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Safety Plan

For Project Sites

Disclaimer: This document was prepared for use at Indian Oi ltanking Project Sites only. It contains typical safety plan. The stipulated conditions are

liable to be changed as per local regulations / site conditions / future developments etc. No express or implied guarantee is made on

correctness / usefulness of the provided guidelines.



Safety Plan

Health, Safety, Security & Environment Project Sites

Document: HSSE/SP-001Version: 1.1

Page: i Local file: HSSE-03

Table of Contents

1 Introduction .......................................................................................….............. 1

1.1 Purpose................................................................................................... ............ 2

1.2 Scope and Applicability.................................................................................... 2

Health, Safety, Security & Environment Policy................................................…. 3

2 HSSE Organisation...............................................................................…............. 4

2.1 HSSE Committee ........................................................................ ..........…......…. 4

3 Assignments of Safety Responsibilities...........................................................…. 5

3.1 Management........................................................................ ..........….. .......…......5

3.2 Supervisor…................…..................................................................... ............…….53.3 Sub-Contractor…....................................................................................................6

3.4 Workers ……………...............................…...........................................................….6

3.5 Security................ ................ ...............................................................................….7

4 Hazard Identification and Control......................... ........... ...........................….. 8

5 Safety Rules and Safe Work Practices............. ........... ..............................………9

5.1 General Safety Rules ......................................................................................…….9

5.2 Hot work (Cutting/Welding)..................................................................................10

5.3 Confined Space Entry ......................................................................................….125.4 Excavation, Trenching & Backfilling.....................................................................13

5.5 Working at heights ............................................................................................….15

5.6 Power & hand tools operation..............................................................................19

5.7 Handling and lifting equipment............................................................................20

5.8 Scaffoldings, Platform and Ladders......................................................................27

5.9 Structural work, laying of reinforcement, cementing & concreting ................31

5.10 Vehicle movement.................................................................................................37

5.11 Radiography.................................................................................... .......................38

5.12 Demolition................................................................................................................39

5.13 Electrical connections / equipment.....................................................................41

6 Accident / Incidents, their reporting and investigation......................................45

6.1 Internal Reporting............................................................ ..........….. .......….......…..45

6.2 External Reporting...…..................................................................... ............……….45

6.3 Incident Investigation..............................................................................………..…45

6.4 Corrective Actions and Follow-up.......…...........................................................…46



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Version: 1.1Page: ii

Local file: HSSE-03

7 Permit to Work System ......................... ........... ..............................…………….…477.1 Types of Permit.................................................................... ..........….. .......…....….47

7.2 Procedure...............................................................…..…..…..…..…..……………….49

7.3 Permit Validity….....................................................................................................…50

7.4 Permit Suspension and Cancellation..........…........................................................50

7.5 Distribution, Administration and Display.................................................................50

8 Safety Inspections / Audits........... ................................ ........... ........... ........... ....51

8.1 Internal Safety Inspection...................................................... ..........….. .......…......51

8.2 External Safety Inspection / Audit............................................................ ..............51

8.3 Job Safety Analysis................................................................................................…52

9 Safety Orientation and Trainings ........... ........................ ........... ..........................53

9.1 New Employee Orientation............................................... ..........….. .......….....….53

9.2 Periodical Safety Training ................................................................ ............………53

10 Personal Protective Equipment............. ........... ................................ ........... ........54

10.1 Minimum requirement.......................................................... ..........….. .......…....…54

10.2 Additional requirements................................................................ ...........…………55

10.3 Suitability and Compatibility ..................................................................................57

10.4 Storage and maintenance..........…...........................................................………..57

11 Fire Safety and Emergency Preparedness............. ........... ................................ .58

11.1 In case of fire / emergency ................................................................. ..........…....5811.2 When fire alarm sounds................................................................ ............…………58

11.3 Causes of Fire and preventive measures..............................................................59

12 HSSE for Sub-contractors............. ........... ................................ ........... ........... .......59

12.1 General Guidelines.................................................................. ..........….. .......…....59

12.2 Format of declaration................................................................ ............…………59A

13 Rescue / Medical Treatment / First Aid... ........... ................................ ........... ....60

13.1 Equipment.................................................................... ..........….. .......….....……….60

13.2 Training................................................................ ............……………………………..62

13.3 Outside Medical Support.........................................................................................62

14 Commissioning safety..........................................................................…............…63

14.1 Planning................................................................................................….........…....63

14.2 Tank Farms............................................................................................................….63

14.3 Electrical....................................................................................................................64

14.4 Aisles, floors and Staircases ...................….........................................................….64

14.5 Fire Safety..............................................................................................................….65

14.6 Miscellaneous........ ................ .............................................................................….65



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1. Introduction

Indian Oiltanking Limited (IOT) is a 50:50 joint venture company of Indian Oil

Corporation Limited (IOC) and Oiltanking Gmbh (based in Hamburg, Germany).

IOC is the only Indian company listed in the Fortune 500. It has an overall market

share of around 57% in the petroleum sector. IOC operates 6 of India’s 15

refineries having a refining capacity share of nearly 35%. It owns and operates

nearly 80% of the domestic pipeline network of more than 5,000 kms and has an

extensive marketing network of more than 17,000 retail stations / agencies backed

by 178 depots and terminals and 35 LPG bottling plants. It also has nearly 70%

Aviation market share with 94 aviation fuel stations

Oiltanking GmbH is the world’s second largest independent terminalling services

company with the widest geographical presence with deep sea and inland

terminals and deepwater jetties in Europe, USA, South America and Singapore.

Oiltanking terminals cater to the requirements of various players in the international

petroleum sector like oil refining and marketing companies, global oil traders,

power and petrochemical plants and other bulk consumers.

IOT provides independent as well as dedicated Terminalling services and also

engineering and construction services to the petroleum sector in the country.

Independent terminalling is a specialised business of storage and handling of

petroleum products including crude and refined oils for multiple users like

petroleum companies, traders and direct users, remaining totally independentfrom refining, marketing and trading companies. IOT has introduced the concept

of providing customized Terminalling and construction solutions to the Indian Oil

Industry through various models – BOO, BO, BOOT and O&M.

The activities of the Company are broadly divided under the following business

segments:

Terminalling services from Owned Terminals

Construction of Terminals, Pipelines and related facilities

Engineering and Consultancy Services

Operations and Maintenance Services for Third Party Terminals



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1.1 Purpose

The Indian Oiltanking Limited is committed to provide its employees and

contractors with a safe working environment. The purpose of Safety Plan is the

provide project site personnel with the instructions, rules and guidance necessary

to provide a safe working environment.

Safety is everybody’s responsibility. Everybody concerned must co-operate whole-

heartedly in the promotion of safety and in the prevention of accidents i.e. each

of us should personally bear the responsibility to minimise and avoid accidents at

all costs in order to create and maintain safe work place.

The company will provide the adequate protective equipment with a view to

inculcate safety consciousness and awareness among all. Every one concerned

must at all times observe strictly the company’s HSSE Policy and the Govt. Safety

Legislation.

1.2 Scope and Applicability

All project sites and persons deployed thereto including subcontractors. It is the

intention that this manual will give the minimum requirements that are needed to

comply with international best practices, Indian Oiltanking Standards and the HSSEPolicy. The management of each Project Site should ensure that its organization

and work practices are in line with the document as displayed. Furthermore, the

manual should be used to educate employees and continuously improve the safe

and efficient completion of the project.

In countries without sufficient HSSE – related legislation this manual should be used

as a guideline to improve construction standards. In places with HSSE – legislation,

such legislation takes precedence over this document in case of contradicting

requirements.

Whilst it is anticipated that this manual will contribute to the development ofconsistent and effective practices and procedures, it should be appreciated that

it is not intended to be complete or comprehensive in nature. The responsibility to

prepare a complete set of documents and procedures, considering specific

requirements and all applicable local and international laws and regulations,

remains with the Project site management.



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Health, Safety, Security & EnvironmentalPolicy

Indian Oiltanking is committed to the safe and efficient operation of its facilities. Our goal is toprevent all accidents, injuries and occupational illness and to protect the environment. In order to achieve this, we will:

Promote Health, Safety, Security &Environment (HSSE) in all companiesand manage it in the same way as anyother critical business activity.

Be prepared for a quick and efficientresponse to emergency situations tominimise the potential impact of incidents should they occur.

Comply with all applicable laws andregulations and apply appropriatestandards where respective legislationdoes not exist.

Design, build and maintain facilitiesand utilize services in a manner toavoid risk to people and theenvironment.

Have a sound HSSE ManagementSystem, in which competencies,responsibilities and communicationchannels are clearly defined.

Provide training and job-specificeducation to all employees supportedby internal standards, procedures andinstructions.

Provide a safe and healthy work

environment for all employees andcontractors with adequate facilitiesand appropriate protective equipment.

Use energy and natural resources

efficiently, prevent pollution and raiseemployee’s awareness to minimiseadverse impacts on the environment.

Identify and analyse potential hazardsand security threats and implementmeasures to avoid, prevent, controland restrict the associated risks.

Set targets and benchmark our performance to achieve continuousimprovement and ensure compliancewith all applicable standards.

The management will visibly and rigorously support the implementation of this policy. We

expect the support of all employees, contractors and others working for us in order to make our HSSE performance one which will earn us the continuing confidence of our customers,neighbours and the community at large.

Hamburg, October 2004 Mumbai, October 2004

Gust Spaepen Jayanta Bhuyan Managing Director - Oiltanking GmbH Managing Director - Indian Oiltanking Ltd.



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2.1 HSSE Organization

Indian Oiltanking LimitedHSSE Organisation Chart

Project Sites

Project Manager

HSSE Department

HSSE Coordinator / Safety Officer (s)

Indian Oiltanking Corporate Center

Managing Director

HSSE Department

Manager - HSSE

2.2 HSSE Committee

Site HSSE Committee plays very important role in the field of Safety, Health &

Environment. It provides the platform for the functioning worker and management

jointly. Safety committee would meet periodically to review the company’s HSSE

programme and performance and recommended necessary steps for the

improvements.

The major function of the HSSE Committee shall be;

Identify unsafe acts & conditions and suggest remedies

Develop safety culture and comply with company’s HSSE policy

Enforce safety rules, procedures and accepted safe practices

Encourage and enforce the use of PPEs

Reduce hazards factor and to develop safe behaviour of all employees

Site HSSE Committee shall comprise of Project Manager as Chairman with

Members from each function viz. Mech., Elect., Civil, Procurement etc. The Safety

Officer / Safety Engineer shall be the Secretary of the Committee. The minimum

number of members of safety committee shall be 4 (Four). Site head / Supervisors

of subcontractors may also be included in safety committee meetings.



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3. Assignment of HSSE Responsibilities

3.1 Management

To provide necessary safety provisions and measures at the work site in

accordance with government safety legislation.

To provide and maintain a safe and healthy working environment at all

worksites.

To formulate and establish safety policy, rules, regulations, work practices,

standards etc.

To provide all levels employees with adequate safety equipment.

To organize and promote safety activities and campaigns to raise their safety

awareness.

To review safety issues and recommendations for the improvement of safety.

3.2 Supervisor

To implement the Company’s Safety Policy, particularly on work areas under

their direct charge, so as to provide and maintain safe working conditions

and practices for all workers.

To inspect working areas daily for potential hazards and make rectifications

to prevent accidents.

To conduct monthly safety talks/briefings and promote safety organize and

participate in any other safety activities to inculcate safety awareness

amongst workers.

To supervise and ensure that sub-contractors under their direct charge follow

the Company’s Safety Policy.

Conduct pep talk & exercise daily for workers.

To enforce safety rules and regulations ensuring that workers comply strictly to

safety.

To report and assist in the investigation of accidents, incidents and safety

violations to find out possible causes and take preventive measures.

Suitable PPE’s to be issued to workers working under their supervisor.



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3.3 Sub-Contractor

Providing its employees with required personal protective items like safety

shoes, hard hat, hand gloves, goggles, safety belts and other such items as

and when may be required to be used during deliverance of duties.

To provide list of such hazardous chemicals as required to be stored at the

job site and the MSDS of the same. Prior approval to be taken for the same.

To report immediately any injury, illness or first aid cases without fail to project

in-charge.

To be present or depute representative in safety meetings and depute

personnel to safety trainings as and when notified of.

To make themselves familiar with the job site and prevalent emergency

procedure, safety plans, safety procedures and practices including

positioning of emergency equipment.

3.4 Workers

To observe and comply with the Company’s safety rules and regulations all

times.

To use personal protective equipment, safety devices and other appliances

provided for his protection.

To maintain good housekeeping in the work area.

To participate in any safety promotion activities such as safety talks, group

meetings, training etc.

To report any unsafe act or condition to his supervisor immediately.

To strictly comply with safety work procedures and practice good safetyhabits so as to prevent injury to him self and others.

Learning and Practicing Safe Work Procedures.

Actively support and abide with all Health and Safety rules.



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Reporting of, and if possible correcting any Safety/Health Hazards they maynotice.

Contributing to incident/accident investigations when asked.

3.5 Security

Ensure that only authorize person enter the premises and are in possession of

valid I-cards, gate pass etc.

To keep a watch on IOTL’s property and ensure the intactness of fencing.

Control of the incoming and outgoing materials.

Ensure non-entry of prohibited items like lighters, matchbox, liquor, drugs,

firearms, and explosives in to the site.

Carryout searches if necessary



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4. Hazard Identificaton and Control

Hazard Activity Control

Muscle pain, strain Lifting

Proper equipment for the

task, exercise, Proper lifting

technique

Cuts, abrasions All

Proper equipment for the

specific job, Proper

personal protective

equipment, Enclosure

guards etc. are in place

Flying objects Drilling, Grinding

Proper equipment with

guards for the job, Personal

protective equipment

(Goggles, Gloves)

BurnsWelding, Grinding, Handling

of chemicals

Proper equipment, PPEs,

MSDS available for

chemicals

Inhalation of Air – Borne

Particles

Welding, Grinding, Drilling,

sandblasting, Handling of

chemicals, Demolition,

Ceiling tiles, Drywall etc.

Proper PPEs, MSDS

available, Look for

probability of dangerous

chemicals present in the

system

Falls, tripping All

Proper equipment use for

jobs, Use of PPEs

Electrical Shock

Use of power tools, working

around energized

equipment

Ensure proper tools withgrounding arrangement,

extension cords are in good

condition, look for wetness,

use of lockout & tagouts

Noise

Drilling, Cutting, Grinding,

hammering, Operation of

heavy vehicles

PPEs



Safety Plan




5. Safety Rules and Safe Work Practices

5.1 General Safety Rules

The construction site shall be considered a restricted area and unauthorised

entry into the site is strictly prohibited. Anyone found trespassing shall be

asked to leave the site immediately.

Photography shall be strictly prohibited unless express approval of project in-

charge

Smoking, the use of fires (naked flame or open fires) and the use of spark

producing equipment or tools are strictly prohibited except in approved

areas of the site with valid work permit. It should be noted that smoking is notallowed even when the permit for use of fire or hot work is given at the place.

No drugs, narcotics ,alcoholic drinks are allowed at site also the personnel

under infulence of the above shall not be allowed at site. To be in possession

of, or under the influence of drugs or alcohol is strictly forbidden.

It is the employee's responsibility to conduct himself/herself in a manner that

enables them to maintain a safe work environment for themselves and their

fellow workers.

Every effort must be made by the employee to keep the job sites clear ofscrap material and other hazards.

All employees should be aware of first-aid box locations and the names of

employees holding valid St. John Ambulance First-Aid certificates.

The Company reserves the right to take disciplinary action when an

employee refuses to abide by any safety rule/policy/procedure. The

disciplinary action may go as far as dismissal.

Horseplay of any degree is not permitted and will not be tolerated. There is to

be no fighting with or threatening of fellow employees.

Each employee should be familiar with the Emergency exits and Fire

Extinguisher in the work area.

All safety hazards observed are to be corrected or immediately reported to

your supervisor including any defects or damage to machinery, machine

parts, equipment, or tools.



Safety Plan




5.2 Hot Work

Common hazard involved in welding / cutting are sparks, molten metal, flyingobjects, harmful light rays, electrical shock etc. Hot work includes Welding,

Gas Cutting, Burning, Grinding, Soldering, Sand Blasting, Chipping, Riveting,

Drilling, Power Tools, IC Engine Operations, Open Flames etc.

A dry chemical type fire extinguisher shall be made availabe in work area.

A running water hose and responsible standby person is mandatory for

carrying out work in hazardous zone or in proximity of operating areas.

Adequate ventilation shall be ensured by opening manholes, and fixing a

shield or foreced circulation of air etc. while doing work in cofined space.

However flammable vapour concetration shall be verified beforehand.

All the adjoining drains / trenches should be cleaned / free from any organic

matter and should be covered suitably.

All opening / pipelines ends / manholes of tanks who could contain

flammable vapours should be properly blinded off if in vicinity of hot work.

Proper arragements for isolation / covering the area from the process side

may be necessary if work is being done in close vicinity of process activities.

Adequate measures for containment of spark produced should be taken

before starting of hot work.

Proper PPEs should be worn as per the requirement of specific job.

Ensure that only approved and well-maintained apparatus, such as torches,

manifolds, regulators, pressure indicators and pressure regulating valves and

acetyle generators are used for gas cutting.

All covers and panels shall be kept in place, when operating an electric ark

welding machines

Return earthing / ground cable should be provided directly to the equipment/ work piece being welded and both the ground and welding cables should

be intact and not cracked or worn out or with joints. The connection should

not be established indirectly through pipelines / structures / equipmet etc.

The welding recepticles shall be rated for 63A suitable for 415 V, 3-phase

system with a scraping earth. Recepticles shall have neceaary mechanical

interlocks and earthing facility.



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An energised electrode should never be left unattended and the power

source shall be turned off at the end of job.

Proper earthing of the welding machine itself should be ensured. The

connection of the welding cable with the output pole of the welding

machine should be done with proper fittings.

Electrode holder shall be of good quality with proper insulation. The welder

should never be allowed to weld when he is wet. Also the usage of proper

personal protective equipment shall be ensured.

Oil or paint drums (whether full or empty) shall be never be kept in vicinity of

the welding area.

All gas cylinders shall be shall be properly secured in upright position and

acetylene cylinders shall be turned and kept is such a way that the valve

outlet points away from oxygen cylinder and vice-versa.

Acetylene cylinder valve key shall be readily available at valve stem. When

not in use cylinder valves shall be kept closed.

Storage of cylinder (either full or empty) shall be done at cool, dry place

under shed. Filled and empty cylinders should be stored separately,

Acetylene and Oxygen cylinder should be stored separately.

Lighted gas torch should also never be left un attended. Also cylinder should

be kept well away from heat sources.

Flash back arrester shall be provided on the oxygen and acetylene cylinder

as an additional precaution.

Cylinders should be transported on trolleys and should never be dragged. All

cylinder should be checked for leakage, color coding and valve cap before

accepting. No cylinder should be accepted without proper color coding

and valve cap.

Hoses of the cutting torch should be properly coloured (red for acetylene

and black for oxygen) and of same length. The ligting of the torch shall be

done by friction lighter instead of machbox. Hoses shall be checked for

leakage before use. Also the hoses should not be dragged.

Lubricants should not be used in Oxy-acetylene cutting set.



Safety Plan




5.3 Confined Space Entry

Shut down, isolate (not just closing valves), depressurise and purge the vessel/ Tank / Confined space as per laid down procedure.

Entry inside teh vessel adn to carry out any job should be done after issuance

of valid permit only.

Ensure proper and accible means of exit before entry inside a confined

space

The number of persons allowed inside the vessel should be limited.

At least one person shall invariably act as standby at nearby exit / manway.

Before entering inside vessels underground or located at lower elevation,

probability of dense vapours accumulating nearby should also be

considered in addition to inside of vessel.

Ensure that O2 level shall be above 19.5% by volume in air. Also

simulteneously it should be ensured that no Hydrocarbon or toxic substances

( such as H2S) are present or are below permissible levels before entry and

the checks should be continued periodically during course of the vessel

entry. Otherwise use of online air respirators / SCBA (Self contained breathing

apparatus) with other personal protective equipment should be considered.

Barrication of the confined space should be considered during hoisting,

radiography, blasting, pressure testing etc.

Only use of 24 V DC flameproof lamp fittings should be used for illumination

inside confined spaces irrespective of the fact that all requisite checks and

gas freeing have been carried out.

Preferably compressed air driven tools should be used while working in

confined spaces or 24DC electically driven tools should be considered

instead.

Minimum PPEs, Safety Helmet, Safety Shoes and Safety belt with a guy line

shall be worn by every person entering confined space.

Don’t wear loose clothing whilst working in confined spaces.

In case of hot work going on the welding electrode holder / gas cutting

torches should be kept outside of the confined space immediately after

completing the job. Cylinders should also be kept outside of confined space.



Safety Plan




All cables , hoses, welding equipment etc. shall be removed from confined

space at the end of each work day, even if the work is to be resumed in the

same space next day.

To the extent possible sludge shall be cleared and removed from outside

before entering.

No naked light or flame or hot work such as welding, cutting and soldering

should be permitted inside a confined space or area unless it has been made

completely free of the flammable atmosphere, tested and found safe by a

competent person and a permit to that effect must have been obtained

prior to starting of work.

Communication should be always maintained between the worker and the

person standby.

5.4 Excavation, Trenching and Backfilling

All excavation work should be planned and the method of excavation and

the type of support work required shall be decided considering the following.

I. The stability of the ground;

II. The excavation will not effect adjoining buildings, structures, roadways;

III. To prevent hazard, the gas, water, electrical and other public utilities should

be shut off or disconnected if necessary,

IV. Presence of underground pipes, cables conductors etc.

V. The position of culvert / bridges, temporary roads and spoil heaps should bedetermined.

Before digging at the site, all excavation work should be planned and the

method of excavation and the type of support work required decided.

All excavation work must be supervised.

Sites of excavation should be thoroughly inspected

I. daily, prior to each shift and after interruption in work of more than one day;

II. after every blasting operation;

III. after an unexpected fall of ground;

IV. after substantial damage to supports;V. after a heavy rain, frost or snow;

VI. when boulder formation are encountered.

Safe angle of repose of particular type of soil while excavating trenches

exceeding 1.5m (5’) depth up to 3.0m should be maintained. Based on site

condition, proper sloping should be provided corresponding to the angle of

repose of the soil (usually 45 deg), and suitable bench of 0.5m width at every

depth of 1.5m of excavation in all soils except hard rock. Otherwise proper

shoring and strutting to prevent cave-in or slides.



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Local file: HSSE-03

As far as possible, excavated earth should not be placed within one meter or

the edge of the trench or half of depth of the trench, whichever is greater.

Don’t allow vehicles to operate too close to excavated area. Maintain

atleast 2m distance from edge of excavation. No load, plant or equipment

should be placed or moved near to the edge of exacvation where it is likely

to cause collapse and thereby endanger any person unless precautions such

as the provision of shoring or piling are taken to prevent the sides from

collapsing.

Adequately anchored stop blocks and barriers should be provided to

prevent vehicles being driven into the excavation. Heavy vehicles should not

be allowed near the excavation unless the support work has been especially

designed to permit it.

If an excavation is likely to affect the security of an structure on which persons

are working, precautions should be taken to protect the structure from

collapse.

Barricade of 1m height (with red and white band / self glowing caution

board) should be provided for excavations beyond 1.5m depth. Provide two

entries / exits for such excavation.

Necessary precautions should be taken for underground utility lines like

cables, sewers etc. and necessary approvals / clearances from theconcerned authorities shall be obtained before commencement of the

excavation job.

Water shall be pumped / bailed out, if any accumulates in the trench.

Necessary precautions should be taken to prevent entry of surface water in

trenches.

During rains, the soil becomes loose. Take additional precaution against

collapse of side wall.

In excavations where hazardous atmospheres have the potential to exist, theatmosphere must be tested before entry. If a hazardous atmosphere is found,

then Confined Space Entry section of this document should be followed.

Locations that are most likely to result in a hazardous atmosphere include

excavations in landfills, in other areas where there is significant

decomposition of organic materials, and in areas next to hazardous materials

storage areas.



Safety Plan




In case of blasting, follow strictly IS:4081-1986 & Indian Explosive Act and rules

for storage, handling and carrying of explosive materials and execution of

blasting operations.

All narrow trenches 4’ or more deep shall at all times be supplied with one

ladder for each 100’ lenght with a minimum of two.

Proper approach to be made to pit which is required to be back filled as well

as to the source of backfilling materials.

All vehicles engaged in backfilling to be provided with reverse horn.

Before pushing backward any vehicle to the spot of backfilling nearby area

to be cleared of workmen.

The point upto which a vehicle could be reversed should be clearly

demarcated preferably by lime or other suitable measures.

In case of backfilling in night proper lighting arragements to be made.

Proper PPEs (dust mask etc.) to be provided to workmen engaged in

backfilling.

5.5 Working at heights

General Provision

While working at a height of more than 2 meters, ISI marked safety belts shall

be used.

While working at a height of more than 2 meters, permit should be issued by

competent person before commencement of job.

Worker should be well trained on usage of safety belt including its proper

usage at the time of ascending / descending.

All tools shall be carried in tool kits to avoid their falling.

If the job is on fragile / sloping roof, roof walk ladders shall be used.

Provide lifeline wherever required.

Additional safety measures like providing Fall Arrester type safety belt, safety

net should be provided depending upon the site conditions, job

requirements.



Safety Plan




Keep working area neat and clean. Remove scrap material immediately.

Don't throw or drop material/equipment from height.

Avoid jumping from one member to another. Use proper passageway.

Keep both hands free while climbing. Don't try to bypass the steps of the

ladder.

Try to maintain calm at height. Avoid over exertion.

Avoid movements on beam.

Elevated workplaces including roofs should be provided with safe means of

access and egress such as stairs, ramps or ladders.

Access and egress to the work area should be properly made by means of

Ramps, stairs, ladders, scaffolds and platforms.

Stairs, Ladders, Platforms etc. should have preferred slope, handrail, mid rail,

toeboard & antiskid properties.

Safety belt / full body harness should be provided to the all workmen

involved in working at height more than 2m. Anchorage should be ensured

to a permanent structure.

In special circumstances fall arrester should be used when use of safety belt is

not practical.

Roof work

All roof-work operations should be pre-planned and properly supervised.

Roof work should only be undertaken by workers who are physically and

psychologically fit and have the necessary knowledge and experience for

such work.

Work on roofs shouldn't be carried on in weather conditions that threaten the

safety of workers.

Crawling boards, walkways and roof ladders should be securely fastened to

a firm structure.

Roofing brackets should fit the slope of the roof and be securely supported.



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Local file: HSSE-03

Where it is necessary for a person to kneel or crouch near the edge of the

roof, necessary precautions should be taken.

On a large roof where work have to be carried out at or near the edge, a

simple barrier consisting of crossed scaffold tubes supporting a tubing

guardrail may be provided.

All covers for openings in roofs should be of substantial construction and be

secured in position.

Roofs with a pitch of more than 10 should be treated as sloping.

When work is being carried out on sloping roofs, sufficient and suitable

crawling boards or roof ladders should be provided and firmly secured in

position.

During extensive work on the roof, strong barriers or guardrails and toe-boards

should be provided to stop a person from falling off the roof.

Where workers are required to work on or near roofs or other places covered

with fragile material, through which they are liable to fall, they should be

provided with suitable roof ladders or crawling boards strong enough and

when spanning across the supports for the roof covering to support those

workers.

A minimum of two boards should be provided so that it is not necessary for a

person to stand on a fragile roof to move a board or a ladder, or for any

other reason.

Work on tall chimneys

For the erection and repair of tall chimneys, scaffolding should be provided.

A safety net should be maintained at a suitable distance below the scaffold.

The scaffold floor should always be at least 65 cm below the top of the

chimney.

Under the working floor of the scaffolding the next lower floor should be left in

position as a catch platform.

The distance between the inside edge of the scaffold and the wall of the

chimney should not exceed 20 cm at any point.



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Catch platforms should be erected over;

a) the entrance to the chimney;b) Passageways and working places where workers could be

endangered by falling objects.

For climbing tall chimneys, access should be provided by:

a) stairs or ladders;

b) a column of iron rungs securely embedded in the chimney wall;

c) Other appropriate means.

When workers use the outside rungs to climb the chimney, a securely

fastened steel core rope looped at the free end and hanging down at least

3 m should be provided at the top to help the workers to climb on to the

chimney.

While work is being done on independent chimneys the area surrounding the

chimney should be enclosed by fencing at a safe distance.

Workers employed on the construction, alteration, maintenance or repair of

tall chimneys should not:

a) work on the outside without a safety harness attached by a lifeline

to a rung, ring or other secure anchorage;

b) put tools between the safety harness and the body or in pockets

not intended for the purpose;

c) haul heavy materials or equipment up and down by hand to or from the workplace on the chimney;

d) fasten pulleys or scaffolding to reinforcing rings without first verifying

their stability;

e) work alone;

f) climb a chimney that is not provided with securely anchored

ladders or rungs;

g) Work on chimneys in use unless the necessary precautions to avoid

danger from smoke and gases have been taken.

Work on independent chimneys should not be carried on in high winds, icy

conditions, fog or during electrical storms.

While working in suspended condition (painting etc.) in unavoidable

circumstances it should be ensured that a Fall Arrester system (with full body

harness) should be taken in to use and the work should be supervised closely.



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5.6 Power & hand tool operation

All portable tools are to be connected through control bus with ELCB.

All contractors should ensure proper Earthing of all electrical equipments

used by them. Suitable earthing pits must be made if required.

Examine electric cable for defects before use.

Do not ever insert free ends of wires into sockets and hold them in place with

matchsticks / other means. Always use industrial three pin plugs.

Check the RPM rating of grinding wheels. The RPM rating must be greater

than or same to that of the driver. Wheel guard should be used in proper

position before grinding. Also proper PPEs must be ensured (goggles & hand

gloves).

Do not tie electric cords to metal rods or nails.

No cable should run under the ground. It must run overhead at a 2 m height

to avoid pinch point and creating trip hazard

All tools and Tackles must be examined daily before commencing work and

record to be maintained.

Defective tools are to return to store.

All electrical tools must be inspected at regular intervals by an authorized

electrical person and record to be maintained.

The weight, size & type of tool should be selected to suit the job carried out.

The handles of tools should be intact and properly tightened. Split handles

should be replaced. To avoid slippage, grease and oil should be wiped off.

Insulated and non-conducting tools shall be tested for electrical resistance.

Wrenches should not be pushed but pulled. Chisels struck by others should be

held by tongs and not by hands.

Chipping should always be done away from self.

Hand tools should not be allowed to lie down on benches, scaffoldings etc.

from where they can fall. They should be properly stored.



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5.7 Handling and Lifting Equipment

There should be a well-planned schedule to ensure that all the liftingappliances and lifting gear are selected, installed, examined, tested,

maintained, operated and dismantled with a view to preventing the

occurrence of any accident;

All lifting appliances shall be examined by competent persons at frequencies

as specified in "The Factories act, 1948 and Rules made thereof" and records

maintained in specified Forms under Factories Rule (Applicability different in

different states).

Check thoroughly quality, size and condition of all lifting tools like chain pulley

blocks, slings, U-clamps, D-shackles etc. before putting them in use.

Safe lifting capacity of all lifting & handling equipment, tools and shackles

should be got verified and certificates obtained from competent authorities

before its use. The safe working load shall be marked on them.

Check periodically the oil, brakes, gears, horns and tyre pressure of all moving

equipments like cranes, forklifts, trailers etc as per manufacturer's

recommendations.

Check the weights to be lifted and accordingly decide about the crane

capacity, boom length and angle of erection.

Allow lifting slings as short as possible and check packing at the friction points.

While lifting/placing of the load, no unauthorised person shall remain within

the radius of the boom and underneath the load.

While loading, unloading and stacking of pipes, proper wedges shall be

placed to prevent rolling down of the pipes.

Control longer jobs being lifted up from both ends.

Only trained operators and riggers should carry out the job. While the crane ismoving or lifting the load, the trained rigger should be there for keeping a

vigil against hitting any other object.

During high wind conditions and nights, lifting of heavy equipments should be

avoided. If unavoidable to do erection in night, operator and rigger should

be fully trained for night signaling. Also proper illumination should be there.



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Allow crane to move on hard, firm and leveled ground.

When crane is in idle condition for long periods or unattended, crane boom

should either be lowered or locked as per manufacturer's guidelines.

Hook and load being lifted shall remain in full visibility of crane operators,

while lifting, to the extent possible.

Don't allow booms or other parts of crane to come within 3 meters reach of

overhead electrical cables.

No structural alterations or repairs should be made to any part of a lifting

appliance, which may affect the safety of the appliance without the

permission and supervision of the competent person.

Hoists

Hoist shafts should be enclosed with rigid panels or other adequate fencing

at:

a) ground level on all sides;

b) all other levels at all points at which access is provided;

c) all points at which persons are liable to be struck by any moving

part.

The enclosure of hoist shafts, except at approaches should extend wherepracticable at least 2mt above the floor, platform or other place to which

access is provided except where a lesser height is sufficient to prevent any

person falling down the hoistway and there is no risk of any person coming

into contact with any moving part of the hoist, but in no case should the

enclosure be less than 1mt in height.

The guides of hoist platforms should offer sufficient resistance to bending and,

in the case of jamming by a safety catch, to buckling.

Where necessary to prevent danger, adequate covering should be provided

above the top of hoist shafts to prevent material falling down them.

Outdoor hoist towers should be erected on firm foundations, and securely

braced, guyed and anchored.

A ladderway should extend from the bottom to the top of outdoor hoist

towers, if no other ladderway exists within easy reach.



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Hoisting engines should be of ample capacity to control the heaviest loadthat they will have to move.

Hoists should be provided with devices that stop the hoisting engine as soon

as the platform reaches its highest stopping place.

Winches should be so constructed that the brake is applied when the control

handle is not held in the operating position.

It should not be possible to set in motion from the platform a hoist, which is

not designed for the conveyance of persons.

Winches should not be fitted with pawl and ratchet gears on which the pawl

must be disengaged before the platform is lowered.

Hoist platforms should be capable of supporting the maximum load that they

will have to carry with a safety factor.

Hoist platforms should be equipped with safety gear that will hold the

platform with the maximum load if the hoisting rope breaks.

If workers have to enter the cage or go on the platform at landings there

should be a locking arrangement preventing the cage or platform from

moving while any worker is in or on it.

On sides not used for loading and unloading, hoist platforms should be

provided with toe-boards and enclosures of wire mesh or other suitable

material to prevent the fall of parts of loads.

Where necessary to prevent danger from falling objects, hoist platforms

should be provided with adequate covering.

Counterweights consisting of an assemblage of several parts should be made

of specially constructed parts rigidly connected together.

Counterweights should run in guides.

Platforms should be provided at all landings used by workers.

Following notices should be posted up conspicuously and in very legible

characters:



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a) on all hoists

on the platform: the carrying capacity in kilograms or other appropriate standard unit of weight;

on the hoisting engine: the lifting capacity in kilograms or

other appropriate standard unit of weight;

b) on hoists authorised or certified for the conveyance of persons:

on the platform or cage: the maximum number of persons to

be carried at one time;

c) on hoists for goods only:

on every approach to the hoist and on the platform:

prohibition of use by persons.

Hoists intended for the carriage of persons should be provided with a cage so

constructed as to prevent any person from falling out or being trapped

between the cage and any fixed part of the structure when the cage gate is

shut, or from being struck by the counterbalance weight or by articles or

materials tailing down the hoistway.

On each side in which access is provided, the cage should have a gate

fitted with devices which ensure that the gate cannot be opened except

when the cage is at a landing and that the gate must be closed before the

cage can move away from the landing.

Every gate in the enclosure of the hoist shaft which gives access from a

landing place to the cage should be fitted with devices to ensure that thegate cannot be opened except when the cage is at that landing place, and

that the cage cannot be moved away from that landing place until the gate

is closed.

Derricks

Stiff leg Derricks

Derricks should be erected on a firm base capable of taking the combined

weight of the crane structure and maximum rated load.

Devices should be used to prevent masts from lifting out of their seating.

Electrically operated derricks should be effectively earthed from the sole

plate or framework.

Counterweights should be so arranged that they do not subject the

backstays, sleepers or pivots to excessive strain.



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When derricks are mounted on wheels:

a) a rigid member should be used to maintain the correct distancebetween the wheels;

b) they should be equipped with struts to prevent them from dropping

if a wheel breaks or the derrick is derailed.

The length of a derrick jib should not be altered without consulting the

manufacturer.

The jib of a scotch derrick crane should not be erected within the backstays

of the crane.

Guy Derricks

The restraint of the guy ropes should be ensured by fitting stirrups or anchor

plates in concrete foundations.

The mast of guy derricks should be supported by six top guys spaced

approximately equally.

The spread of the guys of a guy derrick crane from the mast should not be

more than 450 from the horizontal.

Guy ropes of derricks should be equipped with a stretching screw or

turnbuckle or other device to regulate the tension.

Gudgeon pins, sheave pins and fool bearings should be lubricated

frequently.

When a derrick is not in use, the boom should be anchored to prevent it from

swinging.

Gin Poles

Gin poles should be;

a) be straight & consist of steel or other suitable metal;b) be adequately guyed and anchored;

c) be vertical or raked slightly towards the load;

d) be of adequate strength for the loads that they will be required to

lift/move.

Gin poles should not be spliced and if a gin pole is composed of different

elements, they should be assembled in conformity with their intrinsic material

strength.



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Gin poles should be fastened at their feet to prevent displacement in

operation.

Gin poles, which are moved from place to place and re-erected, should not

be taken into use again before the pole, lifting ropes, guys, blocks and other

parts have been inspected, and the whole appliance has been tested under

load.

When platforms or skips are hoisted by gin poles, precautions should be taken

to prevent them from spinning and to provide for proper landing.

Tower Cranes

Where tower cranes have cabs at high level, persons, capable and trained

to work at heights, should only be employed as crane operators.

The characteristics of the various machines available should be considered

against the operating requirements and the surroundings in which the crane

will operate before a particular type of crane is selected.

Care should be taken in the assessment of wind loads both during operations

and out of service. Account should also be taken of the effects of high

structures on wind forces in the vicinity of the crane.

The ground on which the tower crane stands should have the requisitebearing capacity. Account should be taken of seasonal variations in ground

conditions.

Bases for tower cranes and tracks for rail-mounted tower cranes should be

firm and level. Tower cranes should only operate on gradients within limits

specified by the manufacturer. Tower cranes should only be erected at a

safe distance from excavations and ditches.

Tower cranes should be sited where there is clear space available for

erection, operation and dismantling. As far as possible, cranes should be sited

so that loads do not have to be handled over occupied premises, over public thoroughfares, other construction works and railways or near power

cables.

Where two or more tower cranes are sited in positions where their jibs could

touch any part of the other crane, there should be direct means of

communication between them and a distinct warning system operated from

the cab so that one driver may alert the other of impending danger.



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The manufacturers' instructions on the methods and sequence of erection

and dismantling should be followed. The crane should be tested beforebeing taken into use.

The climbing operation of climbing tower cranes should be carried out in

accordance with manufacturers' instructions. The free-standing height of the

tower crane should not extend beyond what is safe and permissible in the

manufacturers' instructions.

When the tower crane is left unattended, loads should be removed from the

hook, the hook raised, the power switched off and the boom brought to the

horizontal. For longer periods or at times when adverse weather conditions

are expected, out of service procedures should be followed. The main jib

should be slewed to the side of the tower away from the wind, put into free

slew and the crane immobilised.

A windspeed measuring device should be provided at an elevated position

on the tower crane with the indicator fitted in the drivers' cab.

Devices should be provided to prevent loads being moved to a point where

the corresponding safe working load of the crane would be exceeded.

Name boards or other items liable to catch the wind should not be mounted

on a tower crane other than in accordance with the manufacturers'

instructions.

Tower cranes should not be used for magnet, or demolition ball service, piling

operations or other duties, which could impose excessive loading on the

crane structure.

Lifting Ropes

Only ropes with a known safe working capacity should be used as lifting

ropes.

Lifting ropes should be installed, maintained and inspected in accordance

with manufacturers' instructions.

Repaired steel ropes should not be used on hoists.

Where multiple independent ropes are used, for the purpose of stability, to lift

a work platform, each rope should be capable of carrying the load

independently.



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5.8 Scaffolding, Platforms and Ladders

General Requirements

Capacity

a) support own weight and 4 X the maximum intended load.

b) suspension rope & hardware, 6 X the maximum intended load.

c) stall load of scaffold hoist not to exceed 3 times its rated load.

d) designed by a qualified person and built and loaded to design.

Scaffold platform construction

a) Platforms fully planked or decked

b) no more than 1” gaps

c) scaffold platforms and walkways 18” wide

d) ladder jack, top plate bracket, roof bracket, and pump jack

scaffold at least 12” wide

e) guardrails and/or personal fall arrest systems for platforms and

runways not less than18” wide

f) Front edge of all platforms No more than 14” from the face of the

work, 3” from the face for outrigger scaffolds &18” from the face for

plastering and lathing operations

g) Platforms 10’ and less to extend at least 6” but not more than 12”

past support unless designed and installed and/or guarded properly

h) Platforms greater than 10’ no more than 18” past support unless

designed and installed and/or guarded properlyi) Each abutted end of plank shall rest on a separate support surface.

j) Overlap platforms not less than 12” only over supports, unless

restrained to prevent movement.

k) On direction changes, any platform on a bearer at other than a

right angle shall be laid first, and platforms which rest at right angles

over the same bearer laid second.

l) No paint on wood platforms, except edges that may be marked for

identification

m) Fully planked between front upright and guardrail support

n) No mixed scaffold components used unless compatible and

integrity maintainedo) No modification of mixed scaffold components unless a competent

person approves

p) No components of dissimilar metals unless approved by competent

person

Criteria for supported scaffold

a) Higher than 4:1 ratio restrained from tipping by guys, ties, or

equivalent.



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b) Guys, ties, installed per recommendations or at the closest

horizontal member to the 4:1 height

c) Bear on adequate foundationsd) Plumbed and braced

Criteria for suspended scaffold

a) Support devices, 4 X the imposed load.

b) Direct connections evaluated by competent person

c) Minimum lengths for suspension ropes on hoists

d) Tied to prevent swaying

e) Safety devices not used as platforms

f) the safety of workers should be safeguarded by an extra rope

having a point of attachment independent of the anchorage

arrangements of the scaffold;

g) the anchorage and other elements of support of the scaffold shouldbe designed and built in such a way as to ensure sufficient strength;

h) the ropes, winches, pulleys or pulley blocks should be designed,

assembled, used and maintained in line with local regulations.

i) Before use, the whole structure should be checked by a competent

person.

Access

a) Must have safe access, No access by cross braces

b) Bottom rung not more than 24” high

Usea) Never overload

b) No shore or lean-to scaffolds

c) Inspected by competent person

d) Immediately removed or repaired, braced if found substandard

e) Maintain clearance near powerlines

f) Erected, moved, dismantled or altered only under supervision of

competent person

g) No work on snow, ice covered platforms

h) Tag lines on swinging loads

i) Protect suspension ropes from heat, acid, sparks, abrasion etc.

j) No work during storms or high winds

Fall Protection

a) Required at 10 foot

b) Personal Fall Arrester System (PFAS) in lieu of guardrails on some

scaffolds

c) PFAS & guardrails on suspension scaffolds

d) Use crossbracing in lieu of top or midrails in suitable cases



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Falling object protection

a) Hardhats requiredb) Protect employees below

c) Barricades to exclude working below

d) Toe boards at edges of platforms

e) Allows panels and screens

f) Canopies may be used where suitable

Materials used in the construction of scaffolds should be stored under good

conditions and apart from any material unsuitable for scaffolds.

Couplers should not cause deformation in tubes. Couplers should be made of

drop forged steel or equivalent material.

Tubes should be free from cracks, splits and excessive corrosion and be

straight to the eye, and tube ends cut cleanly square with the tube axis.

A scaffold should never extend above the highest anchorage to an extent

which might endanger its stability and strength.

Loose bricks, drainpipes, chimney-pots or other unsuitable material should not

be used for the construction or support of any part of a scaffold.

Inspection should more particularly ascertain that:

a) the scaffold is of suitable type and adequate for the job;b) materials used in its construction are sound and of sufficient

strength;

c) it is of sound construction and stable;

d) that the required safeguards are in position.

A scaffold should not be erected, substantially altered or dismantled except

by or under the supervision.

Every scaffold should be maintained in good and proper condition, and

every part should be kept fixed or secured so that no part can be displaced

in consequence of normal use.

If out-rigger scaffolding is to be used, it should be specifically designed and

inspected before putting in use.



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Lifting appliances on scaffolds

When a lifting appliance is to be used on a scaffold;a) the parts of the scaffold should be carefully inspected to determine

the additional strengthening and other safety measures required;

b) any movement of the scaffold members should be prevented;

c) if practicable, the uprights should be rigidly connected to a solid

part of the building at the place where the lifting appliance is

erected.

Prefabricated scaffolds

In the case of prefabricated scaffold systems, the instructions provided by the

manufacturers or suppliers should be strictly adhered to. Prefabricated

scaffolds should have adequate arrangements for fixing bracing.

Frames of different types should not be intermingled in a single scaffold.

Scaffolding shall be erected on firm and level ground.

All members of metal scaffolding shall be checked periodically to screen out

defective / rusted members. All joints should be properly lubricated for easy

tightening.

Entry to scaffolding should be restricted.

Erection, alteration and removal shall be done under supervision of

experienced personnel.

Use of barrels, boxes, loose bricks etc., for supporting platform shall not be

permitted.

Erect ladders in the “four up-one out position”, Lash ladder securely with the

structure.

Using non-slip devices, such as, rubber shoes or pointed steel ferules at the

ladder foot, rubber wheels at ladder top, fixing wooden battens, cleats etc.

When ladder is used for climbing over a platform, the ladder must be of

sufficient length, to extend at least one meter above the platform, when

erected against the platform in “four up-one out position.”

Portable ladders shall be used for heights not more than 4mt. Above 4mt

flights, fixed ladders shall be provided with at least 24” landings at every 6mt

or less.



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Bamboo Scaffolding

In general, it should be avoided as far as possible. It should not be used in theunit/off-site areas and where hot work is to be done.

For construction and maintenance of residential and office buildings, situated

outside explosive licensed area, bamboo scaffold, if used, should conform to

provisions given in lS-3696 (Part 1)-1987.

5.9 Structural work, Laying of reinforcement, cementing & concreting

General Requirements

The erection or dismantling of buildings, structures, civil engineering works,

formwork, falsework and shoring should be carried out by trained workersonly under the supervision of a competent person.

Precautions should be taken to guard against danger to workers arising from

any temporary state of weakness or instability of a structure.

Formwork, falsework and shoring should be so designed, constructed and

maintained that it will safely support all loads that may be imposed on it.

Formwork should be so designed and erected that working platforms, means

of access, bracing and means of handling and stabilising are easily fixed to

the formwork structure.

Erection and dismantling of steel and prefabricated structures

The safety of workers employed on the erection and dismantling of steel and

prefabricated structures should be ensured by appropriate means, such as

provision and use of:

a) ladders, gangways or fixed platforms;

b) platforms, buckets, boatswain's chairs or other appropriate means

suspended from lifting appliances;

c) safety harnesses and lifelines, catch nets or catch platforms;

d) Power-operated mobile working platforms.

Steel and prefabricated structures should be so designed and made that

they can be safely transported and erected.

In addition to the need for the stability of the part when erected, the design

should explicitly take following into account:

a) the conditions and methods of attachment in the operations of

transport, storing and temporary support during erection or

dismantling as applicable;



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b) Methods for the provision of safeguards such as railings and working

platforms, and, when necessary, for mounting them easily on thestructural steel or prefabricated parts.

The hooks and other devices built in or provided on the structural steel or

prefabricated parts that are required for lifting and transporting them should

be so shaped, dimensioned and positioned as:

a) to withstand with a sufficient margin the stresses to which they are

subjected;

b) Not to set up stresses in the part that could cause failures, or stresses

in the structure itself not provided for in the plans, and be designed

to permit easy release from the lifting appliance. Lifting points for

floor and staircase units should be located (recessed if necessary)

so that they do not protrude above the surface;

c) To avoid imbalance or distortion of the lifted load.

Storeplaces should be so constructed that:

a) there is no risk of structural steel or prefabricated parts falling or

overturning;

b) storage conditions generally ensure stability and avoid damage

having regard to the method of storage and atmospheric

conditions;

c) racks are set on firm ground and designed so that units cannot

move accidentally.

While they are being stored, transported, raised or set down, structural steel

or prefabricated parts should not be subjected to stresses prejudicial to their

stability.

Every lifting appliance should:

a) be suitable for the operations and not be capable of accidental

disconnection;

b) be approved or tested as per statutory requirement.

Lifting hooks should be of the self-closing type or of a safety type and should

have the maximum permissible load marked on them.

Tongs, clamps and other appliances for lifting structural steel and

prefabricated parts should:

a) be of such shape and dimensions as to ensure a secure grip without

damaging the part;

b) be marked with the maximum permissible load in the most

unfavourable lifting conditions.



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Structural steel or prefabricated parts should be lifted by methods or

appliances that prevent them from spinning accidentally.

When necessary to prevent danger, before they are raised from the ground,

structural steel or prefabricated parts should be provided with safety devices

such as railings and working platforms to prevent falls of persons.

While structural steel or prefabricated parts are being erected, the workers

should be provided with appliances for guiding them as they are being lifted

and set down, so as to avoid crushing of hands and to facilitate the

operations. Use of such appliances should be ensured.

A raised structural steel or prefabricated part should be so secured and wall

units so propped that their stability cannot be imperiled, even by external

agencies such as wind and passing loads before its release from the liftingappliance.

At work places, instruction should be given to the workers on the methods,

arrangements and means required for the storage, transport, lifting and

erection of structural steel or prefabricated parts, and, before erection starts,

a meeting of all those responsible should be held to discuss and confirm the

requirements for safe erection.

During transportation within the construction area, attachments such as slings

and stirrups mounted on structural steel or prefabricated parts should be

securely fastened to the parts.

Structural steel or prefabricated parts should be so transported that the

conditions do not affect the stability of the parts or the means of transport

result in jolting, vibration or stresses due to blows, or loads of material or

persons.

When the method of erection does not permit the provision of other means

of protection against fall of persons, the workplaces should be protected by

guardrails, and if appropriate by toe-boards.

When adverse weather conditions such as snow, ice and wind or reducedvisibility entail risks of accidents, the work should be carried on with particular

care, or, if necessary, interrupted.

Structures should not be worked on during violent storms or high winds, or

when they are covered with ice or snow, or are slippery from other causes.



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If necessary, to prevent danger, structural steel parts should be equipped

with attachments for suspended scaffolds, lifelines or safety harnesses andother means of protection.

The risks of falling, to which workers moving on high or sloping girders are

exposed, should be limited by all means of adequate collective protection

or, where this is impossible, by the use of a safety harness that is well secured

to a strong support.

Structural steel parts that are to be erected at a great height should as far as

practicable be assembled on the ground.

When structural steel or prefabricated parts are being erected, a sufficiently

extended area underneath the workplace should be barricaded or guarded

Steel trusses that are being erected should be adequately shored, braced or

guyed until they are permanently secured in position.

Load-bearing structural member should not be dangerously weakened by

cutting, holing or other means.

Structural members should not be forced into place by the hoisting machine

while any worker is in such a position that he could be injured by the

operation.

Open-web steel joists that are hoisted singly should be directly placed in

position and secured against dislodgment.

While using spanners, hammers etc. at height, they should be tied with a rope

fixed to nearby structure so that it will not drop in any case of slip.

Loose bolts, nuts and tools must be kept in boxes and not on structures and

the boxes must have proper anchorage.

During structure erection only one signaler shall give proper signals. However

“STOP” signal should be obeyed whoever gives.

No person shall walk, stand or work beneath a suspended load.

Proper quality of pulley block should be used. In no case pulley block suitable

for fiber ropes should be used for steel wire ropes.

The structural members should be kept in orderly manner on the ground so

that they do not roll down while being handled



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Reinforcement

Ensure that workers use Personnel Protective equipment like safety helmet,

safety shoes, gloves etc.

Don't place the hand below the rods for checking clear distance. Use

measuring devices.

Don't wear loose clothes while checking the rods.

Don't stand unnecessarily on cantilever rods.

To carry out welding/cutting of rods, safety procedures/precautions as

mentioned in Hot work section of this document.

For supplying of rods at heights, proper staging and/or bundling to be

provided.

Ensure barricading and staging for supplying and fixing of rods at height.

For short distance carrying of materials on shoulders, suitable pads to be

provided.

While transporting material by trucks/trailers, the rods shall not protrude in

front of or by the sides of driver's cabin. In case such protrusion cannot beavoided behind the deck, then it should not extend 1/3rd of deck length or

1.5M which ever is less and tied with red flags/lights.

Concreting

Ensure stability of shuttering work before allowing concreting.

Barricade the concreting area while pouring at height/depths.

Keep vibrator hoses, pumping concrete accessories in healthy conditions

and mechanically locked.

Pipelines in concrete pumping system shall not be attached to temporary

structures such as scaffolds and formwork support as the forces and

movements may affect their integrity.

Check safety cages & guards around moving motors/parts etc. provided in

concreting mixers.



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Local file: HSSE-03

Use Personal Protective Equipment like gloves, safety shoes etc. while dealing

with concrete and wear respirators / dust masks for dealing with cement.

Earthing of electrical mixers, vibrators, etc. should be done and verified.

Cleaning of rotating drums of concrete mixers shall be done from outside.

Lockout devices shall be provided where workers need to enter.

Where concrete mixers are driven by internal combustion engine, exhaust

points shall be located away from the worker's workstation so as to eliminate

their exposure to obnoxious fumes.

Don't allow unauthorised person to stand under the concreting area.

Ensure adequate lighting arrangements for carrying out concrete work during

night.

Don't allow the same workers to pour concrete round the clock. Insist on shift

pattern.

During pouring, shuttering and its supports should be continuously watched

for defects.

Road work

Site shall be barricaded and provided with warning signs, including night

warning lamps at appropriate locations for traffic diversion.

Filled and empty bitumen drums shall be stacked separately at designated

places.

Road rollers, Bitumen sprayers, Pavement finishers shall be driven by

experienced drivers with valid driving license.

Workers handling hot bitumen sprayers or spreading bitumen aggregate mix

or mixing bitumen with aggregate, shall be provided with PVC hand glovesand rubber shoes with legging up to knee joints.

Mixing aggregate with bitumen shall preferably be done with the help of

bitumen batch mixing plant, unless operationally non-feasible.

At the end of day's work, surplus hot bitumen in tar boiler shall be properly

covered by a metal sheet, to prevent anything falling in it.



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5.10 Vehicle movement

Park vehicles only at designated places. Don't block roads to createhindrance for other vehicles.

Don't overload the vehicle.

Obey speed limits and traffic rules. Read the road ahead and ride to the left.

Always expect the unexpected and be a defensive driver.

Drive carefully during adverse weather and road conditions. Be extra

cautious at nights. Keep wind screens clean and lights in working condition.

All vehicles used for carrying workers and construction materials mustundergo predictive/preventive maintenance and daily checks

Driver with proper valid driving license shall only be allowed to drive the

vehicle

Routes shall be leveled, marked and planned in such a way so as to avoid

potential hazards such as overhead power lines and sloping ground etc.

While reversing the vehicles, help of another worker should be ensured at all

times

An unattended vehicle should have the engine switched off

Wherever possible one-way system shall be followed

Barriers/fixed stops should be provided for excavation/openings to prevent

fall of vehicle

Load should be properly secured

The body of the tipper lorry should always be lowered before driving the

vehicle off.

Signs/signals/caution boards etc. should be provided on routes .

Proper spark arrestors must be installed on the exhaust pipes of vehicles

entering to ISBL areas.



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Local file: HSSE-03

5.11 Radiography

During field radiography, nearby area around the radiation source should be

cordoned off.

If the field radiography is to be done at the same location repeatedly, it is

advisable to provide either a wire fencing around or a temporary brick

enclosure.

Special permission/permit should be taken for radiography from area-in-

charge.

As far as possible, field radiography should be done only during night time

when there is little or no occupancy there.

Radiation warning signals should be pasted all along the cordoned off area.

Entry into the restricted area by unauthorised persons should be strictly

prohibited during exposure.

The radiation level alongwith the cordon should be monitored by a suitable

and well-calibrated radiation survey meter.

All personnel working with radiography sources should wear appropriate

protective equipment and film badges issued by BARC.

Protection facilities such as manipulator rod, remote handling tongs, lead

pots, radiation hazard placards and means of cordon off shall be available

at each site.

The radiography source shall never be touched or handled directly with

hands.

The package containing radiography cameras and sources should never be

carried by public transport like bus, train etc.

Radiography sources and cameras, when not in use, should be stored inside

a source pit with lock and key arrangement as approved by BARC (Bhabha

Atomic Research Center). The storage room should preferably be located in

an isolated area of minimum occupancy and radiation level outside the

storage room should not exceed 0.25 mR/hr as per BARC Regulations.

In case of an accident (due to loss or of damage to radiography source),

action should be taken in line with BARC Safety Rules/Guidelines.



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5.12 Demolition

General provisions

When the demolition of any building or structure might present danger to

workers or to the public:

a) necessary precautions, methods and procedures should be

adopted, including those for the disposal of waste or residues;

b) the work should be planned and undertaken only under the

supervision of a competent person.

Before demolition operations begin:

a) structural details and builders' drawings should be obtained

wherever possible;

b) details of the previous use should be obtained to identify anypossible contamination and hazards from chemicals, flammables,

etc.;

c) an initial survey should be carried out to identify any structural

problems and risks associated with flammable substances and

substances hazardous to health. The survey should note the type of

ground on which the structure is erected, the condition of the roof

trusses, the type of framing used in framed structures and the load-

bearing walls;

d) a method of demolition should be formulated after the survey and

recorded in a method statement having taken all the various

considerations into account and identifying the problems and their solutions;

All electric, gas, water and steam service lines should be shut off and, as

necessary, capped or otherwise controlled at or outside the construction site

before work commences.

If it is necessary to maintain any electric power, water or other services during

demolition operations, they should be adequately protected against

damage.

As far as practicable, the danger zone round the building should beadequately fenced off and sign posted. To protect the public a fence 2m

high should be erected enclosing the demolition operations and the access

gates should be secured outside working hours.

The fabric of buildings contaminated with substances hazardous to health

should be decontaminated. Protective clothing and respiratory devices

should be provided and worn.



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Local file: HSSE-03

Where plant has contained flammable materials, special precautions should

be taken to avoid fire and explosion.

The plant to be demolished should be isolated from all other plant that may

contain flammable materials. Any residual flammable material in the plant

should be rendered safe by cleaning, purging or the application of an inert

atmosphere as appropriate.

Care should be taken not to demolish any parts, which would destroy the

stability of other parts.

Demolition activities should not be continued under adverse climatic

conditions such as high winds, which could cause the collapse of already

weakened structures.

To prevent hazards parts of structures should be adequately shored, braced

or otherwise supported.

Structures should not be left in a condition in which they could be brought

down by wind pressure or vibration.

Where a deliberate controlled collapse technique is to be used, expert

engineering advice should be obtained, and:

a) it should only be used where the whole structure is to come down

because it relies on the removal of key structural members to effecta total collapse;

b) it should only be used on sites that are fairly level and where there is

enough surrounding space for all operatives and equipment to be

withdrawn to a safe distance.

When equipment such as power shovels and bulldozers are used for

demolition, consideration should be given to the nature of the structure, its

dimensions, as well as to the power of the equipment being used.

If a swinging weight is used for demolition, a safety zone having a width of at

least one-and-a-half times the height of the building or structure should bemaintained around the points of impact.

Demolition of structural steelwork

All precautions should be taken to prevent danger from any sudden twist,

spring or collapse of steelwork, ironwork or reinforced concrete when it is cut

or released.

Steel construction should be demolished tier by tier. Structural steel parts

should be lowered and not dropped from a height.



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Local file: HSSE-03

5.13 Electrical connection / equipment

General Provisions

Only persons having valid licenses should be allowed to work on electrical

facilities.

No person should be allowed to work on live circuit. The same, if

unavoidable, special care and authorisation need to be taken.

Treat all circuits as "LIVE" unless ensured otherwise.

Electrical "Tag Out" procedure "MUST" be followed for carrying out

maintenance jobs.

Display voltage ratings prominently with "Danger" signs.

Put caution/notice signs before starting the repair works.

All electrical equipment operating above 250V shall have separate and

distinct connections to earth grid.

Proper grounding to be ensured for all switch boards and equipment

including Portable ones prior to taking into service.

Make sure that electrical switch boards, portable tools, equipments (like

grinding machine etc.) don't get wet during their usage. If it happens, stop

the main supply, make the tools dry and then only use them. Check proper

earthing.

All temporary switch boards/ KIOSKS put up at work site should be suitably

protected from rain and the level of same should be high enough to avoid

contact with water due to water logging.

Don't work wet on electrical system.

Don't overload the electrical system.

Use only proper rated HRC fuses.

Industrial type extension boards and Plug sockets are only to be used.

ELCB for all temporary connections must be provided. Use insulated 3-pin

plug tops.



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Local file: HSSE-03

All power supply cables should be laid properly and neatly so that they don't

cause hindrance to persons working and no physical damage also takesplace to the cables during various construction activities.

All Power cables to be properly terminated using glands and lugs of proper

size and adequately crimped.

Use spark-proof/flame proof type electrical fittings in Fire Hazard zones as per

area classification under relevant codes and standards.

Check installations of steel plates/pipes to protect underground cables at

crossings.

Don't lay unarmored cable directly on ground, wall, roof or trees. All

temporary cables should be laid at least 750 mm below ground and cable

markers should be provided. Proper sleeves should be provided at road

crossings. In case temporary cables are to be laid on wooden poles/steel

poles, the minimum cable heights should be 4.5 M.

Maintain safe overhead distance of HT cables as per Indian Electricity Rules

and relevant acts.

Don't connect any earthing wire to the pipelines/structures.

Don't make any unsafe temporary connections, naked joints/wiring etc.

Ensure that temporary cables are free from cuts, damaged insulation, kinks or

improper insulated joints.

Check at periodic intervals that pins of sockets and joints are not loose.

Protect electrical wires/equipments from water and naked flames.

Illuminate suitably all the work areas.

All switchboards should be of MS structure only and incoming source shouldbe marked.

Hand lamps should not be of more than 24V rating.

Fire extinguishers (DCP/CO2/Sand buckets) should be kept near temporary

switch boards being used for construction purposes. Don't use water for

fighting electrical fires.



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Local file: HSSE-03

Insulating mats shall be provided in the front and back end of switch boards.

All parts of electrical installations should be so constructed, installed and

maintained as to prevent danger of electric shock, fire and external

explosion.

Periodic checking/certification of electrical safety appliances such as gloves,

insulating mats, hoods etc. to be done/witnessed along with maintaining a

register at site signed by competent authority.

A notice displaying following, should be kept exhibited at suitable places:

a) prohibiting unauthorised persons from entering electrical equipment

rooms or from handling or interfering with electrical apparatus;

b) containing directions as to procedures in case of fire, rescue of

persons in contact with live conductors and the restoration of

persons suffering from electric shock; (including first aid procedures)

c) specifying the person to be notified in case of electrical accident or

dangerous occurrence, and indicating how to communicate with

him.

No other cables/pipes to be laid in trench used for electrical cables.

Utmost care should be taken while excavating Earth from cable trench to

avoid damage or any accident.

Sub-station floor cut-outs meant for switch board installations to be covered

wherever installation is incomplete.

NOTE: A Residual Current Operated Circuit Breaker (RCCB) or Earth Leakage

Circuit Breaker (ELCB), when installed, protects a human being to the widest

extent. RCCB or ELCB should be provided as per Indian Electricity Rules.

Inspection and maintenance

All electrical equipment should be inspected before taking into use to ensure

suitability for its proposed use.

At the beginning of every shift, the person using the electrical equipment

should make a careful external examination of the equipment and

conductors, especially the flexible cables.

Apart from some exceptional cases, where due precautions should be taken,

work on or near live parts of electrical equipment should be forbidden.



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Local file: HSSE-03

Before any work is begun on conductors or equipment that do not have to

remain live:a) the current should be switched off by a responsible authorised

person;

b) precautions should be taken to prevent the current from being

switched on again;

c) the conductors or the equipment should be tested to ascertain that

they are dead;

d) the conductors and equipment should be earthed and short-

circuited;

e) neighbouring live parts should be adequately protected against

accidental contact.

After work has been done on conductors and equipment, the current should

only be switched on again on the orders of a competent person after the

earthing and short-circuiting have been removed and the workplace

reported safe.

Electricians should be provided with approved and tested tools, and

personal protective equipment such as rubber gloves, mats etc.

All conductors and equipment should be considered to be live unless there is

a proof of the contrary.

When work has to be done in dangerous proximity to live parts the currentshould be cut off. If for operational reasons this is not possible, the live parts

should be fenced off or enclosed by qualified staff from the sub-station

concerned.

Testing

Electrical installations should be inspected and tested and the results

recorded.

Periodic testing of the efficiency of the earth leakage protective devices

should be carried out.

Particular attention should be paid to the earthing of apparatus, the

continuity of protective conductors, polarity and insulation resistance,

protection against mechanical damage and condition of connections at

points of entry.



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Local file: HSSE-03

6. Accidents / Incidents, their Reporting and Investigation

All Project sites shall keep records of work accidents resulting in first aid treatment or in

medical treatment. This applies to all incidents on the facility with regard to Indian

Oiltanking employees (Engineers, operators and o1fice personnel) and third parties

(contractors, inspectors, visitors etc.).

6.1 Internal Reporting

All near misses, Incidents & accidents shall be reported through prescribed

format. It is the responsibility of all Indian Oiltanking employees and

contractors on the facility to ensure that all near misses, Incidents & accidents

are reported to their supervisors. The supervisors must ensure that those then

are reported to the HSSE Coordinator and / or the Project Site Manager. This

applies to all Indian Oiltanking Project sites world-wide.

Copies of all the reports shall be sent to corporate office.

6.2 External Reporting

Notification of accidents or dangerous occurrences to external authority is

legally to be done by the factory manager designate of the facility to the

authorities under the local regulations within stipulated time limits. If the

facility where project work is under progress falls under jurisdiction of client or

other agency, reporting to the authority shall be undertaken by them itself. Insuch cases, accident forms of the such agency should also be filled.

If the facility being worked is under license to IOTL, the factory manager

designated shall be responsible for external communication according to

local regulation i.e. Factories Rules of that state. For accidents and

dangerous occurrences involving licensed premises under CCOE, the

intimation of the accidents should also be given accordingly in addition to

the guidelines under local factory rules.

HSSE Coordinator is responsible for the regular communication to third parties

like local authorities, fire brigades, medical centre, hospitals, mutual aidorganizations, contractors, client HSSE Dept. etc.

6.3 Incident Investigation

All accidents reported shall be initially investigated by HSSE Coordinator ASAP

and upon the seriousness and local requirements a decision for a full fledged

investigation shall be taken jointly by HSSE Coordinator and Profit Center

Manger. Reports of such investigation shall be forwarded to corporate office.



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Local file: HSSE-03

6.4 Corrective Actions and Follow-up

All accidents and incidents shall be discussed in the routine HSSE Meetings.

Lessons to be learned and progress with follow-up corrective actions should

be covered during the discussion.

The HSSE Coordinator should report in the HSSE Committee Meetings all major

and high potential loss accidents and incidents that have occurred since the

previous meeting. Progress of the follow-up actions should also be discussed.

Supervisors should discuss accidents and incidents occurring within their areas

and those relevant from other areas at the day-to-day briefing meetings.

A "HSSE Alert" (Fomrat no. GD-007), which is a document alerting others to the

probable causes of an accident/incident and which provides advice on

preventing a recurrence, will be provided by the Corporate HSSE Department

or prepared by the HSSE Coordinator. He must obtain approval of the Senior

Manager before an internal HSSE Alert of any occurrence is distributed or

discussed in safety meetings.

The HSSE Coordinator should prepare in co-operation with the Project

Manager, a monthly follow-up/progress report on outstanding

recommendations.



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Local file: HSSE-03

7. Permit to work system

The permit-to-work system is an administrative control and communication system

designed to clearly identify the various scopes of work to be carried out on the

Project site and their associated hazards to prevent accidents, fire and

equipment damage.

The permit-to-work system covers all the construction work on the Project site

which may create potential hazards. Any work carried out on site must be

covered by a work permit issued by Permit Approving authority.

The Project Site In-charge has the overall responsibility to ensure that the permit-to-

work system is practiced in accordance with it’s purpose and intent and to review

the system periodically to assess the effectiveness of the system and make

necessary adjustments to improve the system.

7.1 Types of permits

Cold Work Permit

Any work carried out within the site must be covered by a work permit issued

by concerned department or area incharge.In addition a clearence must be

obtained from concerned department’s officer before commencement of

job.

Hot Work Permit

Hot work includes oxy-acetylene cutting, electric arc welding, drilling,

chiselling, chipping, hacksawing and any other work requiring the use of a

naked flame or heat generation, and work on electrical systems.

Whenever possible hot work is to take place in an allocated safe area

preferably outside the Operational area if any on site. Sections of pipeworks

for modification, for instance, can be unbolted and removed to a safe area.

In the event that the hot work must be carried out in the operational area,reasonable precautions will be taken. Additional fire fighting equipment such

as fire hoses and dry power extinguishers shall be available. The presence of

a safety officer (from the contractor) at the work site at all times is preferred.

A suitable permit shall be taken to this effect as per the procedure laid down.



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Confined Space Entry Permit

Storage tanks are the main reason for confined space entry, but other confined spaces can be floating roofs, Oil Water Separators, boilers, water

storage tanks, drain dumps, sewers, reactors, vessels and excavated pits. An

otherwise harmless excavation can be rendered lethal by ground hugging

gasses, ingress of toxic or flammable liquids leaking from the ground.

Before sanction entry to a confined space, an assessment of the work area

must be made. Much greater care is to be taken where confined space

would under normal circumstances appear innocuous. Examples are water

tanks and excavations.

Before completion of a Confined Space Entry Permit, the space is to tested

for:a) Oxygen Content, Explosive Vapour &, Toxic Vapour (H2S etc.)

The normal oxygen in air content is between 20% and 22% and any readings

outside this range is to be treated as suspect and investigated. However in no

case O2 contents shall be less than 19.5%. With respect to the explosive

vapour reading, any reading above zero is to be regarded as positive.

Excavation Work Permit

For carrying out excavation at the site the permit shall be obtained. The

permit shall be considered valid only when it is signed by authorized person ofIOTL in addition to other signatories like HSSE Coordinator, Civil Engineer, The

electrical section and engineer incharge of area where excavation is to be

carried out.

Working at height permit

While working at height at more than 2m from floor level permit has to be

obtained for working at height duly approved by competent authority.

Permit to work on electrical apparatus

Work carried out on electrical equipment, connected to an electrical power

source exceeding 230 volts AC shall be de-energized. The details of the

electrical isolation must be included on the relevant Permit issued for the

work. Before any mechanical work is carried out on machinery driven by an

electrical motor, the motor must be electrically isolated and a ‘Do Not

Operate’ signboard shall be displayed at the local start button and

confirmed isolated by pressing the button.



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7.2 Procedure

Permit Application

The contractor who is responsible for the work which requires a work permit

will fill out the APPLICATION part of the permit from stating the scope of work,

equipment number, work location, etc. Prior discussion with the contractors

who are performing the work must be held to ensure that they understand

the job scope and safety precautions.

Permit Approval

The Permit Approving Authority (may be IOTL’s representatives in site wholly

controlled or the clients representative in other cases) will review the

application with the contractors before issuing the permit. If the work has apotential to create hazards in the Project site such as welding job, the Permit

Approving Authority shall specify all necessary safety precautions to be taken

and visit at the work site to ensure that all such requirements are complied

with before issuing the permit.

Confirmation and Acceptance of Permit Conditions

The Permit applicant and the Approving Authority must arrange for a site visit

to confirm that all preparation works are completed and the permit

conditions have been maintained. General conditions such as adequate

emergency escape route, fire fighting equipment, emergency shower stations, personal protective equipment, and barricading of work area shall

be confirmed.

Commencement of Work

Upon confirmation of site conditions and all parties concerned are satisfied

with the safety precautions to be taken, the work shall be commenced with

close monitoring by the permit applicant as the operating conditions in the

Project site may change making the site conditions unsafe. In areas of major

concern or proximity to process, a dedicated fire watch shall be deputed

during the job.

Job Completion and Acceptance

It is essential that when the job is completed, the permit applicant must sign

off the work permit and returns it to the Approving Authority indicating

whether the job has been completed satisfactorily so that site check can be

carried out to ensure that the site has been brought back to a safe condition

e.g. all pipeline connections are properly secured and fixed in position for

decommissioning and all housekeeping has been completed.



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Local file: HSSE-03

7.3 Permit Validity

Hot Work Permits should only be valid for a specific period of time as

mentioned in permit and in all cases be expired at the end of one working

shift from the time of approval. The expired Hot Work Permit can only be

extended if the safety conditions are maintained through physical

confirmation by the in-coming or new shift team members together with the

contractor.

Cold Work Permits should also be valid for a specific period of time. Under

special circumstances, the Operations Manager or his deputy may authorise

that Cold Work Permits be allowed to run up to six days so long as they are

closed on last working week day whichever is earlier. The area where Cold

Work Permits are allowed to run for extended period must be clearly defined.

Approving Authority must ensure that the special condition is communicated

to all shifts. The contractors are informed that the Permits are limited to the

defined area.

7.4 Permit Suspension and Cancellation

If there is an emergency such as fire outbreak in the site, all work permits

issued will be automatically suspended and work must be stopped until

clearance is given by the permit approving authority before work can be

resumed. If the safety conditions established have changed due to theemergency, the work permit should be treated null and void and a fresh one

should be re-issued if work is to be resumed after the emergency is called off.

Approving authority, HSSE Coordinator or any responsible person can

suspend / cancel the permit if it is perceived to be in violation with the

conditions stipulated in the permit. A fresh permit has be issued before work

can resume again with due precautions.

7.5 Distribution, Administration & Display

For hot work / vessel entry / excavation & height permits original to be givento receiver, 1st copy to HSSE Coordinator / dept. and 2nd copy retained by

issuer (Permit Approving Authority). All these permit shall be displayed at site.

For cold work permits the original to receiver and the copy to be retained .

At the end of the day or when permitted work is completed (which ever is

earlier), the original copy of the permit issued to applicant in charge of work

is to be returned to Permit Approving Authority.



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8. Safety Inspections / Audits

A schedule of regular inspections / audits not only improves specific process unitconditions, but also supports a consistent approach to health and safety issues

throughout the project site. The safety audit has two purposes. First, it serves as a

tool for management to ensure that covered operations are in compliance with

the safety as well as other environmental regulations. In addition, the audit allows

management to perform a "real-time" check on the safety of its operations. A

safety audit should also include a written report with recommendations, and a

management response. Actions taken should be to address and correct

deficiencies identified in the report.

8.1 Internal Safety Inspections

The HSSE Committee shall ensure that a minimum of one HSSE CommitteeInspection per month is carried out. A written report will be completed during

inspections.

These inspections will consist of, but not be limited to the following:

a) A thorough physical inspection of the premises with particular

attention paid to; housekeeping, chemical storage, machine

guarding, work station layout, lighting, preventive maintenance,

and equipment and tools.

b) Observation of jobs, with particular attention being paid to: Personal

Protective Equipment, safe job procedures, and discussing any

noted deficiencies with employees involved.

Whenever possible, any dangerous or hazardous situations or deficiencies will

be corrected at the time of inspection. Whenever this is not possible, written

recommendations will be submitted as audit report.

An inspection checklist may be prepared for specific locations to facilitate

internal audits in structured way.

HSSE-Coordinator should carryout daily routine inspection of the site to

correct any dangerous / hazardous situation.

8.2 External Safety Inspections / Audits

External Safety audits / inspections should carried out of the site on random

basis preferably quarterly by IOTL HO. Necessary reports shall be made for

corrective actions and records.

External audits may also be carried out by clients on their sole desertion.

Other audits may also be arranged from external agencies as per

requirement. Compliance of all external audits reports shall be documented.



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8.3 Job Safety Analysis

There are four main steps in Job Safety Analysis. First, the job to be analyzedmust be selected. This selection is base upon the severity of potential losses,

the frequency at which the task is performed and the probability of loss when

the task is performed. The job safety is then broken down in to a sequence of

steps. Potential hazards are identified at each step. Method to control or

eliminate each hazards are then developed and implemented.

Some factors that will influence priority for the selection of jobs for Job Safety

Analysis include;

a) The frequency and severity of accident and incidents that have

occurred.

b) Introduction of new tasks, processes or operations

c) Change to existing tasks, process or operationsd) The frequency at which the task is performed

e) The severity of potential losses.

f) The probability of potential losses

Selection of jobs for initial job safety analysis will be done jointly by the HSSE

Committee. The diversity of our operations and the many clients location at

which we work dictates that it is probably impossible to analyze every job. It is

the company’s intention to analyze as many jobs as possible beginning with

those that could result in severe potential losses.

All JSA’s will be reviewed yearly by the HSSE Committee

The job safety analysis may be used as a basis for safe work procedures. It

identifies tools and personal protective equipment requirements for specific

tasks. It provides information on physical demands associated with the work

activity. Supervisors will use the JSA’s as a documented standard during Job

Training, during investigation of accidents and incidents, safety inspections

and auditing of safe task performance. In terms of accident prevention it is

therefore a pro active tool.

It is the responsibility of the Project Manager to ensure that JSA’s are

completed as required, and that all job safety analyses are revised /updated whenever there is a change in the process / task / operation.

Copies of all JSA’s will be forwarded to HO for records and review.

Copies of all JSA’s will be kept in a convenient location available to all

concerned.



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Local file: HSSE-03

9. Safety Orientation and Trainings

Training must meet the needs of a project site in addition to complying with all

National / Local requirements; specific training needs may include safe working

procedures, fire fighting, evacuation, implementation of health and safety for

construction work, workplace emergencies and first aid procedures.

9.1 New Employee Orientation

As well, inexperienced workers are generally involved in more accidents than

veteran workers. Although experience increases safety awareness, early

education in health and safety and job skills can improve the safety record for

new workers right from the start.

A brief safety induction module for workers, supervisors and engineers shall

include but not limited to;

a) Company’s HSSE Policy

b) Safe working procedures

c) When and how to use personal protective equipment

d) Emergency procedures

e) Electrical safety

f) Hazards in jobs

g) Incident & accident reporting procedure

h) Reporting of substandard conditions, unsafe conditions and unsafeacts.

i) Health & Hygiene

j) Housekeeping

Additional to the above Supervisors and Engineers shall be also trained in.

a) Risk analysis (JSA)

b) Work permit system in detail

9.2 Periodical Safety Training

Periodical Safety Training will be conducted for engineers, supervisors, Trademen and worker on “construction site safety”. The training will contain but not

be limited to; Site planning and layout, Excavation, Scaffolding, Ladders,

Height work, Site erection, Demolition, Confined space, Material Movement,

Welding and Cutting, Electrical equipment, Hand Tools, P.P.E. etc.



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Local file: HSSE-03

10. Personal Protective Equipment

Operations always imply potential health hazards. As it is not possible to treat

every possible danger by appropriate design measures suitable PPE must be used

to prevent injuries.

10.1 Minimum Requirement

Every person entering the Restricted Area of a Project site shall be in

possession of minimum PPE. For Indian Oiltanking operational personnel

requiring PPE this equipment will be provided. For visitors helmets and shoes

are to be provided as a lend out. It is every contractor's own responsibility to

ensure that his personnel is in possession of the necessary PPE.

In every case all PPE used must be conform to local standards or EN

(European Norm) or ANSI (American National Standard Institute). All PPE to be

worn shall be approved by the HSSE Coordinator.

Head Protection

Safety helmets shall be worn at all times during the stay inside the Restricted

Area of a Project site.

The use of labels is discouraged, as the adhesives may affect the helmet'smaterial. Safety helmets made of plastic shall be replaced every three years.

Any helmet damaged or exposed to heavy impact whether damage is

apparent or not shall be replaced immediately.

Foot Protection

Safety footwear shall be worn at all times in the Restricted Area of a Project

site. It must be worn at least when operational, maintenance, construction,

demolition or inspection work is being carried out.

Shoes should be of better construction and must be antistatic if the work isbeing done in close proximity of process areas.

Body protection

Body protection shall be worn to prevent injuries caused by absorption of

hazardous chemicals, severe cuts or lacerations, severe abrasions, punctures

and harmful temperature extremes.



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Local file: HSSE-03

Cotton clothing or clothing made from other antistatic materials (e.g.

Nomex) are preferred over other type of work clothings.

No nylon or purely synthetic fiber cloths should be worn in proximity of process

areas.

Work clothes for operators shall be clean and properly fastened with cuffs

secured to prevent loose clothing becoming caught in moving or rotating

machinery. Loose clothing must not be worn.

Clothes contaminated with oil, chemicals or toxic substances may be a fire

hazard or lead to skin disease or other illnesses and shall be laundered.

Hand Protection

Gloves made from cotton or fabric blends shall be worn to improve grip

when handling slippery objects. They also insulate hands from mild heat or

cold. While executing tasks that could cause injuries from sparks or scraping

against rough surfaces, leather gloves shall be worn. It is recommended to

use gloves with a combination of both materials.

10.2 Additional requirement

The HSSE Coordinator shall ensure that a formal assessment has been

conducted for all activities to ascertain the need for further PersonalProtective Equipment for the employees. An assessment of physical hazards

and of the hazardous materials being handled shall be made and shall draw

up schedule of the PPE required for each operation. Sufficient PPE shall be

available in the sizes necessary to enable at least one change of outer

clothing and two changes of underclothing if necessary. There shall also be

sufficient PPE for immediate rescue operations. The activities of the sub-

contractors regarding the selection and use of PPE shall be monitored by the

HSSE Coordinator.

Head Protection

Additional requirement in head protection may be welding helmets as well

as special helmets for working under high voltage lines.

Foot Protection

Additional foot protection for electrical hazards (people working with HV

equipment may be required. Other requirements may be due to corrosive or

other hazardous material requiring suitable protection.



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Hand Protection

Requirement of disposable gloves for first aid treatment, use of rubber / nitrilegloves while dealing with corrosive chemicals, asbestos gloves while working

with high temperature equipment etc.

Body protection

Additionally for working with corrosive chemicals where there is a chance of

material spilling on to body, full protection of body by wearing full body

chemical suits may be necessary. At the same time proximity suits may be

required for working in close proximity of high heat radiating atmosphere and

fire fighting. Flash fire proof suits come handy when work is to be done in such

area where a flash fire may be anticipated in extraordinary situations.

Eye and Face protection

Safety goggles must be worn while performing construction activities like

Grinding, Gas cutting, Sand blasting etc. Other face protection requirements

includes welding (welding face shield), Splash of chemicals (full face shield)

and spray protection ( safety glasses)

It must be understood that ordinary glasses do not provide protection against

special hazards.

Hearing Protection

Regular exposure of employees to noise, particularly in the workplace, can

result in damage to hearing. In order to safeguard the hearing of employees

engaged in operations that involve exposure to noise. In high noise area

where noise exceeds 85 dBA (for 8 hrs shift), suitable hearing protection by

virtue of using either ear plugs or ear muffs as per requirement.

Respiratory Protection

Areas having either heavy dust or chemical vapours may require use of

suitable respiratory protection. For need of the same work zone monitoringmay be considered for identification of areas requiring such protection. Dust

mask for dust protection and cartridge type filter mask to be used for specific

chemical vapors as per suitability.

Continuous air line or Self Contained Breathing Apparatus may be required

while performing work in oxygen deficient or toxic atmosphere. The normal

filter type masks shall never be used for such applications.



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Local file: HSSE-03

10.3 Suitability, Compatibility & Training

Personal Protective Equipment is not suitable unless it;

a) is appropriate for risks involved ar\d conditions at the place of

exposure.

b) takes account of ergonomic requirements and the state of health

of the person who wears it.

c) is capable of fitting the wearer correctly.

d) is effective to prevent or adequately control risks involved without

increasing the overall risk.

Where more than one item of PPE is; used, it must be compatible with other

items used at the same time. This has to be checked by the HSSE

Coordinator.

The HSSE Coordinator shall provide adequate information, instruction and

training to enable users of PPE to know:

a) the risks which personal protective~ equipment will avoid or

minimise.

b) the purpose for which and manner in which personal protective

equipment is to be used.

c) any action which the employee might take to ensure that personal

protective equipment remains effective and in good condition.

10.4 Storage and maintenance

For IOTL employees, HSSE Coordinator shall be responsible for storage and

issuance of PPEs.

The sufficient inventories of PPEs shall be maintained and records kept and

updated regularly.

There shall also be sufficient PPEs for immediate rescue operation as well as

for emergency use.

Responsibilities of maintenance of the PPEs and at the same time getting itreplaced when these are not suitable for further use rests with the individual

issued with such PPEs.

HSSE Coordinator shall approve the quality of the PPEs being used.

Preferably a display of available PPEs may be made in showcase to enhance

the awareness and usage of the same.



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Local file: HSSE-03

11. Fire Safety and Emergency Preparedness

11.1 In case of fire / emergency

Alert the persons nearby by shouting fire! fire! fire!

If there is a fire alarm system, activate fire alarm or inform any nearby person

to do so. Or arrange to inform the control room / project in-charge / HSSE

Coordinator / Other emergency response teams by available means (phone

/ messenger / walky talky / PA System etc.)

Confirm the location, type & magnitude of fire / emergency.

Try to extinguish the fire with available means (fire extinguishers, fire hoses

etc.) from upwind direction, if the same can be done without endangering

yourself.

Guide the emergency response personnel with the information.

Don’t venture in to rumour spreading or unauthorized statements to outside

agencies.

11.2 When fire alarm sounds

Generally emergency sirens / fire alarms are continuously sounding warbling sirens

(on – off – on – off )

Essential personnel

Persons, whose services may be required during emergency, shall report

directly to the project incharge or the person incharge of response

operations.

Non essential personnel

Stop work immediately.

Switch off all electrical equipment and welding machines.

Proceed immediately to assembly area.

Wait for further instructions from authorized personnel.



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11.3 Cause of Fire and preventive measures

Main causes of fire during projects may be summerised as;a) Careless gas cutting / welding

b) Smoking

c) Throwing lighted matches

d) Uncontrolled rubbish burning

e) Incorrect storage and careless use of flammable liquids and

compressed gases

f) Electrical sparks (loose cabling, wet electrical equipment etc.)

g) Electrostatic discharges

Main preventive / protective measures should be taken are

a) Nobody shall be allowed to misuse or horse play with the

emergency equipment.b) Demonstration on the usage of fire extinguishers shall be arranged.

c) Fencing of loading areas like flammable stores, paint oil storage

and other combustible material storage with “no smoking or naked

flames” sign. Also such areas to be kept free of dry grass /

vegetation.

d) Fire extinguishers shall be conspicuously located and the personnel

should be trained in the use of the same.

e) All hot work shall be routed through permits and thoroughly

inspected and supervised.

f) All electrical equipment shall be of sufficient rating and the junction

boxes, fuse units properly closed and located at sufficient heightfree from dry grass / vegetation in close vicinity. Cable running

either underground or at sufficient heights.

12. HSSE for Sub-contractors

12.1 General guidelines

No Sub-contractor is allowed to begin a job for IOTL until they have provided

proofs of compliance to statutory requirements which shall include but not be

limited to the following. (PF, Labour License, Insurance, WC policy)

Before a Contractor begins work, the Project Manager or his designate, will

meet with the Contractor, or his representative and explain the applicable

Company Safety Policy and Procedures.

Ensure the contractor has an Employee designated to be responsible for HSSE

As a minimum standard, all Sub-contractor’s employees must wear shoes and

hard hats while at our job site. Other PPEs at discretion of management may

also be required.



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Local file: HSSE-03

Sub-contractors must report all injuries occurring to their employees while onour job sites to our Project Manger or his designate. We will keep a record of

such injuries.

All our employees working in areas where work is being performed by Sub-

contractors will be advised of their presence. Our employees should also be

cautioned of any hazards that may exist because of Sub-contractor’s work.

Sub-contractor staff must be present for, and participate in IOTL pre

construction safety meetings and subsequent safety meetings and trainings

as and when called for.

Sub-contractors shall provide a list of any chemical / toxic substance they

plan to bring onto our job site. Only after the MSDS have been reviewed by

our HSSE committee, will permission be given to proceed with their use. All

empty containers and / or left over substances will be removed by the Sub-

contractor.

The Sub-contractor will become familiar with IOTL job site first aid facilities.

The Sub-contractor will become familiar with IOTL Emergency / Fire

Protection Equipment at our jobsite.

The Sub-Contractor or his representative will sign an acknowledgement (formno. FM/HSSE/006) of these procedures. The form will be kept on file by IOTL

Failure to meet any of the above conditions may result in being removed

from the job site and possible loss of work site contract.

13. Rescue / First Aid / Medical Treatment

It is known that the quicker the first aid treatment is given, the less impact the injury

will have on the patient. For more serious injuries, the purpose of first aid is to

maintain the injured in a stable condition until professional help arrives.

13.1 Equipment

First Aid Boxes

First aid boxes and first aid equipment must comply with local legal

requirements. It should be located at strategic points e.g. control rooms,

office buildings, guard rooms



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Local file: HSSE-03

The first aid box should be regularly checked by the HSSE Coordinator for

completeness and for replacement of out-of-date materials.

A booklet shall also be kept in the first aid box detailing basic first aid

techniques.

A list of qualified first aiders and nearby hospitals should also be pasted /

stuck on the wall / kept near first aid box.

Eye wash and emergency showers

Emergency showers shall be provided in all areas where acids or other

corrosive substances are handled. Similar precautions against overheating or

freezing, as above, should be observed. Emergency showers should be

tested weekly and always before any work involving the handling of acids or

corrosive liquids. Defects shall be reported immediately to the HSSE

Coordinator.

Eye baths can stand alone or are incorporated as part of an emergency

shower. Due to the high ambient temperatures experienced in some

locations, water feed lines to eye baths that are exposed to direct sunlight

should be insulated

SCBA & Resuscitation Equipment

Consideration must be given for resuscitation equipment and SCBA to be

provided at the Project site. For chemical and gas Project sites such

equipment will normally be required.

Stretchers

Depending upon the size of the Project site, at least one stretcher should be

provided and stored in a prominent place for the movement of any casualty.

Injured persons should not be moved unless they continue to be in danger of

further injury or the movement is approved by a qualified medical person.

Water gel blankets

Water gel blanket should also be kept for rescue / first aid from burn injuries.

Emergency tool kit

An emergency tool kit detailing various sizes etc. of tools and rescue

equipment may also be considered for project sites.



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Local file: HSSE-03

13.2 Training

There shall be a continuous program of first aid training given by qualified

persons or recognised institutions. Such training should ensure that there is

adequate first aid proficiency available! locally to work stations at all times.

Records should be kept of training given and the development of

proficiency. Training by some recognized authorities does permit certificates

to be issued.

Internal training on first aid to worker by the qualified first aiders shall be

undertaken with normal training programs.

13.3 Outside Medical Support

In case of an emergency that involves injured personnel, outside medical

support will be required . Contact with relevant medical authorities has to be

established and they have to be invited to participate in regular emergency

drills in order to get familiarized with the Project site and the particular

hazards.

Name & Telephone numbers of these installations (outside medical services)

must be prominently displayed at least in the control room, first aid boxes and

the office building. Normally, these numbers shall be included in theEmergency Contact List.



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Local file: HSSE-03

14. Commissioning Safety

During commissioning a facility, a significant number of issues should be reviewed

to make a reasonably sound evaluation of the facility. Checklists for every

conceivable safety and environmental aspect are a handy tool to carryout a safe

commissioning activity.

A new facility should be identified for every potential hazard and such hazards

should be eliminated. With the conscientious application of checklists, a safety

professional can be reasonably assumed to have made an honest, professional

appraisal to ensure the highest possible level of safety implementation. Following

are a set of commonly used checklists for new facilities.

14.1 Planning

S Item Y N Remarks

1 Flow diagrams and layout drawings

available and reviewed

2 Operation Manual Developed reviewed

and all significant activities are covered

with Standard Operating Procedures

and Work Instructions.

3 Safety Procedures are available and

reviewed

4 MSDS (Material Safety Data Sheets) areavailable for all products / Chemicals

5 On-site emergency plan is available for

the facility and known by commissioning

personnel.

14.2 Tank Farms

S Item Y N Remarks

1 Tanks are provided with equipment for

guarding against excessive vacuum or

pressure and the equipment is tested.2 Tanks are properly earthed and floating

roof tanks are provided with bonding

wire with tank shell



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3 Dyke (Secondary containment) is proper

and without any openings etc.

4 Cooling systems and Foam Pouringsystem are commissioned and tested

5 Level transmitters are tested including

hydro testing of the tanks.

14.3 Electrical

S Item Y N Remarks

1 All electrical appliances are properly

grounded

2 All flameproof electrical equipment and

junction boxes are checked for its

properties.

3 All energized equipment are capable of

being de-energized or disengaged

during maintenance activities

4 Tags are available for posting to such

de-energized equipment.

5 All switchgear, circuit breakers etc. are

properly marked for ease in

identification.

6 Low-voltage protection provided in the

control devices of motor driving

machines or equipment that could

cause injury from inadvertent starting.

14.4 Aisles, floors and Staircases

S Item Y N Remarks

1 Material or equipment will not interfere

with the walkways.

2 All floor openings protected by means of

cover, guardrails etc.

3 All drains in work area covered and

manhole covers, trench cover withsupports are provided.

4 Stair cases are having uniform risers and

having a slope between 30-50degree.

5 Material on elevated surfaces stacked in

a manner to prevent its falling.



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14.5 Fire Safety

S Item Y N Remarks1 Facilities for storing flammable material

are provided with Flameproof electrical

fittings with proper ventilation

2 All flanges, tapings and connections are

leak proof for all flammable liquid

handling line / equipment.

3 Only metal drums are used for

dispensing flammable liquids and are

properly grounded.

4 All lines carrying flammable substances

are protected for collision / hitting from

traffic, mobile equipment.

5 “No Smoking or Naked Lights” signs are

posted at strategic locations.

6 Cylinders are provided with a dedicated

storage facility with segregation

between incompatible gases.

7 Appropriate Portable Fire Exitinguishers

are placed at strategic locations.

14.6 Miscellaneous

S Item Y N Remarks

1 All rotating machinery (including drive

belts) are properly guarded to avoid any

physical contact

2 All Hazardous substance containers are

properly identified and marked with

hazard associated

3 All safety and critical interlocks are

tested and functioning properly.

4 All product pipelines are hydrotested at

recommended pressure.

It is known that most accidents/incidents occur during commissioning, shut-down

and recommissioning. It is therefore necessary that extra care is exercised during

these operations and that the HSSE standards and procedures are strictly adhered

to. Particular attention needs to be paid to vents, drains, earthing, bonding and

whether work permits are in force.

Commissioning and recommissioning shall only be undertaken during daylight and

with an adequate number of trained staff. Wherever practicable pre-testing of the

equipment should be considered.

hse plan project sites jan05

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