tata group safety standards · pdf filejob safety analysis 19 ... failure to ensure safety...

Tata Group Safety Standards

Release number: 1

Revision number: 0

Release date December-2013

Issued by Tata Safety Steering Committee-For Internal Circulation Only of 53


CONTENTS

S. No.

Description Page

PREAMBLE 3

1 INTRODUCTION & OBJECTIVE 4

2 SCOPE 4

3 STANDARDS & PROCEDURES

Electrical Safety 5

Fire Safety Management 13

Job Safety Analysis 19

Lockout Tagout 23

Working at Height 30

Contractor Safety Management 36

4 MANAGEMENT SYSTEM 46

ANNEXURE

Generic Definitions 48

Definitions Specific to Fire Safety Management 51

Definitions Specific to Working at Height 51



PREAMBLE

"We do not claim to be more unselfish, more generous or more philanthropic than other people. But

we think we started on sound and straightforward business principles, considering the interests of

the shareholders, our own, and the health and welfare of the employees, the sure foundation of our

success."…….Source: Frank Harris, Jamsetji Nusserwanji Tata: A Chronicle of His Life

This quote from Mr. J N Tata, the founder of the Tata Group, epitomizes his visionary zeal for building an

enterprise on the strong foundations of care for the health & safety and welfare of employees. Over the

years, caring for employees has been ingrained in the DNA of the Tata companies and in many ways is a

differentiator of Tata, as a caring employer.

Mr. J N Tata’s vision has laid the foundation of growth at Tata, and from its modest beginnings to its

exponential growth, especially in the last decade, in becoming a 100 USD Bn enterprise. The Tata Group

has demonstrated business sustainability for well over 100 years and has received recognitions in many

areas, especially in areas of business ethics and corporate responsibility. However one area where the

Group as a whole and the companies are playing catch up is the scalability and the robustness of safety

processes and systems.

A safety committee was formed at the Tata Group level in 2009 to provide thought leadership to the safety

activities and thereby raise the bar across the Group, in this area. The early years were invested in creating

urgency and awareness about a safety mindset across the leadership levels, integrating safety assessments

with the TBEM process, conducting safety audits across Tata companies and putting in place systems and

processes to standardize the definitions and capture key safety metrics.

As a Group, it is imperative to reach a level of Zero Harm to employees and contractors from the current

levels. One of the key building blocks towards achieving this would be putting in place a set of universally

acceptable and applicable safety standards for bringing about collaboration and standardization of safety

efforts across the Group.

Based on the analysis of the key causes of injuries and fatalities across the Group over the past 5 years, the

following 6 areas have been identified for greater detail. These areas are;

1. Electrical Safety

2. Fire Safety Management

3. Job Safety Analysis (JSA)

4. Lockout Tagout (Energy Isolation)

5. Working at Height

6. Contractor Safety Management

The Group has tapped on the existing safety standards, practices and expertise from across Tata

companies, to distill together a set of universally acceptable Safety Standards for implementation across the

Group. These standards have been put together with inputs from experts from Tata Steel Group, Tata

Power, Tata Motors and Tata Chemicals. These standards are universally applicable across industries as

well as geographies.



1. INTRODUCTION & OBJECTIVE

The Tata Group recognizes that during their course of everyday work, employees and contractors are

potentially exposed to unsafe conditions or situations. These standards seek to put in place a

minimum level of control on various activities to ensure ‘Zero Harm’. The standards enclosed in this

document cover six specific areas. These are, Electrical Safety, Fire Safety Management, Job Safety

Analysis, Lockout Tagout, Working at Height & Contractor Safety Management.

They specify the minimum mandatory requirements with regard to personnel and facilities and also

the recommended advisory guidance for ensuring ‘Zero Harm’.

2. SCOPE

This document provides the standard for the Tata Group companies to follow. Each company would

need to put in place appropriate documentation in terms of policies, procedures and checklists for

implementing these standards in their respective companies. This needs to be done considering the

industry and the processes with which they operate.

These Safety standards are universally applicable and apply to all Tata Group companies,

irrespective of their industry or the geography they operate in.

Tata companies would need to ensure that these standards are implemented in conjunction with local

laws and regulations. At any point in time full compliance to the local laws and regulations needs to

be ensured while implementing these safety standards.

3. STANDARDS & PROCEDURES

This document details 6 safety standards and procedures, these are

1. Electrical Safety

2. Fire Safety Management

3. Job Safety Analysis

4. Lockout Tagout

5. Working at Height

6. Contractor Safety Management



3.1 Electrical Safety Standard

3.1.1 INTRODUCTION & OBJECTIVE:

This standard with regard to operation and / or maintenance of electrical equipment specifies

minimum mandatory requirements and advisory guidance for identifying and controlling hazards to

ensure ‘Zero Harm’. The established documentation for the elimination and control of hazards is

henceforth referred to as Electrical Safety Standard.

3.1.2 KEY PRINCIPLES:

Personnel (both Company employees and Contractors) must be competent to carry out electrical

work.

All electrical work must be done in compliance to pre-set work procedures.

Risk assessment should be carried out when working on or near energized electrical equipment.

Testing must be carried out to verify absence of voltage.

Appropriate PPE must be worn, while performing electrical work.

Before carrying out any activity related to operation or maintenance of electrical equipment, it

must be ensured that there is an appropriate Work Permit system and Lockout Tagout (LOTO)

compliance supported with Hazard Identification and Risk assessment (HIRA).

All Electrical equipment must be inspected and maintained. .

Employees / contractors working on / near electrical equipment must be trained in emergency

response / first aid.

Fire and explosion hazards associated with electrical equipment must be assessed and managed.

3.1.3 STANDARDS:

The following key elements govern Electrical Safety:

3.1.3a Competency of Electrical manpower:

Both Company employees and Contractor employees must be competent to carry out electrical work.

Persons who work near electrical equipment and are potentially exposed to electrical hazards, must

be made fully aware of the hazards and must be suitably trained on how to work safely.



All the steps of contractor safety management from the level of preparing tender document,

contractor assessment, kick off meeting before mobilization of man and material, safety training, safe

execution and safe closure of contract has to be followed strictly.

Contract document must be written to ensure compliance of statutory regulations and to comply with

national and international standards to ensure safety of human, plant and property.

Failure to ensure safety shall invite penalty or termination of contract.

Note:

Each company must define in their standard / procedure, the requisite competencies for carrying out

electrical work. A procedure for certifying the qualified persons must also be put in place and only those

employees who have been certified by an authorized agency can be deployed on a job.

3.1.3b Compliance to work procedures

Companies must prepare detailed work procedures for implementing these standards considering the

nature of work and their industry. Thereafter it must be reviewed and approved by a competent and

authorized person. Necessary training of these procedures must be imparted to the employees.

All the work procedures are aimed at minimizing exposure to electrical hazards to an acceptable level

on the basis of risk assessment. Procedures must emphasize the requirement to work on electrical

equipment only after it is ensured that it is isolated from an energy source.

3.1.3c Working on or near energized electrical equipment

Working on or near any live conductor shall take place only in case of exceptions, after a thorough

Risk Assessment has been carried out, appropriate control measures and suitable precautions

(including the provision of suitable personal protective equipment) have been taken. Suitable

precautions may include working on extra low voltage systems (<50 AC or < 120 DC) or, for non ELV

systems, finger safe designed insulated tools and appropriate test equipment and leads. When

working on or near energized electrical equipment it must be ensured that no work should be

performed within the prohibited approach boundary. Permission to work on such locations requires

authorization from a senior authorized person / Engineer in charge (as per company

standard/procedure) regardless of the PPE used or design of equipment.

Voltage testing and diagnostic testing at low voltage level are allowed within the prohibited approach

boundary provided proper test equipments and PPE are used and the Doer is competent and

qualified.


Recommended PPE: Helmet, voltage rated hand gloves, safety goggle with face shield and FR

(Flame Resistant) coat.

3.1.3d Testing for the absence of voltage

All circuits are considered energized until verified dead by testing it with appropriate instruments

such as non-range selectable voltage indicators.

Ensure that all test instruments or equipment used are designed and certified to meet the

requirements and be rated for the appropriate category for the task.

Practice of “Test Before Touch” (TBT) and test the instrument before every use must be followed.

Recommended PPE: Helmet, Shoes, voltage rated hand gloves, safety goggles with face shield and

FR coat.

3.1.3e Dismantling of electrical raceways and cables

The identification, cutting, and removal of electrical raceways and cables often involve a high level of

risk in determining that the correct cable is removed. Maintain proper labeling and identification of

cables at both ends to avoid the error of mistaken identity (Refer Lockout Tagout Standard).

Test for the absence of voltage at the source and destination ends of each cable.

Positively identify each cable before it is cut.

3.1.3f Excavations and penetrations

Ensure that the electrical lines, conduits, and cables in the area of work activity are identified before

performing excavations and / or penetrations of floors, roofs, and walls. Up-to-date maps / drawings

showing underground / concealed cables and electronic tracer systems must be used for locating

cables. Written authorization (through work permits) must be taken before excavation and / or

penetration is commenced.

Note:

Please note that this is also applicable for offices.




3.1.3g Management of electrical hazards

Shock hazard

Prohibited approach boundary limit for circuit parts and conductors shall be crossed only by a

qualified and competent person under the written authorization from management.

Voltage-rated gloves must be worn wherever a shock hazard is present.

Proper design, installation, and maintenance of equipment grounding and/or earthing are critical

to managing shock hazards.

Installation of 30 mA ELCBs (Earth Leakage Circuit Breaker) for all temporary socket feeding

panels and periodic test of ELCB needs to be carried out. The following technologies must be

adopted to complement the overall shock protection program and to minimize the risk of shock:

Battery-powered tools

Reduced-voltage equipment

Double-insulated equipment

Shrouding and barriers

Insulated or voltage-rated tools

Voltage-rated PPE (e.g., gloves or helmets)

Insulated mats for floors

Insulated, flexible barriers for exposed equipment parts

Identification of multiple voltage sources inside cabinets

Segregated voltages to prevent accidental contact where multiple voltage sources exist in one

unit

Finger-safe terminals to prevent finger contact

Installation of RCCB (Residual Current Circuit Breakers) has to be carried out based on the

company’s standards / procedures

Arc / flashover hazards

Arcing faults in electrical equipment are multi-energy events (i.e., involving heat, blast, light, and

sound) that generally produce high levels of energy release in a short-duration. Due to phase to

phase and phase to earth fault conditions, it may cause heavy flashover which may result in severe

injury to employees in the close vicinity. Each Company’s standard must clearly specify the level of

Incident Energy above which the recommended PPE’s (such as cool coat, face shield with goggles,

safety shoes, hand gloves and insulated electrical hand tools) must be used.



Static electricity hazards

Static electricity hazards, including lightning can be a source of ignition, and injuries. Some

operations (e.g. handling or transporting liquids, solids, or gases in portable containers or piping

systems) and certain maintenance activities (e.g. steam cleaning, industrial vacuuming, and

sandblasting), generate static electricity hazards. To protect people and property from static hazards

it is essential to ensure good grounding and bonding of equipment and structures.

Each site shall be equipped with adequate lightening arrestors (Refer to local standards / regulations

for guidance).

Fire and Explosion hazards

Assess and manage the risk of explosion hazards associated with electrical equipment. These should

include, but are not limited to:-

Provision and maintenance of drawings and documents describing the limits of the hazardous

area and its classification.

Selection and procurement of electrical and non-electrical equipment appropriate for the area

classification (refer note below).

Maintenance of the mechanical integrity of the installation, including grounding and bonding.

Promptly arresting the leakage of combustible gases and liquid and avoid accumulation of

combustible waste.

No hot work to be carried out without “HOT WORK PERMIT”

o In the absence of Work Permit System in that particular site, a system must be put in place to

ensure that hot work is conducted in a safe and secure manner

3.1.3h Permit system and Lockout Tagout (LOTO) compliance supported with Hazard

Identification and Risk assessment (HIRA)

Documented “Permit System” must be implemented with total compliance to LOTO. Concept of test

before touch should be followed by everyone working with electrical systems. Control circuit isolation

is not considered safe for electrical working. Power circuit must be isolated, locked and tagged.

Permit for working on energized circuits must be supported by HIRA and it must be discussed with

the working team for developing an understanding of involved hazards and precautionary measures.

Discharging of residual charge from the cables and equipment and short circuiting with grounding

must be done before touching un-insulated portion of the equipment.



3.1.3i Inspection and Maintenance of Electrical equipment

All the panels, equipment, transformer yards and switch yards must be inspected at regular

periodicity with the help of a checklist.

The switchgear room must be maintained clean and free from dust & moisture. Regular pest

control should also be ensured in the Switchgear room.

Safety interlocks of panels and equipment must be maintained in good condition.

Periodic thermal imaging of electrical system should be carried out to indentify hot spots and to

take corrective action.

Electrical hand tools, multi meters, power detector devices and ‘short circuiting grounding clamps

and rods’ must be tested before and after each use.

Electrical testing, measuring and diagnostic equipment must be tested and calibrated periodically

as per statutory requirement and record of such testing must be maintained.

Periodic testing of electrical systems as per statutory provisions must be carried out and record of

such tests must be maintained for the verification by the Electrical Inspector / Statutory Authority.

3.1.3j Fire detection and protection systems readiness

All switchgear rooms, transformers, cable galleries, switch yards, control rooms and other locations

containing electrical equipment must be formally assessed for the potential risk of harm to people and

loss of business that could result from a fire. The assessment must include the likelihood of fire,

which takes into account the equipment location, the equipment's potential to initiate a fire and the

likely extent of the loss should a fire take place. A fire detection or protection system shall be installed

where required, to minimize the risk to persons and to minimize business loss to an acceptable level.

Additional precautions such as equipment segregation, room fire rating, fire barriers between rooms

and along cables and portable fire extinguishers shall also be used to reduce the risks. Installed fire

detection and protection systems shall be inspected and tested periodically with the help of a

checklist and a record of inspection must be maintained in line with the country level standard.

Fire detection and protection systems must comply with the relevant country standards and may

include the following methods of risk reduction;



Note:

Only dry powder or inert gas portable extinguishers should be applied to electrical equipment.

Portable extinguishers shall never be applied to live High Voltage equipment.

Refer Tata Group Fire Safety Standard for further details

3.1.3k Temporary Wiring:

Temporary wiring is allowed only in the following cases:

Construction, remodeling, demolition of buildings and / or structures. Maintenance, repair of

equipment

Emergencies, tests, experiments, and developmental work

Temporary wiring must be removed immediately upon completion of construction, or the purpose for

which it was installed

Special precautions must be taken in case of temporary wiring installation. The precautions taken

must provide a level of safety equivalent or greater than that provided by fixed / permanent wiring.

One must ensure compliance to local regulations, during the use of temporary wiring.

3.1.3l Earthing:

All extraneous metal parts of an electrical installation and adjacent metal work shall be connected to

earth. The design of the earth system shall take into account the protection of life from raised

voltages on external parts and the correct operation of the electrical protection systems. Appropriate

means shall be used to test the integrity of earthing systems periodically. The design of the system

should consider the requirement to test wherever possible.

Area Fire detection and protection system

Switchgear Rooms Multi Sensor smoke and Heat Detector

Oil filled switchgear rooms Multi Sensor smoke and Heat Detector with Gas

flooding system

Cable Gallery - Linear Heat Sensor (LHS) detector and smoke

detector

- Sprinkler system with Quartzoid bulb detector

Oil Filled Transformers & Reactors

(Particularly if indoors)

Deluge system with Quartzoid bulb

detectors

Dry Transformers Multi Sensor smoke and Heat Detector

Control Rooms Multi Sensor smoke and Heat Detector with gas

flooding system



3.1.3m Guidelines for Office / Residential Building:

Refer to the Tata Group Office Safety Protocol.

3.1.3n Emergency Response / First Aid-Trained personnel:

Each company must ensure that employees / contractors working on / near electrical equipment must

be trained in emergency response / first aid.

3.1.3o Overhead Lines:

Work in areas where overhead lines are present should be monitored carefully. A formal risk

assessment / Job Safety Analysis must be carried out and adequate precautions taken before such

work is permitted.

3.1.3p Relocation:

Before relocation of equipment / electrical systems from one place to another a formal risk

assessment must be carried out. When equipment / electrical system are relocated to a new place it

must be ensured that it will work in a safe manner.

3.1.3q Other Key Elements:

o Access control has to be maintained for high tension areas and vital installations

o Appropriate signage has to be displayed in hazardous areas and on equipment as per local

standards.



3.2 Fire Safety Management Standard


This standard specifies the minimum mandatory requirements and advisory guidelines to ensure

prevention of fire related incidents and managing / controlling their impacts if they do occur. The

established procedures for preventing and controlling fire are henceforth referred as the Fire Safety

Management standard.

3.2.2a KEY PRINCIPLES:

The management of Fire-Risk deals with three aspects:

Fire Prevention:

It is the adoption of safe practices initially at the design stage and subsequently in the day to day

operation to prevent break out of fires

Fire Protection:

It involves different facilities which shall help in immediate handling of fire effectively.

Fire fighting:

It is the physical phenomenon of handling the fire with the use of fire protection equipments, facilities as well as with the help of firefighting personnel who have been specifically trained for this job.

All these three distinct aspects are very closely related to each other but are completely separate in

their individual scope.



3.2.2b Key Elements:

All fires can be prevented.

o Companies must adopt a Preventive approach to Fire Safety (i.e. Control on ignition source,

Safe handling of fuel source)

Facilities must be designed and constructed in accordance with applicable laws, codes, and

regulations in force in that jurisdiction. In the absence of local regulations / laws, facilities must be

designed with technically sound practices.

Sites / Facilities should be managed in a way that fires are prevented, injuries and business

losses are avoided, property is protected, and trust is fostered in the communities in which the

company operates

Facilities should be managed, operated, and maintained so that the fire safety features are not

compromised

Fires are to be controlled in the initial stage itself and not allowed to spread

Fire equipment is to be used for intended purpose only

Emergency Plans must be put in place.

As part of the due diligence review, each company must assess the level of fire protection /

prevention in use or being planned in case of:

o Acquisitions and Divestments

o Process shutdowns / phase outs

Note:

It is recommended that individual companies refer to National Fire Protection Guidelines (NFPA)

guidelines and state / country specific guidelines for further guidance.

3.2.3a STANDARDS / KEY STEPS:

Selection / Design Stage:

1. Risk Assessment:

During the selection / design of a site / office / facility, a risk assessment and fire load calculation has

to be carried out.

The following key elements have to be considered:

Risk of fire occurring to the particular facility / site

Assessment of fire load to the particular facility/site

Provision of means of escape


Fire Compartmentation (Passive measures) etc.

Fire Detection (Active measures)

Firefighting & Emergency Handling arrangements

Emergency procedures

In the case of a new facility being constructed it has to be ensured that fire prevention / protection

systems are installed. These systems are to be designed and constructed in accordance with

applicable laws, codes regulations and they must be authenticated by a fire expert or a third party fire

engineer.

For occupied buildings located in the vicinity of a high hazard facility, a separate risk assessment

shall be carried out to assess the risk due to the external threat of fire / explosion.

Hazard studies on ‘high hazard facilities’ (e.g. Process Hazard Reviews, etc.) must consider the

potential scenarios associated with a fire.

Where there is no reasonable alternative to hot working methods, a hot work permit system must be

utilized to ensure that appropriate control measures are put in place.

Fire Risk Assessment should be done by including neighboring areas as well. i.e. asses the

possibility of fire spreading from the neighboring areas to the companies specific site / facility /

business unit

2. Fire Detection & Alarm Systems:

Effective means for detecting an outbreak of fire and warning people who may be at risk must be

established.

Fire detection and alarm systems have to be installed in every site / office / facility.

The following types of detection systems are available and should be chosen based on their suitability

for use at locations where they are required:

VESDA (Very Early Smoke Detection Apparatus) systems

Fire Alarm and Detection System – With Various type of fire alarm detectors like as Heat Detector, Smoke detector, Heat & Smoke Combined detector, Flame detector, Beam Detector, Normal Manual call points (MCP), intrinsically safe Manual call point, Hooter, Beacon light etc.

Gas Detection System – With Various types of detectors like as Ammonia detector, Chlorine

detector, Bromine detector, Hydrogen detector, Carbon monoxide detector, H2S detector, Beacon

light etc.



The detection system to be used is to be selected as per the following criteria:

Type of Occupancy

Nature of Fire and Emergency Hazard

Quantum of Hazard

Selection of appropriate detector device considering the hazard

Physical and environment condition

3. Fire Protection / Control Systems:

The following two types of fire protection systems are to be used:

Passive restraints / protection: Passive fire protection systems need to be installed to contain

fires or reduce the speed at which they may spread, through:

Compartmentalization

Segregation

Separating distances

Use of Fire resistance wall, Floors & doors etc.

Dykes for storage tank

Fire resistant/retardant coatings

Fire retardants paints / Cables

Active restraints / protection: This requirement is a risk based decision, and suggests the

provision for suitable and sufficient fire fighting/escape equipment and devices will be determined

by the fire risk assessment.

A combination of the following types of protection systems should be considered

(a). Portable type system

Portable Fire protection systems, which are used at the incipient stage of fire for immediate

control, need to be installed. Some examples are:

Fire extinguishers (Based on extinguishing media: DCP, Co2, Water, Foam)

Sand buckets

(b). Fixed / Semi fixed type system

Fixed / Semi fixed fire protection systems needs to be installed. Some Examples are:

Fire Hydrant system

Fire Alarm & Detection system

Sprinkler system

Gas flooding system

Medium velocity & High velocity water spray system



(c). Mobile type system

Mobile Fire Protection systems (Fire Vehicles) need to be provided / mobilized as appropriate.

Some examples are:

Fire Tenders – With various type of firefighting media like as Water, Foam, Dry Chemical

powder, Carbon dioxide.

Rescue Van – With Various type of Rescue equipments Like as TRIPOD, lifting Pads, COMBI

TOOL, Hydraulic RAM, Descended/De-rope device, Rescue rope, Rescue stretcher,

Emergency light mast etc.

HAZMAT (hazardous material) Response Van – With Various types of equipments like as

hazardous chemical spill control kit, Leak arrest Kit, decontamination unit, various suits etc.

3.2.3b Inspection and Maintenance:

To ensure integrity and reliability of the fire protection systems, they should be checked, inspected,

maintained, and tested periodically.

The inspection and maintenance should:

Ensure that the systems are avail;3able for intended protection all the time and are in a working

condition at all times

Ensure that the systems perform as per design specifications

Safe systems of work must be established and implemented for entry into gas and water flood

protected areas to ensure that the extinguishing media is not discharged whilst the area is occupied.

Applicable technical codes and standards are to be referred for inspection and maintenance of fire

detection/ protection systems.

Each company must ensure that there is a documented maintenance schedule and must ensure that

this schedule is adhered to.

3.2.3c Emergency Preparedness:

An emergency preparedness plan must be put in place to address emergencies on account of fires.

This emergency plan must ensure that there is no harm to life, environment or property.

Each company shall have two emergency plans based on their requirements. They are:

a) On-Site Emergency Plans

b) Off-Site Emergency Plans

Roles and responsibilities are to be defined in the plan. The plan should also be communicated to all

personnel who may be affected by the emergency.




Each site / premises must include in their emergency plan, risks on account of potential fires and the

appropriate measures for:

raising the alarm, which must be distinct from all other alarms in the company,

evacuation of personnel to an area of safety and accounting for their attendance,

quick reporting the fire to ‘on site’ or ‘off site’ emergency services,

containment of the fire until arrival of the emergency services, and

periodic testing to demonstrate adequacy of the plan / resources to manage the foreseeable

scenarios.

Regular mock drills should be conducted as per the company’s standard/procedure.

3.2.3d Training & Competency testing:

Training has to be conducted by individual companies to ensure appropriate response in times of an

emergency. The training should be conducted, in the following categories:

1. Awareness Training: To be conducted for all employees and Contractors. It should cover basics of

fire, emergency preparedness, emergency response and general do’s and don’ts

2. Specific fire Training- This training and competency testing is to be conducted for individuals on

specific topics such as how to handle fire extinguishers, emergency management plans etc.

Those who are trained in this usually become fire marshals/fire guards (or equivalent)

3. Training and competency testing for Fireman-To be conducted for the dedicated fire response

team as per the individual company’s standard/procedure

Ensure that all employees and contractors are competent enough to handle fire related emergencies.

3.2.3e Auditing:

Audits have to be carried out to ensure identification of areas of strengths and weakness of the fire

safety management systems.

These audits will be undertaken to meet the following objective:

1. To ensure that fire detection/protection and fire fighting systems are in place

2. To ensure that proper inspection and maintenance schedules are followed

3. To ensure that adequate training has been imparted

4. To ensure that proper emergency procedures are in place

Both internal and external audits have to be carried out by companies. These audits have to be

carried out at a predefined schedule.



3.3 Job Safety Analysis Standard

3.3.1 INTRODUCTION:

Every job comes with it its own unique challenges and risks. These risks need to be controlled to

ensure people are not harmed as a result of the work being performed. This Standard sets out the

requirements for Tata Group Businesses to have a task based risk assessment process in place that

identifies, evaluates and controls the risks associated with work activities, and as a result, prevents

those involved in the task or those potentially affected by the task, from being harmed. The

established documentation for the elimination and control of hazards is henceforth referred to as Job

Safety Analysis standard.

Note:

For the purpose of this standard, while analyzing risks related to safety, health related risks should

also be taken into consideration.

Individual company must ensure that all work activity over which they have supervisory or

operational control is subjected to systematic risk assessments. Companies must also put in place

safe systems of work to prevent those involved in, or potentially affected by the task, from being

harmed.


The basic principle of safety mandates that hazards at the workplace are kept to a minimum & the risk

to the employees is eliminated. In order to ensure this, a safe system of procedures / work-practice is

to be adopted & tools and equipment must satisfy safe conditions for working.

It is, therefore, absolutely essential to have procedures for:

Identification of Occupational health and safety hazards / risks of all activities during manufacturing

and other services including management of change.

Undertaking risk assessment to determine the level of risk

Establishing control measures to ensure that the risks are eliminated before undertaking the

activity.

One such procedure, known as Hazard Identification and Risk Assessment (HIRA), is a structured

system under OHSAS 18001.

HIRA includes all risks to all aspects of any work and would consider the exposure, severity and

probability in terms of quantifiable numbers. The difficulty in conducting HIRA is that it requires a lot of

knowledge and expertise that may not always be available and therefore a full scale HIRA may not be

possible, but even then, it is essential to ensure that the jobs are assessed for their potential impact on

safety, risks evaluated and suitable control measures put in place. Hence, there is a need for simpler


methods for assessing the risks and ensuring adequate control measures prior to undertaking jobs

and tasks.

Job Safety Analysis (JSA) is one such technique that will be useful for all jobs where the potential of

significant hazards exists.

Whether a full scale HIRA is required or a JSA will suffice for the job to be undertaken, needs to be

clearly defined in order to avoid confusion and remove the subjectivity during decision making.

The following guidelines will be useful in determining when exactly HIRA is required and when JSA will

be sufficient. However, it must be clearly understood that prior to undertaking any job, it must be

assessed by either HIRA or JSA.

A formal HIRA should be carried out:

Prior to finalizing any SOP (Standard Operating Procedure) and SMP (Standard Maintenance

Procedure)

When an existing job has undergone significant changes

When there is a change in regulatory or technical standards

When there are changes in Technology and / or new hazards have been identified

After an incident or injury has occurred

A JSA should be carried out:

When new / different people will be undertaking the job for which an SOP / SMP is available

When a non-routine task is to be undertaken

When deviations, due to some specific reasons, are required for an SOP / SMP

Whenever a job with an SOP / SMP is being undertaken in circumstances where the conditions of

the job are changed with respect to the SOP/SMP. e.g. A welder working in his fabrication area will

be covered by a SOP with HIRA already carried out, however, if the welding is being done on the

site at a height or a confined space or in an area which may interfere with other jobs we need to

conduct a JSA and use this in conjunction with the HIRA for the welding activity.

3.3.3 STANDARDS

3.3.3a Job Safety Analysis (JSA) involves the following:

Determining the scope of the job and listing the steps in the job.

Identifying possible hazards in the job.

Determining who and/or what is at potential risk

Describing the recommended safe way to do the job in order to prevent incidents and injuries.

Anticipating what might go wrong and devising back-up controls.



This will help to:

Identify and address hazards.

Prevent incidents and injuries.

Get organized to do the job right and more efficiently.

Create procedures that can be used by everyone.

Get people in the habit of working safely.

3.3.3b Key Steps:

The Job Safety Analysis consists of the following 6 steps:

Step 1: Describe the job and the sequence of job steps

Step 2: Identification of the potential hazards of each step

Step 3: Determine who and/or what is at potential risk

Step 4: Description of the recommended safe job procedure

Step 5: Identification of what might go wrong

Step 6: Identification of back up controls

The format for capturing the above 6 steps is given in the Annexure

3.3.3c Team Composition

The JSA is generally carried out by a team comprising;

Employees who do the work

Employees supervising the job

Employees with safety knowledge

Employees with technical knowledge

The number of team members will depend on and vary with the complexity of the job.




3.3.3d Roles and Responsibilities

The responsibilities associated with JSA are:

Facilitating and writing JSA – Supervisor Employees, technical experts

Reviewing the JSA – Supervisor and area line manager, Safety expert

Maintaining the JSA – Employees, Supervisor, Line Manager

3.3.3e FORMAT FOR JSA

Enclosed below is a format for the JSA.

Location of Job: Job Description:

Sequence of

Basic Job

Steps

Potential

Hazards

Who and/or What is at

potential risk of

injury/damage

Safeguard / controls to

be put in place Responsibility



3.4 Lockout Tagout Standard


This standard with regard to servicing and/or maintenance of equipment specifies the minimum

mandatory requirements and advisory guidance for controlling all types of energy including but not

limited to Electrical, Pneumatic, Hydraulic, Stored Energy/Potential energy and Hazardous

Substances. The established procedures for the control of energy are henceforth referred to as

Lockout Tagout (LOTO) standard.


Key Elements:

The following principles govern all Lockout Tagout:

All sources of energy shall be identified prior to initiating any LOTO.

All sources of energy (including stored energy) shall be safely removed or controlled prior to

potential exposure to hazards.

Before the start of any Lockout Tagout, planning has to be done to ascertain what kind of isolation

needs to be done.

Before starting work, each individual working on a task must determine, to his or her

satisfaction, that appropriate isolations are in place and the isolations are secure for the task in

which he or she is involved.

It is the responsibility of each and every individual, potentially exposed to energy to put his/her

own lock and tag, before starting such jobs. Individuals who enter the hazard zone of a lockout

shall be considered potentially exposed to the hazard.

Each person potentially exposed to the energy must understand his/her role and responsibility in

the LOTO program.

All personnel who work in an area where isolation and immobilisation is required shall be informed

of the measures that have been applied to keep them safe, as it relates to them, prior to the

commencement of work. There must be a system for reliably confirming and indicating the

isolation or immobilisation status and its extent.

An energy source shall be considered energized until the source is removed and the energy

isolation is verified according to the LOTO Procedure.

An effective verification step must be performed to ensure the correct equipment is locked out.

A test for the absence of voltage must be performed for all electrical hazards

Where lockouts extend beyond one shift, the company’s standard and lockout/job plan shall

address the continuity of the lockout across the shifts.

Each company’s standard must define a minimum level of authorization for removal of an

absentees lock.



If an isolation point cannot be secured at the place of doing the work an isolation point upstream

must be chosen to be secured.

NOTE:

Each company’s procedures must contain defined roles, responsibilities and authorization for the

following:

a) Persons performing the LOTO

b) Training Delivery & Receiving

c) Auditing

Contractors performing work in Tata Group controlled premises must undergo relevant LOTO

Training

3.4.3 STANDARDS:

3.4.3a PROCEDURE / STEPS FOR PERFORMING LOCKOUT TAGOUT:

The following steps have to be performed for servicing / maintenance and other related activities

1. Identify the Scope of the Lockout Tagout & take work permit according to company’s

standard/procedure

2. Six Step process to be followed thereby Locking and Tagging the equipment under

service/maintenance

3. Maintenance/Servicing to be done

4. Equipment Restart on completion of work

3.4.3b Scoping & Work Permit:

Scope out the task in terms of what is to be achieved, by whom, where and when. Work Permit is to

be taken according to the company’s standard/policy

3.4.3c Six Step Process:

1. Prepare for shutdown:

Identify the hazards and determine the control measures including LOTO requirements.

Authorize the task and confirm the control measures to minimize the risk


Notify all employees who work on that equipment / are likely to work on the equipment, that the

equipment is about to be shut down and should not be operated upon.

Clearly communicate to the personnel performing the maintenance/servicing the procedure for

Energy Isolation/ Lockout Tagout.

2. Shut Down:

Shut down the equipment that has to be locked out.

3. Isolate energy sources with energy-isolating devices:

All personnel who perform lockout must know the following information:

The type of energy supply or hazardous material involved in the work

The specific energy-isolating devices for the task to be performed

The means and hazards of operating the disconnecting/ isolating device

The means of installing a lockout device

Electrical Low Voltage isolator’s explanatory note:

Isolation using conforming isolators: Conforming Isolators are local isolators intended for use by non-

electrically authorised persons for immobilisation. They need to be of high integrity and provide a form

of auxiliary indication for positively confirming that the required isolation distance has been achieved

for all poles when the isolator is in the OPEN position, i.e. a mechanical flag driven directly from the

moving contact assembly, (not via over-centre cam/spring mechanism). All conforming isolators shall

clearly be marked with a permanent label “Conforming Isolator. Observe Flag Indication”

Isolation using conforming isolators can be carried out by personnel that are not electrically

authorised.

Isolation using non-conforming isolators requires that electrically authorised personnel confirm

isolation, i.e. check that the isolator has operated correctly. In most cases this can be done by

opening the panel door and visually checking the isolator position. If isolation cannot be confirmed by

visually checking the isolator then the standard test for dead procedure should be used.

4. Installing Lockout Tagout Devices:

The lockout device must be installed in a way that helps ensure that inadvertent operation of the

energy-isolating device is impossible.

Each person potentially exposed to energy must place an individual lock and tag.



The key of the lock has to be with the person who has locked the equipment.


In case of group LOTO involving multiple agencies e.g., electrical and mechanical contractors and

Company personnel, a clear communication line must be established to all parties involved in LOTO.

Once a Lockout device is installed a suitable tag has to be placed.

5. Release or restrain stored or residual energy:

When the system or equipment contains some source of stored energy (e.g. springs, flywheels,

gravitational effects, or capacitors), the stored energy must be relieved or otherwise blocked with

components that control the potential hazard.

Also, Consequential effects of isolation should be ascertained before embarking on isolation.

Where energy can re-accumulate due to system design, configuration, or installation, a means of

preventing this re-accumulation must be used.

6. Verifying Isolation of equipment & “Trying”

Verifying that the energy source has been removed

All isolations shall be verified to determine that the energy has been removed.

The following are examples of how to verify the removal of energy sources: opening drains, viewing

pressure gauges, site glasses, or level indicators, visually verifying that rotating equipment has

stopped, visually verifying that components have been disconnected (e.g. couplings, belts, and

chains have been removed) and verifying that stored energy has been removed or is appropriately

blocked.

Caution: Gauges/Indicators should be viewed before the energy source is removed to

confirm they are in working order. Drains can become blocked and not function as designed.

When verifying isolations, personnel should take precautions to avoid putting themselves at

risk or creating additional hazards.

For tasks where there is exposure to electrical hazards, a break in the power conductors

should be visually inspected, wherever possible. All lockouts must include verification of a complete

physical break in power conductors by testing for absence of voltage with a company-approved

voltage-detecting device.


Trying the equipment to determine that the energy is under control

When the equipment is “tried” (i.e., the control device operated) to verify its isolation from sources

of energy or hazardous materials, the area surrounding the equipment shall be cleared of people

and equipment prior to attempting to start the equipment. “Try” procedures must help ensure the

isolation of all sources of energy and the positive control of hazardous materials by trying to start or

move the equipment. The “try” procedure must also account for all items (e.g., interlocks) that may

prohibit the equipment from starting or moving.

3.4.3d Lockout Locks:

Types of Locks:

Discrete - Locks that are different from one another; each can only be opened by a unique key.

Personal - A discrete lock, individually keyed, issued to an individual for his or her use in securing

isolations.

Series or system - A group of locks that are opened by a single key and are used in area/group

lockouts. Various sets of locks may be in use; however, only one key can open any given lock in a

particular set.

All lockout locks shall be identified as follows:

Series or system locks shall indicate the lockbox number, system, or equipment being

locked out.

Personal and discrete locks shall indicate the individual who applied the lock.

All the Lockout Locks have to be standardized for the colour, shape, size etc. and must not be used

for any other purpose other than lockout. Locks should be individual and not shared.

3.4.3e Danger Tags:

Danger Tags shall be designed to be different from all other tags available at the company. Each

company shall establish a mandatory requirement for danger tag design for all lockout

applications. The danger tag shall be readily identifiable as a Danger Tag. The tags should include

standardized wording (e.g., “Danger—Work in Progress. Do Not Operate”). The danger tag must

have unique identification number and must provide space for the name of the Authorized person

and the date the tag is installed and the Work Permit Number. It may also provide space for other

information (e.g., the type of work or the reason for the tag). Danger tags and its contents must

be able to withstand the weather and / or work environment in which they are used for the duration of

the lockout. Danger Tags shall not be used for any other purpose than to indicate an isolation point

for controlling energy.



3.4.3f Types of Lockouts:

Simple lockout

A simple lockout is accomplished by individuals placing personal locks and tags directly on the

points of isolation. This is the preferred method of lockout and should be used when appropriate

Group lockout

For group lockouts, each company shall define the following in writing:

The person in charge shall be responsible for keeping all energy sources, hazardous materials,

and electrical, process, and mechanical hazards under control as the work progresses.

When multiple agencies(Example: multiple contractors and Company personnel,) are working on

the same process, everyone involved in the work must understand and observe the mandatory

requirements of all the lockout procedures of all the agencies involved.

The lockout process must cover all issues identified in all agencies procedures (if existing).

3.4.3g Maintenance/Servicing:

The maintenance / servicing activity has to be performed only after performing the above mentioned 6

step process. Only those who have Locked / Tagged the machine and trained on LOTO are authorized

to perform service/maintenance.

3.4.3h Equipment Restart on completion of work:

Communicate the completion of work, ensure that all precautions are taken and withdraw all

personnel from the danger area and remove personal locks De-isolate and reinstate operation

3.4.3i Training:

All employees must undergo training in LOTO. Three training programs in Lockout Tagout should be

designed and delivered. These are:

1. Awareness Training: This training is to be delivered to all employees to bring about a general

understanding of the concept of LOTO

2. Management/Supervisory Training & Competency testing: This training & Competency testing is to

be delivered to all management and supervisory staff who authorize/control Lockouts and Tagouts.



3. Practitioner Training & Competency testing: This training and competency testing is to be delivered

to all personnel that are directly involved in the Lockout Tagout process.

3.4.3j New equipment / installations / jobs / process:

It is important an inventory of the LOTO requirements is done in the beginning as a start point for

implementation of LOTO and an annual survey needs to be done to ascertain if any new equipment

has been put into operation.

A survey has to be done also when there is a change in machines, new machine installation, jobs,

process or a change in procedure.




3.5 Working at Height Standard


This standard describes the principles that help protecting all employees and contractors from the

possible hazards involved in working at height. It also specifies the minimum mandatory requirements

and advisory guidance for controlling hazards related to working at height during various activities

such as operations, maintenance, servicing, erection and construction. The established

documentation for the elimination of hazards on account of working at heights is henceforth

referred to as Working at Height Standard.

It provides vital information to facilities / sites / offices as they implement procedures to control the

hazards associated with working at heights in-line with their Safety Commitment.

This standard primarily addresses Working at height (Any height where a fall can result in an injury

and where there is no physical protection such as handrails). Work permit is warranted for Working at

height.


Fall from height can result in serious / fatal injury. Before performing any work at height a proper risk

assessment has to be carried out. Wherever possible the work has to be planned in such a way that it

eliminates the need for working at height. While working at height, one must ensure that the hierarchy

of controls (i.e. Elimination, Substitution, Engineering Control, and PPE) is followed.

In the event that working at height has to be carried out, good judgment is necessary to ensure that

adequate and proper protection is taken. Following are some typical examples, illustrating where a

safety full body harness should be used:

a) Elevated working positions where the hazard of a fall exists and where there is no physical

protection such as handrails. This does not include normal work on low stepladders, loading

platforms or such similar jobs.

b) Working near unprotected roof edges or on sloping roofs

c) Working on open steel, form work, piping, or equipment

d) Working from straight ladders when both hands are needed for carrying out the work

e) Working on incomplete scaffolds, suspended stage or other type of suspended scaffolding

Besides the use of a safety full body harness with double lanyard, the personnel should be mindful to

the following:

1. All hazards shall be identified prior to initiating any work at height.

2. All hazards (including slip, trip, and fall) shall be safely removed or controlled prior to potential

exposure to the hazard.


3. Before starting work, each individual working on a task must determine, to his or her

satisfaction, that appropriate controls are in place

4. Each person involved in the job must understand his/her role and responsibility in compliance to

working at height procedure.

3.5.3 STANDARDS/ PROCEDURES/ KEY STEPS:

3.5.3a Procedure For Working At Height:

1. Work permit shall be taken according to company’s standards / procedures

2. Job Safety Analysis(JSA) shall be conducted prior to obtaining the work permit

3. Each company must have a process in place that ensures employees are medically fit to perform

their duties and that their health is not adversely affected by occupational hazards.

3.5.3b. Fall Protection Systems & Equipment:

Types of Fall Protection Systems:

1. Fall Restraint Systems

A fall restraint system commonly consists of full body harness, appropriate length lanyard and a

suitable anchorage point. Fall restraint systems prevent individuals reaching an open edge.

2. Fall Arrest Systems

Fall arrest systems mitigate the consequences of a fall. The system consists of a proven anchor

point, connectors, a full body harness, lanyard and a deceleration device. The entire system must

be capable of withstanding impact forces involved in stopping or arresting the fall. Consideration

must be given to what is below the area of work and what the person may strike during the fall.

3. Fall Protection Systems:

a) Full Body Harness

A full body harness shall be used for fall arrest purposes. Safety belts / half body

harnesses are prohibited for use as a fall arrest device.

Employees must use site-approved harness only.



b) Double Lanyards

Double Lanyards shall be made from "Dacron" polyester rope or web material, or wire rope,

and shall be fitted with locking snap hooks.

c) Lifelines

Lifelines, if used, must be of sufficient strength to withstand the large forces involved in falls.

Lifelines are to be installed or modified only by Qualified Installers. Lifelines shall be load

tested as required by OSHA or the applicable country guideline. When more than one person

utilizes a lifeline simultaneously, the load allowance of the lifeline should be increased so as to

provide the same level of support as it did while only one person was using it. This use has to

be approved by a qualified person. A qualified installer may fulfill this requirement if he is

specifically trained and qualified to do so

d) Self-retractable Lifelines

Self-Retractable lifelines can be used as a method of providing vertical lifelines for ladders,

scaffolds, etc. Self retracting lifelines and lanyards that automatically limit free fall distance to

0.6 M or less shall be capable of sustaining a minimum tensile load of 1350 kg / 2780 lbs,

applied to the device with the lifeline or lanyard in the fully extended position.

e) Safety Nets:

Safety Nets are to be installed directly below the work platform, after the risk has been

assessed. Safety nets shall be installed as close as possible to the working level but in no

case, more than 7.7 meter below the working level. Material, equipment and other items that

fall into the net are to be promptly removed. Safety nets are to be inspected before use and

then daily for wear or damage caused by falling materials. Safety net installation shall be

inspected by the concerned maintenance / construction supervisor.

3.5.3c GUIDANCE ON APPLICATIONS OF PROTECTION EQUIPMENT

Applications related to working at height while using

1. Step Ladders: Step Ladders should be used only for Shorter time duration (maximum 30 minutes)

and Light work (up to 10 kg load).



Guidance:

Do not work off the top two steps (top three steps for swing-back/double-sided stepladders)

unless you have a safe handhold on the steps

Side-on working is not allowed

Do not overreach – make sure your belt buckle stays within the stiles and keep both feet on

the same rung or step throughout the task.

While using a step ladder to climb one must use 3-point contact and appropriate fall protection

devices

2. Straight Ladders and Extension Ladders

When a straight ladder or extension ladder is being used for access to a work area (as

opposed to working from the ladder) where frequent trips up the ladder will be made,

consideration shall be given to providing fall protection such as a retractable lifeline or rope

grab for those climbing the ladder

Straight ladders and extension ladders shall always be held by a coworker while the ladder is

being tied off. The person on the ladder shall attach their lanyard to the anchor point before

tying off the ladder itself

Ladder shall be positioned with an angle with horizontal ground >75O

Guidance for working on Straight Ladders:

o Can be used only for Short duration work (maximum 30 minutes) and Light work (up to 10

kg load)

o Do not overreach - make sure your belt buckle stays within the stiles and keep both feet

on the same rung or step throughout the task

o Do not work off the top three rungs – this provides a handhold

3. Fixed Ladders

Permanently mounted ladder such as those on the side of buildings or vessels If working from a fixed ladder where there is a possibility of falling off, tie-off is required. The

fixed ladder may be used as a tie-off point When a fixed ladder is being used by many people to access a work area (an example would

be for vessel repairs during a shutdown), consideration should be given to providing fall protection equipment for the duration of that job

If a cage is present around the fixed ladder then fall protection is not required for normal day-to-day climbing. If there is no cage present then fall protection must be used

A landing platform is to be placed once every 7 meters

;




4. Scaffolds

No wooden (bamboo) scaffolds should be used.

The Scaffold material used must be of sound construction and there should be a firm foundation for all scaffolds.

Fall protection is required whenever working outside the plane of the handrails or if working against the handrails with awkward body position. Personnel shall not climb on, or work from, any scaffold handrail, mid-rail, or bracing member. Instead they should use ladders to get into the scaffold.

Fall protection shall be used while building scaffolds. Wherever practical, a retractable lifeline should be used to protect those building scaffolds but is not permitted to be attached to the scaffolding due to the side force thrust hazard. Double lanyards should be used in this case so that the person may maintain continuous tie-off.

5. Access of pipe racks, cable trays, structural steel, roofs, etc

When working on roofs edges, fall protection equipment shall be used, unless roof edges

are protected by a Protective Barricade. Furthermore, any work on a sloped roof requires

fall protection.

6. Mobile Elevated Work Platforms (Man lifts/Scissor Lifts/Bucket Trucks)

When working from man lifts, scissor lifts, bucket trucks, or other similar equipment, tie-off is

required. Most such devices have internal tie-off points and these should be used so that it

provides fall protection during any unfavorable situation. Ensure that the ground conditions are

stable (i.e. There is no risk of the Elevated Work Platform becoming unstable or overturning).

Also care has to be taken so that the Mobile Elevated Work Platform does not get caught on

any protruding features or overhead hazards, (e.g. steelwork, tree branches or power lines).

The Mobile Elevated Work platform must also be examined, inspected and maintained as

required by the manufacturer's instructions and daily checks must be carried out.

7. All other Situations

The objective is to provide fall protection for individuals whenever there is the potential for an

injury from falls. Situations not covered by the above guidelines should be evaluated for their

fall potential and fall protection procedures shall be used where that potential exists.


Note:

Special consideration shall be made when there is a possibility of the safety harness/lanyard

becoming entangled in rotating equipment (e.g. rotating shafts of pumps and/or vehicles).

8. Fall protection equipment

All fall protection equipment must comply with local regulatory requirements. They have to

be inspected at regular intervals and have to be visually inspected before each use.

The fall protection device must be designed in such a way that it is able to withstand the

adverse conditions (e.g. High temperature, Acid exposure etc.) that it is being used in. If

this protection is not available and there is evidence of damage to the harness, then the

harness must be taken out of service and destroyed

Note:

A proper rescue plan must be defined appropriately as per the work activity.




3.6 Contractors Safety Management Standard

3.6.1 INTRODUCTION:

This standard pertains to Contractual work and is aimed at ensuring that all work undertaken by

contractors, including sub‐contractors, is conducted in a manner that;

It protects the health and safety of all employees of Tata group, employees of contractors, sub-

contractors, consultants and visitors to the company premises.

It establishes formal performance measurement procedures to monitor and evaluate contractor

safety performance.

The established documentation for ensuring the safety of contractors employees through safe working

procedures is henceforth referred to as Contractors Safety Management Standard.

This standard applies to the management of all contractors and sub contractors where the business is

operated and controlled by Tata Group. The Contractor Safety Management Standard establishes

policies and procedures applicable to all contractors, contractors’ employees, and contractor’s

agents/representatives, and sub-contractors regarding safety, health, and environmental

responsibilities on Tata group premises, and for work performed for Tata group. The purpose of this

standard is to ensure that work performed by contractors does not place the contractor, Tata Group

employees or others at risk of injury.

Note:

For the purpose for this standard, safety includes aspects of health too.


RESPONSIBILITY:

The same safety standards must be applied to contracted employees as they are applied to

Tata employees.

For labour only

arrangements, contractors must be included in Tata safety processes.

For supervised

and set apart

contracts, the requirements in this standard must be applied.

This Standard does not relieve Contractors of their responsibility towards their employees, for safety,

health, and environmental compliance under law, code, ordinance, or statute.

Providing a safe work environment for Contractors is the responsibility of both the company

and the Contractor(s). The following sections list specific responsibilities of each

organization.



Individual company:

Company responsibility includes,

Ensuring a contractor pre-prequalification process is applied that evaluates the safety systems,

capability and performance of contractors prior to work commencing

Before placing a contract the type of relationship required for each contract e.g. Labour only,

Supervised or Set aside, must be determined by taking into consideration the commercial and

safety risks involved.

Providing an environment in which contractors can work without the risk of an injury

Ensuring that tenders for contracts contain sufficient information to enable an evaluation of the

safety risk and control measures associated with the work activity

Provide information relating to the hazards and the risk control measures designed to prevent

injury and/or loss

Monitoring, Auditing and Inspecting contractor activities at their work location

Sharing good practices to promote continuous improvement in contractor and company safety

performance

Contractors:

Contractors and sub contractors’ responsibility includes,

Ensuring that work areas and activity under their control do not place their employees, company

employees or others at risk of injury or ill health.

Ensuring that equipment brought into company property is used, stored and maintained in a safe

condition

Company’s equipment loaned to contractors for use on site is maintained in safe working

condition.

Establishing safe systems of work and supervision to ensure the work activity does not expose

individuals to risk of injury or ill health and damage of company assets.

Conducting periodic safety inspections of all assigned areas

Identifying and controlling hazards that are created by the contractors activity

Providing appropriate personal protective equipment (PPE) for the tasks undertaken by their

employees and ensuring compliance

Ensuring safety training is provided to their employees appropriate for their assigned tasks

Liaising with the contract owner from the company, to ensure effective management and

communication of safety matters

Reporting any accident / incident / Near miss / Dangerous occurrence that resulted or could have

resulted in an injury or property damage and assist in any resulting investigation

Maintaining the necessary insurance coverage required by the company and local regulation

Establishing and maintaining an effective Safety & Health Program in accordance with applicable

federal, state and local regulations

Deploying safety personnel / professionals to monitor, inspect and audit the safety requirements

of their activities.


3.6.3 STANDARDS/KEY STEPS:

3.6.3a REQUIREMENTS OF CONTRACTOR SAFETY MANAGEMENT:

Organisations and people providing services that can impact company’s operations and reputation

must perform in a manner consistent with company’s policies and business objectives. There must be

effective systems in place to ensure that company’s safety values, behaviours and approaches are

applied to contractors. It must be ensured that;

Systems are in place to ensure pre-qualification, selection and tender assessments take place.

Assessments are appropriate in nature to the scope of work requirements.

Written procedures exist that clearly define the scope and requirements of the selection process.

Contractors selected have safety management systems that align to company’s safety principles

and expectations, and periodic auditing is conducted by the contractor and the site premises to

ensure that these principles and expectations are met.

An appropriate senior executive has overall responsibility for contractor / supplier activities and

appropriate numbers of coordinators are available to monitor contractor activities.

Work control requirements and expectations are clearly set out in written procedures that include

supervisory requirements as appropriate.

Systems are in place to ensure the effective management of interfaces between contracted

services and company’s operations.

Internal information channels exist to ensure appropriate communication takes place between

contracted service providers and the company.

Systems are in place to enable local operations teams to provide feedback on contractor

performance.

Contractor and supplier performance is periodically evaluated to ensure partnership expectations are

continually met. Identified deficiencies must be corrected.

3.6.3b SIX STEP CONTRACTOR SAFETY MANAGEMENT PROCESS TO IMPLEMENT THE

REQUIREMENTS

The process of Contractor safety management System is guided by the six step process, as

enumerated in Table – 1.

Contractor selection

Contract preparation

Contract award

Orientation & training

Managing the work

Periodic evaluation



Table 1

Sl. No Step Key Elements

1 Contractor

Selection

Identify contractors who comply to company’s operating safety

principles

Critically evaluate contractor’s past safety performance

2 Contract

Preparation

Develop contract package with safety expectations clearly outlined.

Help the contractor understand how to deliver safety requirements

specified in the contract.

3 Contract Award Thorough & effective review of contract safety specifications at bid

& pre-contract award meetings

4 Orientation &

Training

Ensure that contractor’s workers embrace the “safety culture” of

the contractor safety management system.

5 Managing the

Work

Assess field safety execution against contract requirements

Assure that audits or safety visits are directed at injury prevention

Put in place processes that drive continuous improvement and

avoid repetition of common errors

6 Periodic

Evaluation

Establish process & procedure for rewards and consequence

management

Enable other divisions / job / constructions to share success

3.6.3c CONTRACTOR SELECTION

Objective:

Identify contractors who are compatible with the company’s operating safety principles. Critically

evaluate the contractor’s performance criteria. The following four criteria have to be evaluated;

Workers’ Compensation Payout: The total amount paid out to sick or injured employees as workers’ compensation in the last three years. This is a direct cost of poor safety performance by the contractor.

Injury rates: Calculate the Lost Time Injury Frequency Rate (LTIFR) and Calculate the Severity

Rate (SR)

Program Regulatory Citations

Fines and/or Warnings enforced on a potential contractor by a Government Agencies and/or

Ministries or by their previous company

Gather and analyze this information from subcontractors routinely used by prime contractor



Competency. Following are the questions which need to be addressed effectively during the competency assessment;

Does the contractor have any previous record of successful completion of jobs at the

company’s, Tata company or at other company sites

Does the contractor have qualified, trained, experienced personnel and supervision for all

safety aspects of the work

Does the contractor, conduct job safety inspections, and maintain incident investigation logs

Is the contractor insured and bonded

Does the contractor have sufficient resources (equipment, staff) to complete the work safely

Can the contractor adequately monitor subcontractor activity

Are there any written, comprehensive, and current safety systems

Can the contractor show evidence that the systems are effective (for example, do they have

safety audit records with measurable results)

Is there any record of safety training, as well as appropriate certifications and licensing

Are there clearly delineated safety roles and responsibilities for everyone in the contractor

organization e.g.: management staff, supervisors, workers, safety specialists.

Individual companies can decide to evaluate the contractors on more parameters than those set out in

this standard:

Contractor Selection Team Experience:

The team will comprise of Procurement / Purchasing, Safety Professional and Contract Owners. Their

collective capabilities should include:

Identification of contractors who are compatible with client’s operating safety principles

Critical evaluation of the performance criteria such as Workers’ Compensation Payout, injury rates,

programs, competency

Working knowledge of LTIFR / Severity Index

Government Regulations

Insurance: workers’ compensation, requirements, policies, laws etc.

Medical evaluation

Reference / referral information

The identification of appropriate safety equipment

Safety regulations and Security evaluation

Note:

The composition and capability of the team should be considered in light of the nature of work being

performed.



3.6.3d CONTRACTOR PREPARATION

Objective:

Develop a pre-tender package with the safety requirements clearly stated to clarify expectations

for particular contracting needs

Help understand how to deliver safety requirements as specified in the contract document.

Ensure contract specialists (Procurement, Legal, Contract Owner and, Safety Professionals)

participate in it

Steps to be followed for Contract Preparation:

Determine the Scope of Work.

Perform a Hazard analysis of that Work.

Create appropriate contractual safety specifications.

Determine plans and documentation requested from Contractor prior to bid.

Explain Safety performance expectations

Write standards for execution of the work

Identify capabilities of key personnel

Identify the behaviours expected of contractors

3.6.3e CONTRACT AWARD

Objective:

The objective is to effectively review contract specifications with regard to safety at the tender

stage and pre-contract award meetings

Preparation of a thorough and effective review of contract safety specifications at the tender

stage and pre-contract award meetings.

Review the contractors safe system of work and agree changes with the contractor where you

perceive the management of risk could be improved

Develop key personnel to do this work effectively

Ensure the right people, from the owner and contractor participate in these meetings

Bid and Pre-Award Meetings:

Select a competent person to explain the safety requirements

Conduct pre-tender and pre-work meetings to communicate expectations for safety

requirement in the contract.

Establish contractor understanding of the safety requirement in the contract.

Ensure that a process is in place for passing safety information to the appropriate people.




3.6.3f ORIENTATION AND TRAINING

Objective:

To ensure contractor’s supervisors and workers are aware of safety requirements & norms and

promote compliance.

No person shall be deployed at facility / site / business unit without having undergone safety

induction and job specific training at site

Training: Training shall be divided in two groups:

Orientation training - Training on general Site / Facility / Business unit safety rules/norms

(Everyone must undergo this training)

Specific Training – This training shall cover the requirements relating to the specific hazards,

risks and control measures, under the control of the company, in the area of work.

Contract workers must embrace the “safety culture” of site / Job / Construction and comply with the

requirements of the orientation and area specific safety training

Note:

Contractors must have a process in place that ensures employees are medically fit to perform their

duties and that their health is not adversely affected by occupational hazards.

Responsibility for Orientation and Training:

Contract owners provide orientation training based on the hazards, risks and control measures

of the site / facility / business unit

Area specific safety training should focus on the hazards, risks and control measures relating

to the area of work where contract work is being undertaken. The training should be delivered

to all contractor employees

Contract Owners must arrange for:

The provision of orientation and area specific safety training

Exchange of relevant safety documents such as Standard operating procedures, Safe

work procedures local Standards etc

Safety coordination meetings / Mass meeting etc.


Contractors are required to:

Designate sufficient resources to complete orientation and training effectively.

Ensure those employed in the work activity are competent to undertake the work they are

designated for.

Discuss work-specific safety plans with all employees involved in the work activity.

Confirm the key requirements of the safety plan are understood by all employees involved in the

work activity.

Evaluate effectiveness of planning, communication and training processes through monitoring,

inspection and audit processes.

3.6.3g MANAGINING THE WORK

Objective:

Assess field safety execution against contract requirements specified in the tender

Assure that audits are directed at injury prevention

Maintain a follow up process that drives continuous improvement and avoids repetition of common

errors

Working in a Collaborative Manner:

The contract owner and contractor should aim to optimize the safety performance of the contract

by working in a collaborative manner during the execution of the work. This can be achieved by

Reviewing Job Plans before each piece of work begins.

Conducting formal field walk-throughs (observations).

Observing and documenting findings and corrective action plans.

Broadly communicating findings and learnings from incident events.

Monitoring and responding to changing conditions.

Investigating safety incidents (injuries and near misses) for learnings.



The Key Elements for Evaluating Safety:

Formal safety work place inspections

Monitoring and reviewing safety training and meetings

Incident investigations (“near-misses” should be investigated as well, not just injuries)

Updating job plans as circumstances and conditions change

Periodic auditing of safety management systems and processes

Development of Key Performance Indicators (KPIs) that relate to the safety performance of the

contract

Broad communication of findings and learnings from the above processes

Communication Tools for Contractors:

Holding group meetings / tool box prior to beginning each day’s work.

Using bulletin boards or status boards in the workplace to display performance statistics and

safety messages.

Scheduling regular safety meetings that focus on specific relevant topics

Hazard Communication Programmes

Reviewing procedures for work activities with those engaged in the tasks

Reviewing emergency plans with employees

Contract Owners Should Evaluate, whether:

Roles and responsibilities for monitoring safety activities are well defined

There is a “partnership” between the contract owner and contractor for monitoring safety

activities

Safety observation activities focus primarily on “violations” or on prevention

Safety plans are updated when the work environment changes

Safety KPIs are appropriate to the contract and are routinely collected and reviewed

Learnings are broadly communicated from the safety evaluation processes




3.6.3h PERIODIC EVALUATION

Objective:

Establish a process that eliminates poor safety performance and recognizes / rewards contractors

who improve or excel.

Enable different divisions / sites to share successes

Post-Contract and Interim Evaluations:

Owner and contractor jointly evaluate contractor safety performance against contractual

expectations.

Owner and contractor evaluate effectiveness of major meetings.

Owner and contractor should conduct emergency drills and / or evacuation drills with

evaluations and feedback.

Owner and contractor provide constructive feedback to each other.

From learning, owner and contractor update databases, fine tune process, and make

improvements.

Owner determines whether the contractor remains on the tender list and whether or not to

recommend this contractor for future work.

Evaluate Contractor Safety Performance Against Contractual Expectations: Measurable results(Few examples are listed below, but not limited to)

Injuries / illness / incidents

Other Incidents excluding injury / illness / incidents

Workers compensation and general liability claims

Audits, Inspections & Timelines of corrective action

Subjective results

Behavioral compliance with safety requirements

Alignment with company’s values



4. MANAGEMENT SYSTEMS

4.1 Contact Resources:

The contact resources mentioned below will be able to provide guidance and insights on how these standards can be applicable at your workplace and need to be implemented. You are requested to direct your queries to these executives to seek information on implementation of these standards in your company.

4.2. Management Records:

Each company must have a company level document to ensure that the minimum requirements set forth in this standard are complied with. This document should be prepared within 6 months of release of this standard.

4.3. Standard Renewal Process:

This standard will be reviewed and modified whenever deemed necessary, however not later than three years from the date of the last revision.

4.5. Training and Communication Requirements:

TQMS will organize training programs on these standards. The programs will be conducted by the respective subject matter experts.

4.6. Contact:

The contacts for these standards are as follows:

Standard Contact Person Contact Email-ID

Electrical Safety Shrinivas Katti [email protected]

Fire Safety Management D Thakur [email protected]

Job Safety Analysis Suresh Tanwar [email protected]

Lockout Tagout Suresh Tanwar [email protected]

Working at Height Gulam Rasul Topiwala [email protected]

Contractor Safety Management

Agam Kumar [email protected]

In addition to the above contact persons for the standard, in case of any queries / clarifications for these standards, please get in touch with Gautam Gondil from TQMS at [email protected] or on 92255 43979 (Mobile number).

mailto:[email protected]




ANNEXURE




GENERIC DEFINITIONS:

Contractor: Any non-company entity that provides materials and / or services

Contract Owners: Any company employee who has overall control of the contract and who

certifies the bills of the contractors after completion of jobs.

Contracts involving labour:

Labour only: This is where the contractors work under company’s direct supervision. Work by

the contractor employees is managed and monitored by the company.

Supervised: This is where the contractor agrees to the work requirement & standard and

manages own employees and activities.

Set apart: This type of contract is usually for project type work and separate from company

operations. The contract is carried out within the site and the work is undertaken in an area

‘set apart’ and totally controlled by the contractor

Competency- Is a blend of knowledge, skill, training and experience that allows a person to provide

quality input on a particular subject.

Control Measures- The preventive measures, including the safe systems of work, that are put in

place as a result of a risk assessment to either eliminate a hazard, or control the risk, to acceptable

levels. Control measures are to be put in place in the following order of hierarchy.

a. Elimination: Eliminating the Risk altogether.

b. Substitution: Removing the Risk/hazard causing element and replacing it by an element that

does not produce risk / hazard

c. Engineering Control: Keeping the people potentially exposed isolated from the hazard

d. Administrative Control: Changing the way people work (E.g. Job Rotation, Training etc.)

e. Personal Protective Equipment

Hazard–Source or situation with potential for harm, something that can cause body injury /

occupational illness, damage company property.

Job - A piece of physical work defined by time or other limits and that has a clear start and end

point

Task / Activity - A sequence of steps taken to conduct a job. A task is a sub element of a Job.

Non Routine Job / Task - Where an SOP / SMP is not available or the conditions of the SOP / SMP

have changed

Risk - The likelihood (probability) which can lead to potential negative consequences.



Risk Assessment - A systematic and structured process whereby hazards present in a workplace,

or arising from workplace activity, are identified, risks assessed / evaluated, and decisions

prioritized in order to reduce risks to acceptable levels.

Severity – The level of consequence / harm of an event that could occur due to exposure to the

hazard present.

FIRE-BASICS AND DEFINITIONS SPECIFIC TO FIRE SAFETY MANGEMENT:

FIRE-BASICS:

Definition:

Fire is a chemical reaction where matter reacts with oxygen under certain conditions to release heat

and light energy.

Ingredients of Fire:

Three elements are necessary for initiation of a fire or combustion and it’s known as “Fire Triangle”,

Fuel: in form of vapour, liquid and solid.

A source of ignition (Heat or thermal energy): Sufficient to initiate and propagate the chemical

reaction of combustion

Oxygen: In sufficient proportion to form a combustible mixture

New understanding in ‘Fire Safety Management’ has necessitated the addition a fourth element to the

Fire Triangle (i.e. the chemical chain reaction) making the fire triangle now a “Fire Tetrahedron”

The most common sources of ignition are the heat produced by chemical reactions (such as striking a

match), by electrical energy (such as an arc), or by mechanical energy (such as friction).



Types of Fire:

Fire Types NFPA CODE – 10

Class "A" Fires in ordinary combustible materials, such as wood, cloth, paper, rubber, and

many plastics

Class "B" Fires in flammable liquids, combustible liquids, petroleum greases, tars, oils, oil-

based paints, solvents, lacquers, alcohols, and flammable gases

Class "C" Fires that involve energized electrical equipment

Class "D" Fires in combustible metals, such as magnesium, titanium, zirconium, sodium,

lithium, and potassium

Class "K"

(NFPA) /

Class “F”

(EU/UK)

Fires in cooking appliances that involve combustible cooking media (vegetable or

animal oils and fats)

Electrical Fire: Any fire involving or started by electrical equipment is classified as an Electrical Fire.

This is based on the means of ignition rather than the combustion material and applies only so long

as the circuit causing the fire is alive. Once it is switched off the fire is of the class A, B, or C. The

normal procedure in such fires is to cut-off the electricity and uses an extinguishing method

appropriate to the burning material.

Fire Extinguishing Method

Extinguishing fire involve removal or limiting of one or more of the factors depicted by the fire triangle.

The method of extinguishing fire may be classified under the following heads:

Starvation – Elimination of fuel

Smothering – Removal of oxygen supply

Cooling – Removal of Heat

Fire Classification

Fires can be classified based on the intensity and extent as given below:

Small- A fire in its incipient stage which is controlled by the first line of fire fighting team.

Major fire –

The fire which is spreading to other equipment or areas

Which threatens to go beyond the control of first and second line firefighting and when

external help is sought

Any lost time incident due to the fire.

Plant / Unit shut down due to fire



DEFINITIONS SPECIFIC TO FIRE SAFETY MANGEMENT:

Flash Point –The minimum temperature at which the liquid gives so much vapour that this

vapour, when mixed with air, forms an ignitable mixture and gives a momentary flash on

application of small pilot flame under specified conditions of test.

Fire Point – It is the minimum temperature at which a liquid gives off sufficient vapors to form a

mixture with air near the liquid surface within the container and gives sustained fire when an

external source of ignition is brought to it.

Auto Ignition Point –The lowest temperature to which a solid, liquid or gas requires to be raised

to cause self-sustained combustion without initiation by a spark or flame.

Explosive Limit –Explosive limits are those concentrations of inflammable vapour or gas in air

below or above which, propagation of a flame does not occur on contact with a source of ignition.

Lower Explosive Limit -The Lower Explosive Limit (LEL) is the minimum concentration of

inflammable vapour/ gas in air below which the vapour air mixture is too “lean” to burn or explode.

Upper Explosive Limit -The Upper Explosive Limit (UEL) is the maximum concentration of

inflammable vapour/ gas in air above which the vapour air mixture is too “rich” to burn or explode.

Volatility - When liquid is in an open container and exposed to the atmosphere, it will gradually

change into vapor and disappear. This process takes place more rapidly with some liquids than

with others. Example: If a small quantity of gasoline is exposed to the air it disappears very

quickly, diesel requires longer period to evaporate and grease even longer. The inherent tendency

of a substance to vaporize is termed as volatility.

DEFINITIONS SPECIFIC TO WORKING AT HEIGHT:

Anchor Point - A secure point of attachment for lifelines, lanyards, or retractable lifelines.

Structural steel or process piping of 2 inch (5cm) diameter or greater may be used as an anchor

point. Sprinkler piping, instrument tubing, or conduit should not be used as an anchor point. In the

absence of anchor points, spring loaded stamp post may be installed and a lifeline can be put

across the same. While using this, it has to be ensured that it provides the same level of safety as

any other anchor point.

Attendant - A person at the perimeter of work area who is assigned the role of monitoring and

communicating with the authorized workers, controlling access to the area, maintaining

designated conditions as specified on the permit, and initiating the rescue plan.

Certification - A verification process which documents that a person has the necessary training,

skill, or experience and the ability to perform designated roles and tasks.

Continuous Tie-Off - The requirement that a person be tied off at all times when working on

elevated areas, where the potential for a fall exists. This is most commonly accomplished by

using double lanyards, a vertical lifeline, or a retractable lifeline.


Double Action Locking Snap Hook - A device for securing lanyards that requires two separate

locking pins be depressed before the snap will open.

Double Lanyard - A system utilizing two lanyards connected in a "Y" configuration, which allows

one lanyard to be attached to an anchor point while the second lanyard is being moved to a new

anchor point, thus providing protection from falls at all times.

Full Body Harness - A Class 3 full body harness, heavy duty, with leg straps.

Lanyard - A flexible line to secure the wearer of a safety harness to a lifeline or fixed tie-off point

Lifeline - A flexible cable, either horizontal or vertical, which is anchored at both ends and to

which other personal fall prevention devices can be attached and which meets the minimum load

specifications. Most countries requires lifeline integrity to withstand 5000 lbs/2300kg (or country

specific requirements) of force per man supported.

Qualified Inspector - Any person who has been specifically trained to inspect and evaluate the

condition of harnesses, lanyards, etc. Completion of the site training course for fall protection

certifies an employee as a Qualified Inspector. (Strategic Business Unit (SBU) / Site Management

and Project Management to provide qualified resources). As working at height is also being

performed by contractors, company standards must clearly define the “qualified inspector” for

contractors and the work performed by them.

Qualified Installer - Any professional, experienced Fall Protection systems person who has been

specifically trained in the installation of lifelines and fall protection systems.

Retractable Lifeline - A retracting lifeline which allows free travel without slack rope, but locks

instantly when a fall begins. These devices must limit the force of deceleration to no more than

800 lbs/365kg or country specific requirement and are only recommended for vertical descent.

Rope Grab - These are automatic lifeline devices which act by inertia to grab the vertical lifeline

should a fall occur. Rope Grab shall be ¾” (19mm) synthetic rope or ½” (12mm) wire cable.

Shock Absorber – A device used in combination with lanyards that is designed to reduce the

force when fall is broken. If working at a height of less than 6 meter shock absorber should not be

used.

Work permit - The written or printed document that is issued to control working at heights.

Work supervisor - A person who is authorized; to verify that all conditions for working at heights

have been met, to define ongoing precautions to maintain safe working conditions during the

work, to authorize the work to occur, and to cancel the permit allowing the work; also known as

proprietor, work group supervisor, or authorizing person.

Working at heights - Elevated working positions where the hazard of a fall exists and where

there is no physical protection such as handrails. Types of work covered include working from all

types of ladders, scaffolds, mechanical lifts, inside confined spaces, sloped roofs, areas where

there are no overhead tie-off points, when working at the edge of a flat roof, erecting steel or



Installing / replacing roofing and pipe racks. However, this does not include normal work on low

stepladders, loading platforms, or similar locations.

It is to be noted that fall from height can also be due to fall from the ground level to an

underground level (i.e. in excavations, underground tanks etc.)


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