WORK Revision No 0

Revision Date 0
1. HWP No: __________________________ Inspected by: _____ ___________

2. Hazards and Precautions:
Date and Time

Precautions within 10 meters (35 feet) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Suitable fire extinguisher or Fire hose or reels are immediately available and
operative.
Fire watcher available & trained for using fire extinguisher and knows ERP
procedure.
Hot work area ventilated, isolated and barricaded.
Combustible/Flammable materials (solids, liquids, gases) removed and adjacent

area is safe.
Immovable Combustible/Flammable materials protected by fire blankets or hard
sheet.
Combustible floors have been protected by non-combustible materials (wetted
liquid or sand etc.)
Floors have been swept clean, holes & other openings in walls have been
protected.
Equipment for hot work checked and found okay.
Electrocution hazard.
Gas cylinders are sited at least 3 meters from the source and secured properly in
vertical position with regulator & flash back arrestor
Enclosed/confined spaces have been emptied or tested, or known to be free of
flammable vapors.
Is explosimeter / Gas analyzer tests required and has been taken? Oxygen:
__________ LEL:_________ H2 _______ Signature of Tester : _______
3. Action need to be taken: ____________________________________________________________________________________________________

__________________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________________________________________
382
PORTABLE LADDER INSPECTION Revision No 01
Department Location of ladder:

Inspection conducted by Date
Ladder identification: Ladder length (ft.): Ladder Condition: Good Need Repair
Ladder Step Straight Extension Specialty Specialty Ladder Fiberglass Metal Wood
type: type: material:
General for all Yes No NA

1 Are the joints between the steps/rungs and side rails tight?
*- Are all hardware and fittings secure (nails, screws, bolts, rivets, hinges, etc.)?
+2
3 Are there any loose, cracked, split, dented, rusted, corroded, broken or missing rails, steps or rungs?
4 Are there any sharp surfaces or burrs on rails, steps, rungs or spreaders?
5 Are any steps, rungs, endcaps or shoes damaged or missing?
6 Are the slip-resistant ladder surfaces (rails, steps and rungs) clean and free of dirt, oil and grease?
7 Do all movable parts operate freely without binding or undue play?
8 Is the instructions/warning label missing or not readable?
9 Is the ladder completely stable (no wobbling, resting on an even dry surface)?
Step Ladder Yes No NA
10 Does step ladder have slip resistant shoes, steps, top cap, spreaders or locking hinges?
11 Is the spreader loose, bent or broken?
12 Is the spreader or locking device fully functional?
13 Other:
Straight Ladder Yes No NA
14 Does straight ladder have slip resistant shoes, side rails, rungs, endcaps, and instruction/warning label?
15 Other:
Extension Ladder Yes No NA
16 Does ladder have slip resistant shoes, side rails, rungs, endcaps and instruction/warning label?
17 Does ladder have guides or brackets, rung locks, and rope and pulley system for fly section(s)?
18 Are there any loose, broken, missing or defective (don’t seat properly) extension locks?
19 Is the rope for the pulley system frayed or worn?
20 Other:
Specialty Ladder Yes No NA
21 Are any parts of platform or guard rails missing, loose, bent or broken?
22 Are any casters loose, have rust or corrosion?
23 Are any fasteners, locks or hinges loose, bent, broken or missing?
Item # Comments/Action Items (tagged out as damaged and removed from use)
383
PERMIT TO WORK Revision No 02

1. Permit TO Work No: _______________________ W.O No: __________________ Date: _______ ___ ______
2. Equipment Code: __________________________ Area: ______________________________________________
Equipment Description: _______________________________________ ________________ ___ ____
Job Description: ______________________________________________________ _______________________
_______________________________________________________________________________________ __
3. LOTO (Isolation): Yes #__________ No Lock Box #____________
Done by: 1- _______________ __________________________Date: ___________Time: ____________
2- _______________ __________________________Date: ___________Time: ____________
Verified by: - ________________________________________ Date: ___________Time: ____________
(Print Name and signature)
HWP: Yes #_____ No WAHP: Yes #_____No CSEP: Yes #_____No
Cross Reference of other work Permit that is likely to be effect the mentioned job:
S.NO Work Permit No Job Description

Hand Protection Face Protection Respiratory Protection Foot Protection Body Protection Ear & Head Protection
Elect. Gloves Goggles Dust Mask Gum Shoes Boiler Suit Ear Muff
Leather Gloves Welding Vapor Mask HV Shoes Fire Suit Helmet
Chemical Shield SCBA
Gloves
JHA/RAS/PSC # (if any) No: _______
Special Instructions (if any):
5. Verification done by: _______________ __________________ Date: ______ _ ____ Time: ____________
(Print Name along with signature)
Name and Signature: _____________________________________Date: ___ _ _______Time: ____________
7. Craft Person Acceptance (Print name along with signature)
Permit To Work
Accept Release
8. Is Temporary Lock / Tag Out Release (TLTR) Required for testing? Yes #___________ No
TLTR PTW Suspension (Fill by Shift Engineer)
Requested By Valid Cancelled
Name / Signature Date / Time Name / Signature Date / Time Name / Signature Date / Time
9. Is the JHA JHA/RAS/PSC for the activity appropriate? Yes NO if No pleases Comment:
Special Comments/Suggestion (if any):
10. Isolation Removal: (Area Engineer Name and Signature) 11. Completion:
11. Removed by: 1- _____________________________
Shift Engineer Name and Sign: _________________
2- _______ _______________________
Date: _____________Time:_____ ________
Verified by: _____________ ______________ _
384
PERMIT TO WORK MASTER Revision No 01
LOG Revision Date 28-10-2020

PTW # Equipment & Job Description Date Issued Date Released
385
LOCK OUT AND TAG OUT Revision No 01
1. LOTO No: _____________________ PTW No: __________________Date & Time: ______________________

2. Equipment Code: _________________Equipment Description: ______________________________________
Job Description: ______________________________________________________ ______________________
_____________________________________________________________________________________ __
3. Isolation Check List: Continuation sheet used: Yes No
Isolated by De-isolated by
Sr. Equipme Lock
Equipment Description Position NO
Tag
No nt Code
Name Sig. Name Sig.
4. Prepared by: ______________________________________ Date: ________________ Time: _______

(Shift Engineer Name and Signature)
386
LOCK OUT AND TAG OUT Revision No 01
MASTER LOG Revision Date 28-10-2020

LOTO No PTW No Equipment & Job description Date Issued
387
PERMIT TO WORK QUARTERLY Revision No 01
INSPECTION FORM Revision Date 28-10-2020

1. PTW QI Number: __________________________________ Date:
PTW No: _________________________________________ PTW Issued Date:
2. Damage or Defaced Tag/Lock replaced.
Lock/Tag Equipment PPS Tagged

Equipment Description
No Code No Position
Special Instruction:
3. Tags hung by area Engineer Name & Sign. Date: Time:
4. Inspection & replacement of damage or defaced Tags is completed.
Shift Engineer Name & Sign.: ______________ Date: Time:
Note: -
This form will be attached with Lock out and tag out order & retains for one year.
388
Revision No 01
LOCK ACCOUNTABILITY FORM Revision Date 28-10-2020
1- PTW No: _______________________ Equipment code: __________________________________
2- Equipment description: _____________________________________________________________
3- Work Description: _________________________________________________________________
4- Type/Colour of lock: ______________Lock No: ___________ Location of lock: _________________
5- Owner of lock: (Craft Person Name) ___________________________________________________
6- Name who removes lock: (on behalf of craft person) ______________________________________
7- Reason for removing lock/change of Craft Person: _______________________________________
________________________________________________________________________________
8- Shift Engineer (Name & Sign): ___________________________Date: ____________Time: ______
9- Manager Operation (Name & Sign): _______________________ Date: ___________Time: ______
Note:
Before commencing the Craft Person Department Lock removal procedure, Manager of Craft Person will
ensure that the assigned job has been completed in all respect and PTW need to be released.
Manager of lock owner shall inform to Shift Engineer about the new craft person and reason of lock
removal.
389
TEMPORARY LOTO RELEASE Revision No 01
28-10-2020
FORM Revision Date
28-10-2023
Last Review
1. TLTR No: PTW No: Date: _____________________
2. Test Activity Detail: _______________________________________________________________________________________

____________________________________________________________________________________________________________
3. List all Lock(s) and tag(s) that are to be removed for the TLTR. Continuation Sheet Used
Sr. Equipment Lock No / Temporary Status
Equipment Description
No code Tag No (Open/Close)
4. Locks & Tags Removed By: (Name & Signature) Lock Box No:
1. _______________ Date: ___________Time: ________ 2. ________________ Date: __________Time: _______
5. Verified By: (Craft Person) ____________________________________Date: ___________Time: __________

(Print Name along with Signature)
6. Authorization to Work (Shift Engineer): ____________________________ Date: ___________Time: __________
(Print name along with signature)
7. Craft Person Acceptance (Print name along with signature):
Test Accepted Released Work Status
Name & Sig.
No. Date Time Date Time Continuing Complete
1
2
3
4
8. TLTR Completion Control (Print name along with signature):
Test Lock/Tag Hung By Verified By Approved By

No. Name & Sig. Date & Time Name & Sig. Date & Time Name & Sig. Date & Time
1
2
3
4
390
TEMPORARY LOTO RELEASE Revision No 01
28-10-2020
MASTER LOG Revision Date
28-10-2023
Last Review
TLTR No Equipment &Testing Activity Detail Date Issued Date Released
391
Revision No 01
Permit to Work Audit Checklist Revision Date 28-10-2020

Permit No. Type Date of Audit
Work Description to be
Entered
PTW & LOTO Elements Yes No N/A Comments

1 Equipment Description,
2 Adequate description of work?
3 Tag Number, Location Entered?
4 Correct Signatories, Times and Dates?
5 Precautions entered/RA attached?
6 Is Control room aware about PTW in force?
Check with Electrical Engineer for isolation appropriate for
7
task
Check with Area Engineer process/mechanical isolation
8
appropriate for task
9 Atmosphere checks recorded?
10 Fire watcher authorised and aware of responsibilities?
11 PPE’s as per description of work used?
12 Standby man authorised and aware of responsibilities?
13 Gas test performed
Precaution measures taken on all hazards mentioned on
14
work permit.
Are relevant procedures cross referenced and being
15
followed?
16 Are primary permit requirements being followed?
17 Is the workforce aware of conflicting work?
18 Is the permit displayed at the worksite?
19 Is the worksite safe?
Is there a TBT and does it adequately cover the task in
20
hand?
21 Working with incomplete permit.
Are all equipment control valve handles provided with a
22
means for locking /tagging out?
Were up to date diagrams, manufacturers’ literature and/or
23 pre-existing procedures used to determine and verify
isolation points?
Is the person(s) performing the LOTO on the authorized
24
employees list?
Was the equipment shutdown in accordance with approved
25
operating instructions?
Were all sources of energy properly isolated, locked and
26
tagged?
Were the test points selected sufficient to establish a zero
27 energy state? Were possible sources of stored energy
blocked, bled, or dissipated in a safe manner
House Keeping Checklist
28 Is Worksite tidy?
29 Is the area clear of any visible tripping hazards?
392
Revision No 01
Permit to Work Audit Checklist Revision Date 28-10-2020

30 Are equipment/tools secure for vessel motion?

31 Is the area safe from risk of falling objects?
32 Is there a clear escape route?
33 Is there adequate lighting in the area?
Total Number of Non Compliances
Auditor – Non-compliance(s) and any other comments;
Auditor Name: Muhammad Akhtar Rasul Signature:
Operation Manager - Action(s) taken on non-compliance(s) and any other comments
Operation Manager Signature

General Manager- Action(s) taken on non-compliance(s) and any other comments
GM Signature
393
CONFINED SPACE ENTRY Revision No 01
PERMIT Revision Date 03-02-2017

1. CSEP No: ______________________ PTW No (if any): __________________ Date: _____ ______
Equipment Code: __________________ Area: ________ ___ Craft Person: ______ ___ _____
Space to be Entered: _____ _________________________________ ____________
Purpose of Entry: ________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________
2. Hazards and Precautions (Check)

_______ Oxygen Deffciency (< 19.5% OR > 23.5%) ____ Notify Concerned Department
_______ Flammable Gases or Vapors (> 10% of LEL) ______Zero Energy State (Lockout All Energy Sources)
________Toxic Gases or Vapors (> PEL) ______Cleaned, Drained, Washed and Purged
________ Mechanical Hazards ______Ventilation To Provide Fresh Air
________Electrical Shock ______Secure Area (Post, Sign and Flag)
________Material Harmful to Skin ______Procedure with each Person involved
________Engulfment ______Atmospheric Test in Compliance
________Thermal ______ Hot work required
________Pneumatic ______Other
3. PPE and Other Equipment Required (Check)
____________________________________________
_____Protective Clothing Authorized Attendants: _______________________________
______Hearing Protection _______ ______________________
______Life Line, Safety Harness / Safety Belt
______Respirator Authorized Entrants: ______ ______________________
______Lighting (explosive proof) __ _____ ______________________
______Fire extinguisher
ELECTRICAL EQUIPMENT/ TOOLS:
______Earth leakage circuit breaker Standby Safety Personnel: ____________________________
______Approved for hazardous location (24V & 70V)
______Other _____________________________ Communication aid (specify): _____________________________
4. Atmosphere Testing Record

Tester Name & Date & Time O2 > 19.5% LEL < H2S < CO < SO2 Others
Signature O2 <23.5% 10% 10ppm 10ppm <2ppm
5. Shift Engineer Approval and Authorization

Name and Signature: _____________________________________Date: ___________Time: ____________
Accept Release
7. Completion:
Shift Engineer Name and Signature: _______ ________
Date: ___________ _ _Time____ __________
394
Revision No 01
MOCK DRILL REPORT
Date: Mock Alarm Time:
Place: ERT Response Time:
Purpose:
Scenario:
MATRIX (THINGS WENT WELL): -
IMPROVEMENT AREAS: -
Prepared By Verified By
Asst. Manager HSE GM plant
395
FIRE SYSTEM IMPAIRMENT Revision No 02
31-05-2021
NOTICE FORM Revision Date
31-05-2021
Last Review
Impairment Case No: ________________ Date of Impairment: ________________
Part 1 – Pre- Impairment
A. Before isolation of fire protection system
1. Location of Work / Impairment: ________________________________________________________

2. Reason for Impairment: ______________________________________________________________
___________________________________________________________________________________
3. Area Effected during Impairment: ______________________________________________________
___________________________________________________________________________________
4. Level of Impairment (✓): Level 1: (…..) Level 2: (….).
5. Nature of Impairment (✓): Emergency (…..) Planned: (….) Hidden/ Concealed: (….)
6. Estimated duration of Impairment:
From (date & time): ___________________________ To (date & time): ________________________
7. Equipment’s Impaired:
Fire Suppression Mark (✓) Fire Detection Mark (✓)
Water sprinkler system Heat & flame detection system
Fire hydrants / monitor Smoke detection system
Fire hose reels Hazardous gas detection system
Fire foaming system Fire alarm detection panel
Fire pump Alarm / Sounder / Beacon
Entire fire water system Others
8. Fire Precautions Taken:
Description Yes N/A Description Yes N/A

Is staff & EHS Committee notified? Is area maned for ?
Is firefighting equipment provided? Is fire watch required?
Is hot work stop in impaired area? Are hazardous operations suspended?
Is Emergency response team notified Is alternate temporary protection exist?

B. After isolation of fire protection system
9. System shut Off / Impaired (date & time): ______________________ PTW (if any): ______________
10. Isolation (LOTO) done by (name & sign): _______________________________________________
11. Impairment Tags placed by (name & sign): ______________________________________________
12. Impairment Coordinator (name & sign): _________________________________________________
13. Manager HSE (name & sign): ________________________________________________________
Page 1 of 2
396
FIRE SYSTEM IMPAIRMENT Revision No 02
31-05-2021
NOTICE FORM Revision Date
31-05-2021
Last Review
14. Fire Watch (name and sign): _________________________________________________________

Part 2 - Post Impairment – (After restoration of fire protection system)
EHS committee members should be informed immediately after the restoration of system on email and
telephone.
15. Impairment notice cancelled (date &time): _____________________________________________

16. Fire system restored by (name & sign): ________________________________________________
17. Impairment tags removed by (name & sign): ____________________________________________
18. Impairment Coordinator (name & sign): ________________________________________________
19. Manager HSE (name & sign): ________________________________________________________
20. Sr. Manager Operation (name & sign): _________________________________________________
Note:
This form will be filled by Impairment Coordinator when fire suppression / detection equipment’s are
impaired or shut down inside the premises of plant.
First part of this form will be filled before impairment of system and star of maintenance / repair work on
fire protection system after information to EHS committee members and Emergency Response Team.
Second part of this form will be filled after restoration of impaired system and completion of maintenance
/ repair work
Page 2 of 2
397
Revision No 02
FIRE WATCH LOG SHEET Revision Date 31-05-2021

Impairment Case No: ________________ Date of Impairment: ____________________
Fire Petrol Area: ____________________________________________________________________
Date Time (Hrs) Name Sign Finding
398
FIRE IMPAIRMENT RECORD Revision No 02

31-05-2021
Revision Date
Sr. No Area/ Equipment Impaired Date of impairment Date of Impairment PTW Remarks
applied lifting Reference
399
PERSONAL SAFETY Revision No 01
01-01-2018
CHECKLIST Revision Date
Sheet No: _____________ PTW No: ___________________ DATE: ___________________
Activity/Job Description: _______________________________________________________________________

_____________________________________________________________________________________________
HAZARD-RISK-MEASURES [Please tick as applicable]
Sr.
✓ Hazards Identified Risk Measures Understood / Taken
No
01 High Pressure!!! Injury Wear eye protector and required PPE, Keep away at safe distance,
steam, oil, fuel, air, Don’t touch or disconnect pressurized parts [pipe, hose and component joints]
water etc. without releasing pressure completely.
02 Temperature!! Burning, Wear lather hand gloves and required PPE, Keep away at safe distance, Don’t
heated surface, steam, injury touch or disconnect pressurized parts [pipe, hose and component joints]
hot box etc. without cooling to normal temperature.
03 Chemical & sealant Injury, Wear Safety goggles and required PPE, Keep your face away at safe
burning distance, check water source for flushing nearby if needed.
04 Flying chip from cup- Injury Wear Safety goggles and required PPE, make a cover surrounding your job
brush, grinder area to arrest flying chips and isolate by red tape.
05 Height Fall Use safety belt with minimum sag and required PPE, Fix ladder and platform
firmly.
06 Insulation Lung Wear nose mask and required PPE, Isolate area, Keep insulation in plastic
infection bag and clean by water [making wet].
07 Gas from painting or Lung Use nose and eye protector, arrange fan/blower for plenty fresh air circulation.
fumes, WD-40!! infection
08 Using lifting devices Injury, Check hooks, safety locks and overall condition. Fix safely. Never pass under
/Turn gear! fatigue, hung load. Keep crane hook overhead / Before turning engine ensure ‘ALL
death CLEAR!!’ Inform others working in the same area.
09 Electrical shock fatigue, De-energise the system, Use insulated gloves and stands or bench. Keep
death away when live wires or cables.
10 Slip/Trip/ Fall Injury Look before you step and move, Look at support where you stand.
11 Metal Sharp Edge Injury Identify sharp edge parts, handle with care, wear leather gloves.
12 Carrying heavy parts Back pain Firm and careful gesture, share load with partner, avoid carrying load more
than 10 kg.
13 Rotating machinery Injury Wear eye protection; keep safe distance, Avoid loose / full sleeve dress!
14 Cold burn, -1500C!! Injury Wear insulating hand gloves, avoid inhaling very cold fume.
15 Defective tools!! Injury Inspect before and during use, Discard and report if defective, Keep your face
away from loading point
16 Messy Work place Fall Arrange cables, tools such a way that a walkway exists
17 Bad Housekeeping Slip, Fall Clean waste material off during work to avoid slips [RAG, GLOVEs etc.]
18 Insufficient Lighting Striking Make extra light arrangement to increase the Lux level.
with, fall
19 Spills (Water, oil, Slip, Fall Routine inspections of vessels and pipelines. Use secondary containment.
chemicals) Confined and remove the spilled material at local point by using spill kit and
special PPE. Barricade the area.
20 Dust, Vapours, Fumes, Lungs Use special face mask (i.e. dust mask, half and full face mask etc.). Use
Fog and Smokes infection respirator/SCBA in highly fume concentration area.
21 Gas Leakages Human Routine inspections of vessels, valves and pipelines. Avoid hot work near gas
health cylinders and other gas appliances.
22 Fungi's, Bacteria Human Proper Housekeeping and hygienic conditions at working place; Healthy food
health stuff, Regular examination of employee blood.
23 Fire and Explosion Injury, Routine inspections of oil, chemical vessels, containers, pipelines, electrical
material appliances. Remove the leakages as soon as possible. Avoid hot work near
damage gas cylinders and other flammable material. Proper housekeeping.
24 Inappropriate Storage Fire, spill, Chemicals compatibility and secondary containments for liquids, Proper heap
injury height and easy access to use.
25 Presence of spiders, Human Encourage cold/hot fumigation. Use proper PPE (shoes, coverall etc.). Herbs
ants, snakes (Bites) health and grasses should be removed timely. Proper light arrangement in dark area.
26 Outdoor work (Under Sunstroke Avoid working in direct sunlight, Drink plenty of water/juices, and take frequent
sun) short rests and bath.
400
Title HAZARD IDENTIFICATION & RISK ASSESSMENT FORM Issue Date 01/01/2016
Revesion No 1
Revesion Date 26/10/2018
Location
Activity/System Description
Risk Assessment Done By
Plant NPL Author HSE Manager Archive Site Archive Status Finalized
Note:
1
Each workplace, equipment, machine, material, process and activity in the organization/department shall be evaluated for their potential hazards and risk ranking.
Revised the Hazards/ Aspect Identification and Risk/ Impact Assessment whenever, 1. Critical accident happen in the area. 2. Change in equipment, process or chemical. 3. Internal or external audit recommendation. 4. MOC Committee recommendation 5. Change in regulation or Management
decisions. 6. At least review once every three years.
2
AG - Affected Group, E - Employee, C - Contractor, P - Public, V - Visitor
Risk Identification Risk Analysis Risk Evaluation Risk Treatment

Severity (A) Potential Risk
1
Item/ Event/ Source Residual Risk Ranking After Additional Control (A x
(Severity without Likelihood (B) Ranking
(Workplace, Equipment, B x C) Additional Control
Item Activity Consequences Controls) Existing Preventive Control(s) (AxB = AB)
Machine, Material, Direct Recommended Implementation
No. Potential 2 (OH&S, Environment, Fire, OH&S Env Recovery Measures OH&S Env Direct Loss
Process, Service, AG Loss Additional Control(s) (
Hazard(s)/Aspect(s) Explosion, Direct Direct
(After Incident)
Product, and Activity) C)
Property/Equipment Damage) OH&S Env OH&S Env
Likelihood
Likelihood
Likelihood
Severity
Severity
Severity
Loss Loss
Level
Level
Level
Level
Level
Level
Rank
Rank
Rank
Rank
Rank
Rank
Non Emergen
Routine Engineering Administrative Special PPE Responsible Completion Date
Routine cy
1-Insignificant1-Insignificant 2-Minor
3-Moderate 3-Moderate 4-Major
D-Unlikely
D-Unlikely
D-Unlikely
Moderate
4-Major
2-Minor
2-Minor
2-Minor
E-Rare
E-Rare
E-Rare
High
Low
Low
Low
Low
14 5 9 3 1 3
D-Unlikely
D-Unlikely
Moderate
4-Major
2-Minor
2-Minor
2-Minor
E-Rare
E-Rare
E-Rare
E-Rare
High
Low
Low
Low
Low
10 5 9 3 1 3
3-Moderate 1-Insignificant 2-Minor
Moderate
D-Unlikely
D-Unlikely
D-Unlikely
4-Major
2-Minor
2-Minor
E-Rare
E-Rare
E-Rare
High
High
Low
Low
Low
14 5 14 3 3 6
1-Insignificant 2-Minor
D-Unlikely
D-Unlikely
D-Unlikely
4-Major
2-Minor
4-Major
2-Minor
E-Rare
E-Rare
E-Rare
High
High
Low
Low
Low
Low
14 5 14 1 3 1
3-Moderate 3-Moderate 3-Moderate
3-Moderate 3-Moderate
C-Possible
D-Unlikely
D-Unlikely
D-Unlikely
Moderate
4-Major
2-Minor
E-Rare
E-Rare
High
High
Low
Low
Low
14 13 9 3 5 3
C-Possible
D-Unlikely
D-Unlikely
D-Unlikely
Moderate
4-Major
2-Minor
2-Minor
2-Minor
E-Rare
E-Rare
High
High
Low
Low
Low
14 13 9 3 5 3
C-Possible
C-Possible
D-Unlikely
D-Unlikely
D-Unlikely
4-Major
4-Major
2-Minor
2-Minor
E-Rare
Critical
2-Minor
High
High
Low
Low
Low
14 13 18 5 5 3
RISK RANKING
Likelihood
5 A-Almost Certain
4 B-Likely
3 C-Possible
2 D-Unlikely
1 E-Rare
Consequences
1 1-Insignificant
2 2-Minor
3 3-Moderate
4 4-Major
5 5-Catastrophic
Risk
Score Consequences
Likelihood Risk Rank
Level
5-CatastrophicA-Almost Certain 5-Catastrophic
A-Almost Certain
Critical 25
5-CatastrophicB-Likely 5-Catastrophic
B-Likely Critical 24
4-MajorA-Almost Certain 4-Major A-Almost Certain
Critical 23
5-CatastrophicC-Possible 5-Catastrophic
C-PossibleCritical 22
4-MajorB-Likely 4-Major B-Likely Critical 21
3-ModerateA-Almost Certain 3-Moderate A-Almost Certain
Critical 20
5-CatastrophicD-Unlikely 5-Catastrophic
D-UnlikelyCritical 19
4-MajorC-Possible 4-Major C-PossibleCritical 18
3-ModerateB-Likely 3-Moderate B-Likely Critical 17
2-MinorA-Almost Certain 2-Minor A-Almost Certain
Critical 16
5-CatastrophicE-Rare 5-Catastrophic
E-Rare High 15
4-MajorD-Unlikely 4-Major D-UnlikelyHigh 14
3-ModerateC-Possible 3-Moderate C-PossibleHigh 13
2-MinorB-Likely 2-Minor B-Likely High 12
1-InsignificantA-Almost Certain 1-Insignificant
A-Almost Certain
High 11
4-MajorE-Rare 4-Major E-Rare High 10
3-ModerateD-Unlikely 3-Moderate D-UnlikelyModerate 9
2-MinorC-Possible 2-Minor C-PossibleModerate 8
1-InsignificantB-Likely 1-Insignificant
B-Likely Moderate 7
3-ModerateE-Rare 3-Moderate E-Rare Moderate 6
2-MinorD-Unlikely 2-Minor D-UnlikelyLow 5
1-InsignificantC-Possible 1-Insignificant
C-PossibleLow 4
1-InsignificantD-Unlikely 1-Insignificant
D-UnlikelyLow 2
1-InsignificantE-Rare 1-Insignificant
E-Rare Low 1
401
RISK RANKING
Likelihood
A A-Almost Certain
B B-Likely
C C-Possible
D D-Unlikely
E E-Rare
Consequences
1 1-Insignificant
2 2-Minor
3 3-Moderate
4 4-Major
5 5-Catastrophic
Risk Level
Risk Rank
Score Consequences Likelihood
5-CatastrophicA-Almost Certain 5-Catastrophic A-Almost Certain Extreme

25
5-CatastrophicB-Likely 5-Catastrophic B-Likely Extreme
24
4-MajorA-Almost Certain 4-Major A-Almost Certain Extreme
23
5-CatastrophicC-Possible 5-Catastrophic C-Possible Extreme
22
4-MajorB-Likely 4-Major B-Likely Extreme
21
3-ModerateA-Almost Certain 3-Moderate A-Almost Certain Extreme
20
5-CatastrophicD-Unlikely 5-Catastrophic D-Unlikely Extreme
19
4-MajorC-Possible 4-Major C-Possible Extreme
18
3-ModerateB-Likely 3-Moderate B-Likely High 17
2-MinorA-Almost Certain 2-Minor A-Almost Certain High 16
5-CatastrophicE-Rare 5-Catastrophic E-Rare High 15
4-MajorD-Unlikely 4-Major D-Unlikely High 14
3-ModerateC-Possible 3-Moderate C-Possible High 13
2-MinorB-Likely 2-Minor B-Likely High 12
1-InsignificantA-Almost Certain 1-Insignificant A-Almost Certain High 11
4-MajorE-Rare 4-Major E-Rare High 10
3-ModerateD-Unlikely 3-Moderate D-Unlikely Moderate
9
2-MinorC-Possible 2-Minor C-Possible Moderate
8
1-InsignificantB-Likely 1-Insignificant B-Likely Moderate
7
3-ModerateE-Rare 3-Moderate E-Rare Moderate
6
2-MinorD-Unlikely 2-Minor D-Unlikely Low 5
1-InsignificantC-Possible 1-Insignificant C-Possible Low 4
1-InsignificantD-Unlikely 1-Insignificant D-Unlikely Low 2
1-InsignificantE-Rare 1-Insignificant E-Rare Low 1
Control Rank
CONTROLS RANKING
PPE Low 1
PPE Medium 2
PPE High 3
Procedures Low 4
Procedures Medium 5
Procedures High 6
Engineering Low 7
Engineering Medium 8
Engineering High 9
Percentage Complete
0%
10%
20%
30%
40%
50%
60%
70%
402
80%
90%
100%
403
KITCHEN HYGIENE INSPECTION FORM Revision No 01


Satisfactory
Description Action will be Taken
Yes No
Are food room clean and tidy and do staff clean as
they go?
Are all food and hand contact surfaces e.g. work
surfaces, slicers, fridge handles, food probe in
good condition, cleaned and disinfected regularly?
Are suitable cleaning chemicals are available and
stored correctly and proper cleaning methods
used?
Are cleaning cloth suitable for use and
cleaned/disinfected regularly?
Are high risk food checked regularly?
Is food in fridge and freezers covered?
Are ready food/salad/vegetables/fruits items

trimmed and washed thoroughly?
Is kitchen staff fit for work and wear neat and
clean clothing?
Is hand wash basin have hot water, soap &
hygienic towels/tissue?
Is jewelry limited to plain ring?
Is fly killers installed at kitchen & food storage

area?
Is food items protected from risk of contamination
from pest?
Is food factory cleaned, stored and properly
maintained?
Is kitchen waste store and dispose off correctly?
Is unfit food clearly marked & stored away from

other food?
Remarks:
Area: _________________ Date: ________________

Inspected By: (Name & Sign) _________________
404
NOISE, ILLUMINATION AND Revision No 01
02-05-2019
TEMPERATURE MEASUREMENT FORM Revision Date
Inspection Date: ________________________
Standard Limits Analyzed Result

Sr. No Area Noise Level Temperature Temperature
Lux Value Lux Value Noise Level (dB)
(dB) (0C) (0C)
Suggestions and Recommendation:
Measurement Executed By Signature

Equipment Used
1|Page
405
01
Housekeeping Evaluation Form Revision No
Rating: (I) Excellent (91-100%) (II)Good (81-90%) (III) Fair (71-80%) (IV) Unacceptable (<70%) (V) Alarming (<50%)
Visible Inspection LEAKS (Yes/No) Temporary REMARKS Rating
Location Findings (Yes/No) Fixings (Yes/No) (%)
Dust Dirt Rag FO LO Water Wires Others

Engine 1
Auxiliaries
Platforms
Engine 2
Auxiliaries
Platforms
Engine 3
Auxiliaries
Platforms
Engine 4
Auxiliaries
Platforms
Engine 5
Auxiliaries
Platforms
Engine 6
Auxiliaries
Platforms
Engine 7
Auxiliaries
Platforms
Engine 8
Auxiliaries
Platforms
406
01
Engine 9
Auxiliaries
Platforms
Engine 10
Auxiliaries
Platforms
Engine 11
Auxiliaries
Platforms
STG
Auxiliaries
Compressor Room
Fuel Treatment House
RO Water Container 1
RO Water Container 2
Firefighting Container
Chemical Shed
New Washing Area
HRSG 1~6 Area
HRSG 7~11 Area
Boiler Office
W/Shop
W/Shop changing Room
Offices
Ware House
Laboratory
Decanting Area
Decanting Bays & Rooms
407
01
Weight Bridge Office

Day Tank yard
Main Tank yard
Admin Building
Offices
Mess Room
Kitchen
Toilets & Wash Rooms
Project Building
Toilets & Wash Rooms
Gate Office
Inspected By: AM HSE, Area Supervisor and Housekeeping Supervisor Date: --------------------------
Remarks:
408
Revision No 02
CHANGE MANAGEMENT FORM Revision Date 11-05-2017

1. MOC No(fill by MOC custodian):
2. Title of Modification:
Initiation Date:
B Y
3. Modification Type: Technical Change Procedure Change Administrative Change Others

I N I T I A T O R
Modification Proposed for: (please tick or highlight from below)

Enhancing Safety Improving Reliability Improving Maintenance
Protecting Environment Improving Operations Cost Saving
Protecting Human Health
4. Concept for Change:

Nature of Problem or Requirement (attach supporting documents)
Proposed Modification/ Concept Details (attach detail documents)

S . N o 2 ,
Who will perform the work (Please tick or highlight from below)
Electrical Operation Mechanical Civil Admin EHS/Other Outsource

3
Modification/Concept Proposed by
&
4
Name Signature Date
5. Concept Approval and Budget:

Head of Department of MOC Initiator
The above concept is discussed in Weekly meeting. Concept agreed and further study
for its feasibility is requested. MOC Agreed Meeting Date & Ref :__________ Yes No
Type of Budget to be utilized: (Check By ✓ ) CAPEX O&M

Additional Comments (if any):
Name Signature Date
409
Revision No 02

6. Assessment and Evaluation:

HEAD OF OPERATION DEPARTMENT
Completion Completed
Description Check (tick one) Responsibility Initials
Date On
Operating conditions need to be
Yes No
updated
Operating method need to be
Yes No
changed
Utility or other relevant system
Yes No
requires any change
Staff training required due to change Yes No
Additional Comments (if any)
Name Signature Date
HEAD OF MAINTENANCE DEPARTMENT

Date On
Detailed Engineering required Yes No

Method statement for work
Yes No
execution required
Will this change maintenance
Yes No
method(s) / Procedure(s)
Name Signature Date
HEAD OF ELECTRICAL DEPARTMENT

Date On

Method statement for work execution
Yes No
required
Will this change maintenance
Yes No
method(s) / Procedure(s)
410
Revision No 02

Name Signature Date
HEAD OF CIVIL DEPARTMENT

Date On
Method statement for work execution
Yes No
required
Name Signature Date
HEAD OF EHS DEPARTMENT
Check (tick Completion Completed

Description Responsibility Initials
one) Date On
PHA/HIRA Required Yes No

FMEA / What If Analysis Yes No
Name Signature Date
GENERAL MANAGER PLANT

Concept Approved Yes No
Name Signature Date
411
Revision No 02

7. Modification Completion Report:

Work order no. PTW No.
(MOC custodian) (MOC custodian)
Executed by (Craft Person)

Name Signature Date
Drawing updated by
(Relevant Department)
Name Signature Date
PPS Code number allocated by

Name Signature Date
PPS code identification strips

placed by
Name Signature Date
Operating procedure updated

(if required)
Name Signature Date
WHIS updated by (if required)

by EHS Officer/ EHS
Committee
Name Signature Date
Responsible for final closing

and checks as per
procedure(MOC custodian)
Name Signature Date
412
Revision No 01
WORK AT HEIGHT PERMIT Revision Date 23-11-2017
1. WAHP No:_________________ PTW No (if any): __________________Date:__________________________

2. Job Description : ___________ ________________ _ ___ _ _
______________________________________________________________________________________
Area: __________________________________________________________________________________
3. Related Work Permits:
HWP: Yes #_____ No CSEP: Yes #_____No CWP: Yes #_____No SEDP: Yes #______ No
4. The following equipment will be used during the works(equipment should be fit for use)
Elevated work platform (i.e. scissor lift) Roof and/or ladder anchor points Winch Safety net
Step/Extension ladder Edge protection Mobile scaffold Fixed scaffold Ropes and harness
Other (please specify): ______________________________________________________________________
5. Scaffold inspection carried out after erection and its checklist attached with permit: Yes N/A
6. The following control measures have been implemented and observed for the duration of the works:
Barricading Signage Spotter Observe By (name & sign) ____________

7. The following environmental factors have been assessed and are suitable for the works:
Rain Wind Temperature Noise Stored material Fog Light

Hand Protection Face Protection Respiratory Protection Foot Protection Body/Head protection Ear/ Fall Protection
Leather Gloves Welding SCBA HV Shoes Hard Hat/Helmet Full body
Shield harness
JHA/RAS# (if any) No: _______
9. Checked By: (Craft Person name & Sign) ___________________ Date: ________________Time:____________
10. Verified By : (HSE Officer or Designee) ____________________ Date: ______________ Time: __________
11. Approval and Authorization:
Shift Engineer (Name and Signature): _____________________________________Date: ___________Time: ____________

Accept Release
13. Completion:
Shift Engineer (Name and Signature): __________________________ Date ____________Time______________
413
SCAFFOLD ERRECTING, Issue Date 23-11-2017
ALTERING AND DISMENTLING Revision No 01

PERMIT Last Review 03-02-2020
1. SEDP No:_________________ PTW No (if any): __________________Date:______________________________

2. Location/Area : ___________ ________________ _ ___ _ ____ _
3. Purpose of Permit Application (✓): Scaffold erection ( ) Scaffold modification ( ) Dismantling of Scaffold ( )
4. Type of Scaffold (✓): Fixed tower ( ) Mobile tower on castor wheel ( ) Cantilever/Suspended/Hanging ( )
5. Height of Scaffold: (up to working platform): ____________Feet. Scaffold Material: _______________________
6. Requested by (Name, designation & signature):_____________________________________________________

7. Precautions and Instructions: (Yes/No/NA)
Applicant shall be responsible and ensure that precautions and instructions indicated in the permit are taken against
all hazards in connection with working at height if the permit approved.
Scaffold Supervisor and erectors must wear PPEs Scaffold must not be overloaded
including work at height
Engaged only Approved Scaffold Contractor Castor wheel used must be with locking
(except tower scaffold or scaffold <4m) mechanism
Engaged on competent Scaffold supervisor and Scaffold materials are in good condition &
erectors (submit certificates if any) without defects
Area must be barricaded and warning signs Tower scaffold, height erected less than 8x the
displayed lesser base
Scaffold must not be tie-in to any fragile building Tower scaffold/tie back /outrigger in place for
structures height erected more than 3x the lesser base
.Stabilize soft and uneven ground with hardcore / Clear work area after erection/modification
steel-plate/sole plate /timber to make safe for /dismantling of scaffold
scaffold erection
Scaffold Supervisor must supervise the erection / Provide lifeline if not possible to anchor safety
modification/dismantling of scaffold harness to any rigid structures
Erect safety net/hard boards over area which is Scaffold must not be erected near power lines
near to people access and excavated area.
Scaffolding works must STOP during adverse Provide adequate lighting for erection /
weather/absence of Scaffold Supervisor modification / dismantling of scaffold at night
Ensure full compliance with standard design and Tags for scaffold erection, operational and
drawing. dismantle must be placed at prominent location.
8. Scaffold Supervisor:(name & sign) ______________________________Date: ________________Time:____________
9. Verified By: (HSE Officer or Designee ) ___________________________Date: ________________Time:____________
10. Checked By : (Craft Person name & sign) ________________________ Date: ______________ Time: __________
11. Approval and Authorization:
Shift Engineer (Name and Signature): _________________________________Date: _________________Time: ___________

Accept (before erection of scaffold) Release (after scaffold dismantle)
Note: Take permission from Shift Engineer before Scaffold Alteration & Dismantling (Yes/No): _________________
13. Dismantle of Scaffold: Start date & time: ___________________Completion date & time: __________________
14. Completion:
Shift Engineer (Name and Signature): __________________________ Date ____________Time______________
414
SCAFFOLD INSPECTION Revision No 01
CHECKLIST Revision Date 03-02-2020
Inspected: (Date & Time) ______________________ WAHP: ________________
Inspected By: (Name & Sign) ___________________________________________
Yes/No Yes/No/ Yes/No/

Footings Bracing Boarding/Platform
/NA NA NA
Soft and uneven Façade and ledger Bad boards
No base plates Some missing Trap boards
No sole boards Loose Incomplete boarding
Undermined Wrong fittings Insufficient supports
Satisfactory Satisfactory Satisfactory
Guard Rails & Toe
Standards Couplings
Boards
Not plumb Wrong fittings Wrong height
Joined at same height Loose Some missing
Wrong spacing Damaged Loose
Damaged No check couplers Damaged
Ledgers Ties Ladders
Not level Some missing Insufficient length
Joined in same bays Loose Not tied
Loose Damaged Damaged
Damaged Other Other
Comments:
415
EYE AND BODY SHOWER Issue Date 01-01-2016

Revision No 01
MONTHLY INSPECTION Revision Date 06-07-2018
Eye and Body Shower No: ______________ Inspected Date: ______________
Area / Location: _________________________________________
Sr. Status
Description
No Yes No N/A
Eyewash
1 Eyewash activated & flushed of contaminants ( 1- 3 minutes)
2 Eyewash covers are present, clean, open & close properly
Water flow is soft / even and flowing properly from both eye
3
pieces / nozzles
4 Area is well lighted Access is unobstructed
5 Inspection tag is signed & dated
Body Shower
Shower activated & flow is effective & continuous. Activator

1
lever remains open without holding it down
2 Access is unobstructed
Activator lever/chain remains open without holding it down

3
Emergency sign is posted
4 Area is well lighted
5 Inspection tag is signed and dated
416
Revision No 0
HSE DOCUMENT CONTROL LIST Revision Date
Document No Document Title Issue Date Revision No Revision date Review Date Next Review Comments
417

FIRST AID BOX INSPECTION Revision No 01

Location of Box: ___________________________________ Date of Inspection: ___________________________

Inspected By: _____________________________________ Next date of Inspection: ________________________
Stock Stock
Sr. Storage Remarks /
Medicine Name Symptom Available Added Expiry date
No Condition Observation
(Qty) (Qty)
1 Tab Panadol Ext. For pain & fever
2 Tab Ponstan Forte For pain & fever
3 Tab Avil Anti-allergy

For pain abdomen. &
4 Tab Flagyl 400 mg
L/M
5 Tab Gravinate For vomiting
6 Tab Trisil For acidity
For L/M (Loose
7 Cap Imodium
Motion)
8 ORS For rehydration
9 Pyodine 60 ML Antiseptic
10 Cream. Polyfax S/O For wounds

Cream. Dermazin or
11 For burns
Quench
12 N/S Solution with Set For eye wash
13 Saniplast First aid bandages
14 Cotton Bandage Wrap up the wound
418

FIRST AID BOX INSPECTION Revision No 01

Stock Stock
Sr. Storage Remarks /
Medicine Name Symptom Available Added Expiry date
No Condition Observation
(Qty) (Qty)
15 Ray Band/Surge Gauze For covering wound
16 Sticking Tape 1" For dressing

Disposable Polythene
17 Protection of hands
Gloves
Disposable Examination
18 Protection of hands
Gloves (Latex)
19 Dressing Scissors For dressing
20 Dressing Forceps For dressing
21 Crape Bandage 4" For muscles pain

For support of
22 Wooden Splint
fracture
23 Cervical Collar For neck support
24 Safety Pins For dressing

For support to
25 Poly Sling fracture of arms &
shoulders
26 Dressing Pan
Note: Medicines which are not enlisted in this checklist, are not allowed to keep in First Aid Box.
Kindly write the use of medicine in “First Aid Box Use Record” register properly.
419
Document ID NPL-HSE-A032/02
FIRST AID BOX ITEMS USE Revision No 01
RECORD Revision Date 20-01-2022
Location of Log Book: _______________________
Sr. Description of Quantity Date of

Cause of Usage Name of User
No Product/medicine Used Usage
Note: - It is very important to know about the first aid box product name and its usage before taken it
from box.
420
AMBULANCE INSPECTION Revision No 0
FORM Revision Date 0
Inspection Date: ____________________ Inspected By: ______________________________
Sr. # Vehicle general condition Yes No NA

1 Is the exterior of the vehicle clean and free of damage?
2 Is the interior cab of the truck clean and free off damage?
3 Is the patient compartment clean and free of damage?
Fuel and general engine fluids check Yes No NA
4 Fuel level at checkout? (Indicate the closest amount) 1/4 1/2 Full
5 Are engine oil levels acceptable?
6 Are windshield wiper fluid levels acceptable?
7 Is there any indication of leaking fluids?
Emergency alert systems and general lights Yes No NA
9 Headlights functional?
10 Clearance lights functional?
11 Emergency lights functional?
12 Scene lights functional?
13 Sirens functional?
14 Backup alarm functional
15 Brake lights functional
16 Tail lights functional?
17 Turn lights functional?
18 Portable torch light present and functional?
Patient compartment Yes No NA
19 Linens stored and clean?
20 Regular trash can present?
21 Bio hazard trash Can present?
22 Examination and compartment lights are functional?
23 Attendant chair and bench condition is satisfactory.
24 Fire extinguisher available and functional?
25 Hand wash station is functional and hand wash solution is present?
26 Tissue for hand cleaning is present?
27 Oxygen gas cylinder condition is okay and level of gas is suitable?
Patient care equipment Yes No NA
28 Stretcher is present, functioning normally.
29 Stretcher patient restraints including shoulder straps present?
30 Portable stretcher available and functional?
Oxygen system (regulator, gauge, monometer oxygen hose and mask, level
31
indicator etc.) is healthy and functional?
32 B.P apparatus present and functional?
Medicine/response bag present, clean and fully stocked with no expired
33
items?
Remarks: ________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
421
EMERGENCY EQUIPMENT CABINET Revision No 0
INSPECTION FORM Revision Date 0

Cabinet No: _________ Location of Cabinet: _______________________________ Inspection Date: _________________
Inspected By: (Name & Sign) ________________________________________________________
Cabinet General Conditions

S. NO Description Yes No NA
1 Are cabinet doors moving and function properly?
2 Are cabinet compartments clean and tidy?
3 Are cabinet doors lock functional and door glass intact?
Fire Suit Fire Suit No ___ Fire Suit No ___ Fire Suit No ___
S. NO Description Yes No NA Yes No NA Yes No NA

Is all fire suit components i., e, coats, pants, hood, helmet, boots, gloves etc.
1
completely present?
2 Is installation of coat and pants available and both items are placed on it?
Is any component fire suit soiling? If yes then marked below;
3
(coats, pants, hood, helmet, boots, gloves)
Is any component fire suit contaminated with dust and dirt? If yes then marked
4
(coats, pants, hood, helmet, boots, gloves)
Are fire suit components (coats, pants, hood, helmet, boots, gloves etc.)
5
physical damage for?
5.1 Cuts, tears, punctures, cracking or splitting
5.2 Thermal damage
5.3 Are seams becoming un-sewn and missing or broken stitches?
422

6 Is stretching or elongation of the face opening of hood?
7 Is helmet missing any component of suspension and retention systems.
8 Is helmet damage or missing components of the face shield or goggles.
Self-Contained Breathing Apparatus SCBA No ___ SCBA No ___ SCBA No ___

1 Cylinder Inspection
1.1 Is the cylinder in acceptable shape?
1.2 Is current Hydro Test date valid?
1.3 Does cylinder valve function properly?

1.4 Is cylinder free from dust and dirt?
2 Backpack and Harness
2.1 No damage observed in straps. Are they in acceptable condition?
2.2 Is any damage or missing part of back pack?
2.3 Is the pack in acceptable condition?
2.4 Are the hoses in good condition?
2.5 Is backpack and harness free from dust and dirt?

3 Functional Checks
3.1 Are all the straps and buckles working & moving freely?
3.2 Is the mask in good condition?
3.3 Is the nose cup seated properly?
3.4 Is regulator with the face mask connect/disconnect easily?
423

3.5 Is the regulator cover in good condition?
3.6 Is Emergency Bypass valve working correctly and freely?
Air-Purifying Respirators (Half mask, Full face piece) Mask No ___ Mask No ___ Mask No ___
1 Rubber Face Piece:
1.1 Is there excessive dirt?

1.2 Are there cracks, tears, or holes?
1.3 Are full face respirators cracked, scratched, or loose-fitting lenses?
2 Head Straps:
2.1 Are there breaks or tears?
2.2 Is there loss of elasticity?
2.3 Broken or malfunctioning buckles?

3 Inhalation Valve and Exhalation Valve:
3.1 Is there detergent residue, dust particles, or dirt on valve or valve seat?
3.2 Any cracks, tears, or lack of flexibility in the valve material?
3.3 Any cracks and flexibility of valve seats?
4 Filter Element:
4.1 Is it the proper filter for the hazard?
4.2 Are there worn threads; both in filter and face piece?
4.3 Any cracks or dents in filter housing?
4.4 Are cartridge gaskets in place? (If applicable)
424

4.5 Is filter cartridge expired?

4.6 Issue date: _____________ Expiry Date: ________________
4.7 Is smell, taste, or irritation detected form filter?
Remarks:
425
Revision No 0
HSE AUDIT / VISIT REPORT Revision Date

Audit / Visit Date: _______________
Concerned
Sr. No Observations Recommendations Area/Location Target Date
Dept.
426
Document ID NPL- HSE-C036/01
Revision No 1
ANNUAL HSE TRAINING PLAN Revision Date 20/01/2022 `
Sr. No Training Topic January February March April May June July August September October November December
HSE
10
11
12
Emergency Preparedness and Response
Note:
Date and timings for training session will be decided on monthly basis.
Fire drill/Evacuation will be carried out according to plan.
Prepared By Endorsed By
AM HSE GM Plant
427
Revision No 01
HSE TRAINING ATTENDANCE FORM Revision Date 20-01-2022
Training Topic: ______________________ Training Month: ___________________
Sr. No E-Code Employee Name Designation Department Shift Training Date Signature
428
Company Name: Nishat Power Limited Licensee No.: IGSPL/15/2007 Review Date: 31-May-2022
Evidence of
Compliance/Action
Law/ Plan
Authority/ Department/ Compliance
Regulation/ Legal & Statuary Method of
No. Regulatory Type Section Status (Data, Reports,
Code/ Manual/ Requirements Compliance
Body Responsible (Yes/No) Certificates No.,
Article Name
Letter No. or other
Communications)
1. Power Safety NEPRA Section: 7. Licensee HSE Occupational Development of HSE Yes HSE Manual
Code 2021 Management System Health, HSE
Requirements Safety and Management
1. Licensee shall establish, Environment System/ Manual
implement, maintain and
communicate
“Occupational Health,
Safety & Environment
(HSE) Management
System/ Manual”
depending upon its own
requirements,
organizational needs,
types of activities,
processes, products,
services and risks/
aspects. Licensee shall
cover all his operational
sites and adopt industry’s
best practices and
standards related to his
work activities besides
compliance to Power
Safety Code and other
requirements.
2. Power Safety NEPRA Section: 7. Licensee HSE Occupational Compliance in HSE Yes HSE Manual
2. HSE Management Environment System/ Manual
System/ Manual shall
outline specific essential
measures to be taken by
429
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
Licensee to prevent
injuries to company
employees, contractor
personnel, visitors,
general public, natural
environment and
damages to property.
3. Roles and responsibilities Environment System/ Manual
shall be clearly identified
and documented in HSE
Management System/
Manual for all positions/
functions that are
responsible for the
control of system of
construction, installation,
operation, maintenance,
testing, turnaround, and
HSE critical activities.
Roles and responsibilities
shall be communicated to
responsible and
interested parties. It shall
also cover operational
interface or joint
responsibilities of each
job step by agreement,
where required.
430
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
4. Licensee shall cover all Environment System/ Manual
definitions, glossary,
abbreviations of all
important terms and
words being used, in his
HSE Management
System/ Manual.
5. Power Safety NEPRA Section: 7. Licensee HSE Occupational Submission of HSE Yes Submission Letter
No NEPRA Approval
5. Licensee shall submit his Environment System/ Manual
Letter
HSE Management to NEPRA
System/ Manual in
compliance to this Power
Safety Code to NEPRA
for approval within ninety
(90) working days (from
the effective date of this
Code or award of
license) and shall
implement his HSE
Management System/
Manual accordingly to
eliminate or prevent
incidents.
6. Licensee’s written HSE Environment System/ Manual
Management System/
431
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
Manual shall address all
sections/ sub-sections of
Power Safety Code as
applicable as per
licensee work activities/
job scope.
7. Boiler ACT - Directorate 2. (a) The owner of any Asset Registered boiler. Maintenanc Yes Registration
2002 of Industries boiler which is not Integrity/ e Certificate.
registered under the Safety
provisions of this Act may
apply to the Inspector to
have the boiler registered.
8. Boiler ACT - Directorate 5. On any date fixed under Asset Third Party Admin/ Yes Inspection Report.
2002 of Industries this Act for the examination Integrity/ inspection and Maintenanc
of a boiler, the owner Safety maintenance. e
thereof shall be bound : —
(a) to afford to the
Inspector all reasonable
facilities for the
examination and all such
information as may
reasonably be required of
him.
9. Factories Act - Labour Chapter -3 (13) Cleanliness Hygiene Drainage system Admin Yes Dedicated staff for
1934 Department is available as cleaning.
per design and
manual cleaning
is done regularly.
10. Factories Act - Labour Chapter -3 (14) Disposal of Hygiene Generated Utilities Yes Disposal Record
1934 Department wastes and effluents. wastes and
effluents are
432
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
disposed on
regular basis.
11. Factories Act - Labour Chapter -3 (15) Ventilation Occupational HVAC packages Electrical Yes PM Record.
1934 Department and temperature. Health are available to
control ventilation
and temperature
in every work-
room.
12. Factories Act - Labour Chapter -3 (16) Dust and Occupational Monitoring of Operations Yes Monitoring Reports
1934 Department fume. Health and hazardous dust
Environment and fumes.
13. Factories Act - Labour Chapter -3 (19) Lighting. Occupational Building is Electrical & Yes • Illumination
1934 Department Health designed and HSE Survey Report
approved as per (once in three
Building Codes year)
Of Pakistan. • Corrective
Lighting is Maintenance
maintained by Record of lights
regular
maintenance and
illumination
surveys after
every three
years.
14. Factories Act - Labour Chapter-3 (20) Drinking Occupational Drinking water Admin Yes Portable drinking
1934 Department Water. Health bottles with water bottles
dispensers are Procurement
provided at Record.
suitable
locations.
433
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
15. Factories Act - Labour Chapter-3 (21). Latrines Occupational Latrines and Admin/Civil Yes • Approved
1934 Department and urinals. Health & urinals are Building Plan.
Hygiene provided for male • Corrective
and female Maintenance
workers as per Record
Building Codes
Of Pakistan.
Latrines and
urinals are
maintained by
regular
maintenance and
dedicated
Janitors.
16. Factories Act - Labour Chapter -3 (26) Fencing of Safety Fencing and Operation/ Yes Corrective
1934 Department machinery. enclosures are Maintenanc Maintenance
provided to e Record
moving parts,
maintained by
regular
maintenance and
dedicated staff.
17. Factories Act - Labour Chapter -3 (25) Emergency Third Party HSE Yes Third party Fire
1934 Department Precautions in case of fire. inspection and Gap Analysis
maintenance. Report
18. Factories Act - Labour Chapter -3 (33) Cranes and Safety It is maintained Maintenanc Yes PM & Inspection
1934 Department other lifting machinery. by regular e Record.
maintenance and
dedicated staff.
Third Party
inspection and
maintenance.
434
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
19. Factories Act - Labour Chapter -3 (33-D) Floors, Safety Floors, stairs and Civil/Admin Yes • Approved
1934 Department stairs and means of means of access Building Plan
access. are provided as • Janitors/Cleaners
per Building Record.
Codes Of
Pakistan. It is
maintained by
regular
housekeeping.
20. Factories Act - Labour Chapter -3 (33-E) Pits, Safety Pits, sumps, Civil/Admin Yes Approved Building
1934 Department sumps, opening in floors, trenches and Plan.
etc. openings are
properly covered
and secured as
per approved
building plan.
21. Factories Act - Labour Chapter -3 (33-G) Occupational Mandatory PPE HSE Yes • PPE
1934 Department Protection of eyes. Health & are used as per Assessment/
Safety PPE Procedure
Assessment/ • Mandatory PPE
Procedure while at site.
conducting
critical job
activities.
22. Pakistan EPA, 12. Initial environmental Environment Third Party Initial HSE Yes IEE
Environmental Punjab examination and Environmental Report/Environmen
Protection Act, environmental impact Examination tal Approval for
1997 assessment. -(1) No Operational Phase
proponent of a project shall
commence construction or
operation unless he has
filed with the Federal
Agency an initial
435
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
environmental examination
or, where the project is
likely to cause an adverse
environmental effect, an
environmental impact
assessment, and has
obtained from the Federal
Agency approval in respect
thereof;
23. Pakistan EPA, (2) The Federal Agency Environment Impact HSE Yes Report
Environmental Punjab shall (a) review the initial assessment of
Protection Act, environmental examination potential positive
1997 and accord its approval, or impacts such as
require submission of an product
environmental impact generation,
assessment by the employment
proponent; or (b) review generation,
the environmental impact commercial and
assessment and accord its business growth.
approval subject to such Impact
conditions as it may deem assessment of
fit to impose, or require that potentially
the environmental impact significant
assessment be re- adverse impacts
submitted after such such as water
modifications as may be quality & quantity
stipulated, or reject the (impact on water
project as being contrary to table), solid
environmental objectives. waste generation,
soil
contamination
and air pollution.
436
Evidence of
Compliance/Action
Law/ Plan
Article Name
Letter No. or other
Communications)
24. National EPA, The NEQS specify the Environment Periodic HSE Yes Periodic monitoring
Environmental Punjab standards for industrial and monitoring of air Results
Quality municipal effluents, emissions,
Standards gaseous emissions, effluent discharge
(NEQS), 2012 ambient air requirements, and noise
vehicular emissions, noise monitoring to
levels and water quality meet NEQS
standards. prescribed
parameters.
25. Mineral and Department 140. Prohibition of Safety Two LPG Admin Yes LPG Storage Area.
Industrial of smoking, fires, lights, and cylinders (45 kg)
Gases Safety Explosives. dangerous substances. are stored in
Rules 2010. trolley at
designated
location away
from smoking,
fires, lights, and
dangerous
substances.
26. Mineral and Department 141. General Precautions. Safety Visual monitoring HSE Yes HSE Inspections
Industrial of
Gases Safety Explosives.
Rules 2010.
27. Mineral and Department 142. Special Precautions Safety Work Permit HSE/ Yes PTW Procedure
Industrial of against accidents. System Operations
Gases Safety Explosives.
Rules 2010.
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451

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1- LICENSEE HSE MANAGEMENT SYSTEM

➢ NPL HSE management system/manual is prepared in guidelines of NFPA, OSHA,

Sr. No Description Page No

1 NPL HSE Manual 1

2 HSE Legal Compliance Register 430

3 Environmental Approval from EPA Punjab 440

6 EOBI Registration Certificate 446

7 Petroleum Storage License 447

8 Boiler Inspection Certificate 448

9 Electrical Installations Test Certificate 451

10 Approval for Local Purchase/Consumption of H2SO4 452

NISHAT POWER LIMITED

Nishat Power Limited

NPL-HSE- D001 General – Table of Content

Part-I HSE Administration

NPL- HSE- A001 Front Matter

Part-II HSE Procedure

NPL- HSE- A005 Incident Reporting and Investigation

NPL- HSE- A036 Training Procedure

Part-III HSE Policy and Plan

NPL- HSE- E001 Smoking Policy

Part-IV Formats and Checklist

NPL- HSE- C002/01 Employee Safety Orientation Form

NPL- HSE- C016/08 TLTR Master Log

Issue Date 01-01-2016

Last Review 20-10-2019

Next Review 20-10-2022

Issue Date 01-01-2016

Last Review 20-10-2019

Next Review 20-10-2022

Pattoki, District Kasur.

Operation Date Commercial Operation from 6th June, 2010.

however, it is scheduled to operate throughout the year with load

ORIENTATION Revision Date

ORIENTATION Revision Date

 Hand and Head Protection

 Keep a safe distance from machinery.

2.4. Committee Meetings

INCIDENT REPORTING AND Revision No 02

INVESTIGATION Revision Date 20-12-2021

INCIDENT REPORTING AND Revision No 02

INVESTIGATION Revision Date 20-12-2021

INCIDENT REPORTING AND Revision No 02

INVESTIGATION Revision Date 20-12-2021

0. No Impact Requires no treatment

1. Minor Requires localized (In-house) care with short term effects

INCIDENT REPORTING AND Revision No 02

INVESTIGATION Revision Date 20-12-2021

Requires timely external care (evacuation) with medium to long term

4. Major Requires urgent emergency assistance with long term effects

Requires urgent emergency assistance with serious ongoing long-term

3.9. Potential Severity Rating

Severity Rating Definitions for Potential Severity Rating

An incident where the potential outcome has a negligible

4- Roles & Responsibilities

INCIDENT REPORTING AND Revision No 02

INVESTIGATION Revision Date 20-12-2021

4.2. Shift Engineer

INCIDENT REPORTING AND Revision No 02