Annexure 11 - Safety Handbook

7/27/2019 Annexure 11 - Safety Handbook

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WSQB-5-CONSTRUCTIONWartsila India Ltd Power Plants

Doc. id: 2500 W036 b

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Date / Status: 20-July-2009 APPROVED

Made/Approved: M. Sukumar /James Rajan

Replaces: 2500 W036

Name: Construction

Subject: Safety Handbook

SAFETY HANDBOOK

Table of Contents

1. Purpose of this Handbook

2. Safety Policy

3. Responsibilities

3.1 Site Manager / In charge

3.2 Site Engineer / Supervisor

3.3 Sub-Contractor(s)

3.4 Accident Reporting

4. Safety Guidelines & Procedures

4.1 General guidelines

4.2 Procedure for safety implementation at sites

4.3 Personal protective equipment (PPE)

4.4 Excavations

4.5 Scaffoldings

4.6 Ladders, Height & Roof work

4.7 Electrical safety

4.8 Confined spaces

4.9 Tools

4.9.1 General4.9.2 Hand Tools

4.9.3 Electrical & Pneumatic Power Tools

4.9.4 Jacks

4.10 Material Handling

4.11 Welding & Cutting

4.12 Chemical cleaning & pickling

4.13 Pressure testing of pipes & tanks

4.14 Fire Prevention

4.14.1 Types of fire

4.14.2 Types of portable fire extinguishers

4.14.3 Measures to be taken in case of fire


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4.14.4 Regulations for fire prevention

4.15 Initial start-up of EG set

4.16 Radiography

4.17 Dress code at site

4.18 House keeping

4.19 Traffic at site

5. Safe Operating Plan

5.1 Working at heights

5.2 Pickling

5.3 Use of cranes

5.4 Excavations

5.5 Working in confined spaces

5.6 Grinding, gas cutting & welding

5.7 Masonry work


6. On Site Emergency plan

6.1 Declaration of an Emergency

7. Work Permit System

7.1 Introduction

7.2 Definition of restricted & hazardous areas

7.3 Authorised issuer7.4 Authorised receiver

7.5 Issuance & approval

7.6 Handling of issued Work Permit

7.7 Guidelines for Work Permit

8. Formats & Checklists


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1. Purpose of this Handbook

This Handbook provides basic information and instructions to assist Wartsila India Ltd.

employees at Construction sites to fulfil their Operational Health & Safety (OH&S)

responsibilities.

It is intended to be a quick reference and complements more detailed information and

documentation in paper or electronic form if any.

The general requirements of this Handbook apply to Wartsila India Ltd., Sub-Contractors and

Customer. The Handbook provides awareness on

Wartsila Construction Safety Policy

Our obligations to take all reasonably practical steps to care for health & safety of

employees & others at or near the workplace.

Our obligations to create & maintain a safe & healthy work environment.

Guidelines & Procedures for achieving the above.


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2. Safety Policy


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Wartsila values and respects human life and consequently strives to provide a safe and

hazard free work environment and to minimize the adverse occupational health and safety

impacts of our operations and products.

It is our aim to achieve

Accident / Incident free construction

Preventing time and cost overruns in projects due to poor safety.

Increased Customer confidence in Wrtsil Safety Systems

3. Responsibilities

Wartsila management is in charge of overall deployment of safety management system.

Management will:

Allocate resources required to ensure Safety at work, of all site personnel.

Formally review & approve Safety Policy & Procedures.

Demonstrate commitment to Health & Safety through participation in formal / informal

discussions, work place visits, site audits and hazard inspections.

Participate in the resolution of Safety issues.

Review serious accidents / incidents and monitor corrective actions.

Ensure Safety awareness for all employees.

Monitor Health & Safety performance within area of responsibility.

Wartsila Construction Site Organization is responsible for implementing Safety at sites. Site

organization is also responsible for informing the management of non-conformity, emergency

situations and any changes that affect Safety.

3.1 Site Manager / In charge

Is responsible for following safety policy for the area and ensuring that every Wrtsilemployee on site understands and complies with the policy and safety procedures:

implements Safety Program and maintains Wrtsil safety policy site safety organisation chart for the site shall be prepared and displayed at site is accountable for all construction operations communicates safety statistics, accident reports, etc. to Wrtsil and/ or customers

representative


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observes that work on site is inspected daily to ensure that minimum safetyrequirements are followed

maintains discipline at site in terms of safety performs daily inspections

prepares work permits on restricted areas implements / organizes the employees training activities, conduct regular safety

meetings corrects found safety rules defects is familiarized to local/ customers safety requirements maintains close cooperation with customers safety officer in safety issues controls emergency situation ensures that accident reports are prepared, reviewed and distributed makes proposals for improvements of safe work at site

Wrtsil Site Manager is authorized to stop any work, reject any person from the site,material, or equipment that does not conform to the safety requirements.

3.2 Site Engineer / Supervisor

Site Supervisors are responsible for understanding and observing the Safety proceduresand shall: work in accordance with accepted safety practices improve safe work on site and make safety suggestions obey and observe the companys and customers safety policy and safe work

guidelines & procedures Carry out tool-box talk perform daily inspections prepare work permits on restricted areas

report all unsafe practices and unsafe conditions use the personal protective equipment provided and/ or requirement by the job teach safety to new employees & workers and set a good example report any injury or accident immediately

3.3 Subcontractor (s)The subcontractor is responsible for understanding and observing the safety proceduresand will always: work in with accepted safety practices obey and observe local, Wartsilas and customers safety policy and safe work

procedures report all unsafe practices and unsafe conditions


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supply personal protective equipment for their manpower according to localrequirements

teach safety to their new employees and set good example report any injury or accident immediately

make safety a part of everyday job

All personnel at site are responsible for

adhering to all safe working procedures in accordance with instructions

Taking reasonable care of themselves and others who may be affected by their

actions.

Reporting all known or observed hazards or risks to their immediate manager or

supervisor or customer site supervisor.

Reporting all incidents / injuries, near misses and dangerous occurrences.

3.4 Accident Reporting

Site Manager shall:

a. Report to head office / superior all accidents on phone, fax / e-mail within 24 hours of theaccident.

b. Report fatality or close to fatal condition the matter immediately to head office / superiorand customer.

c. Send Accident report within 48 hours of the accident.

d. Report damage to equipment or property to head office / superior and customer & send

report to head office.

e. All major accidents to be reported in form no. 2500 F064

4. SAFETY GUIDELINES & PROCEDURES

4.1 General Guidelines

1. Site Manager is in charge of deployment of the laid down Safety Policy, Guidelines &

Procedures.


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2. Safety Guidelines & Procedures that apply to Wartsila also apply to Sub-Contractors and

Clients.

3. All contractors should strictly follow the requirements of the Safety Handbook issued to

them and also ensure the following.

a. Contractor should employ at least one person who is trained in First Aid and Safety.

b. Wrtsil & Contractor/s should have adequate number of fully equipped First Aid Boxes.

Each First Aid Box shall contain Antiseptic Lotion & cream, clean bandage rolls, clean

surgical cotton. Scheduled drugs / antibiotic drugs shall not be kept.

c. All Personnel working at site should use necessary Personal Protective Equipment (PPE)

d. Smoking is not allowed in work place.

e. Contractor should deploy sufficient number of sand filled bucket and appropriate Fire

Extinguishers at the workplace

f. Walking on suspended load/insulated pipe is not allowed.

g. No one will be allowed to work inside tank or confined area alone - a Safety Line or watch

person should be employed.

h. Any explosives to be entered (only if is a must) into the work place only with prior

approval/authorization from the Site in Charge.

i. Persons found intoxicated or suffering from the effect of Alcohol should be removed from

the work place.

j. The workplace should be well illuminated.

k. Prior to commencement of any heavy fabrication, equipment handling and other erection

works, contractor and WIN in charge shall ensure the ground level / compaction and if

required carry out the strengthening of ground.


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l. A good housekeeping must be followed to avoid any accident and delay in work. Cleaning

up before and after the job is better than cleaning up after the accident.

m. All scrap materials should be stored in a separate identified place. Upon unpacking,

wooden planks with upturned nails / screws shall be immediately removed to scrap yard

n. The work place should be cleaned of all debris daily at the end of work. There should be a

box/place where all these debris can be collected and discarded.

o. All openings should be covered suitably and necessary barricades handrails and signals

should be used.

p. Obey all warning signs and barriers indicating hazards for X ray, high pressure, high

tension, over head loads, blasting, hot works, earth works etc.

q. Persons acting with disregard to Safety Regulations even after issuing warnings should

be removed from the site.

r. Never let the pressure of time tempt anyone to take risks. All Wartsila personnel should

remain alert & vigilant and any accident should be immediately reported to the Site In

charge who will in turn report the same to office.

4.2 Procedure for Safety Implementation at sites

.a. Safety posters shall be supplied to every site during site mobilization. These

posters shall be displayed at all important work spots at site.

b. Deployment of skilled manpower. Skilled manpower means all the welders shall be

qualified as per the procedure format no: 2500 F052. For fitters, riggers, grinders,

electrician, etc WIN site engineer shall ensure their similar experience in the past.

c. Emergency evacuation plan to be prepared at site.

d. Upon site mobilization the factory doctor or the local doctor should be identified and

his phone number and address to be prominently displayed in the site office.


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e. All equipment & tools shall be inspected for their fitness before use. Defective

equipment & tools should be tagged Unsafe Do not operate tag. Site Manager

shall organise the Site Engineers to carry out such inspections.

f. Selection of slings to be done as per the recommended load charts. Usage of

damaged slings should be avoided.

g. All the power tools & electrical connections to be checked by an electrician

h. All the power cables used shall be double insulated.

i. The ELCB shall be installed in the MDB.

j. All the hazardous area shall be barricaded.

k. Use walky-talky for proper communication wherever it is required.

l. All the heavy /higher elevation erection work to be preferably performed during the

day light.

m. Site Engineers shall hold Tool box talks weekly, during induction of new work men

and also prior to start of fresh jobs at work spots / in site office wherein a group of

workers engaged in a particular activity, along with their supervisors, shall be briefed

about safety regulations such as use of PPE, hazardous conditions, safety guidelines

etc. Records of such tool box talks shall be maintained in Doc. 2500 F200 (Tool Box

Form) It shall be ensured that all supervisors & workers covering all work areas shall

one time or the other be called for such meetings.

n. Site Manager & Site Engineers shall check the site daily for safety non-compliances,

unsafe conditions and acts. These shall be notified to the contractors in Doc. 2500

F201 (Spot Safety Observation Form)

o. Contractor/s shall be fined @Rs.1000/- for every instance of non compliance of safety

norms and house keeping as stated in this safety handbook, at site.

p. Construction sites shall be subjected to safety audits and findings shall be reported in

Doc. 2500 F202 (Site Safety Audit Report)


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q. Works permit shall be applicable for the works carried out in the existing systems and

does not involve hot works. Enforcement of work permit shall be decided by site

manager based upon site needs/customer needs.

r. Hot work permit shall be applicable for the works carried out in the existing systems or

in the systems that are in operation and which involves hot works like welding, cutting,

grinding etc. Enforcement of hot work permit shall be decided by site manager based

upon site needs/customer needs.

4.3 Personal Protective Equipment (PPE)

1. All personnel at site must wear suitable PPE. Minimum Standard of dress at site is:

Proper fitting clothes / Boiler suit / Overalls, Helmet and Safety Shoe.

2. PPE shall include all clothing and accessories designed to create a barrier against

workplace hazards. Wearing loose clothing which might tangle in wiring or machinery

is not permitted.

3. All employers / contractors have the responsibility of providing appropriate PPE to

their employees & workers. Visual Inspection of PPEs should be done before its use

by the user

4. Wrtsil site office shall maintain extra helmets for visitors. All visitors are required to

wear helmets while at site.

5. Wartsila site personnel trained in safety shall ensure that each employee / worker of

the contractor is aware of the effective use of PPE. This shall be achieved through

briefing of newly arrived workmen at site and through daily Tool Box Discussions


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6. Faulty protective equipment shall be rejected and replaced immediately with new one.

7. The following PPE shall be made use of by personnel at site and shall be selected on

the basis of nature and magnitude of hazard, degree of protection required,

acceptable level of exposure and risk while the protection is in use:

8. Helmet: For head protection from blows & impacts. Helmets resist penetration, absorb

shock of blows and can also offer protection against electric shocks. Class A type of

helmets shall be used in most cases. All site personnel and visitors are required to

wear helmets.

9. Safety Shoes: For foot protection from impalement by sharp objects. Also protect feet

from slipping & crushing. Safety shoes with steel toes must be worn. Worn out

shoes must be immediately discarded and replaced with new pair. All site personnel

are required to wear safety shoes.

10. Clothing: Loose fitting clothes must not be worn at site. Where required, boiler suits,

overalls & aprons shall be worn.

11. Safety belts & lifelines: These safeguard from accidental falls and must be properly

secured at the workplace. All persons working at heights more than 3 metres such as

roof, structures, chimney etc. in absence of scaffolding, platform & handrails are

required to wear safety belts/harness, fall arrester, life line etc wherever required.

12. Goggles: For eye protection from impact of flying particles particularly during grinding,cutting, chipping & cleaning with compressed air. The goggles are made of shatter

proof clear glass in moulded PVC frame. These should be worn by persons involved

in the said activities.

13. Welding: The welding mask protects eye from the intense light & UV radiation emitted

by the welding arc. These masks are made of vulcanized fibre with adjustable sponge

padded head gear. Central metal frame aperture accommodates glass of size 107 x

83 x 3 mm, dark green colour of shade 11 DIN sandwiched with a pair of clear

protective glass of same size. The mask is to be worn by all welders & helpers

exposed to intense light & radiation from welding arc.


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14. Respirator: Protect lungs from inhalation of dust & abrasive particles. These are to be

worn by personnel engaged to activities such as sand blasting.

15. Hand gloves/Masks: Leather hand gloves should be worn by welders. Rubber gloves

should be worn by electricians exposed to high voltage & by persons engaged in

pickling, exposed to hazardous chemicals such as acids & alkalis etc. Masks shall

also be used during insulation, pickling/painting and also welding in confined areas.

16. Ear muffs / plugs: For ear protection when the noise level is over 80 dB(A). Ear muffs

or plugs shall always be used in all areas designated as a high noise areas such as

DG hall.

4.4 Excavations:

a. For excavations in an area where underground pipes and cables are installed, the work

needs continuous supervision.

b. To avoid any damage to pipes or cables, etc. exposed during the excavation, sufficient

supports must be provided under them.

c. Excavation works shall be kept illuminated.

d. Proper barricading shall be done around the excavated area.

e. Adequate & suitable warning signs shall be put up in conspicuous places at excavation

work to avoid any person falling into the excavation.

f. Excavations such as ditches, trenches, etc. shall be sloped sufficiently to prevent cave-ins

or slides.

g. Excavated material such as heap of soil should not be stored less than 0.65 metres from

the edge of excavation.


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h. Where the depth of excavation is more than 1.5 metres, suitable means of access &

egress (getting out) such as ladder, ramp, staircase etc., as the case may be, shall be

provided.

i. For trenches less than 1.2 metres deep, no timbering or shoring is required unless there

is a danger of any material collapsing & falling. For trenches up to 4.5 metres deep, a

survey by trained civil engineer and experienced person is required to determine

requirement of timbering & shoring. If required, conventional timber shuttering or steel

trench sheets and adjustable props should be used. The props may be mechanical or

hydraulic.

j. Where banks of an excavation are undercut, adequate shoring is to be provided to

support the material or article overhanging such bank.

k. Safety Helmets should be worn at all times.

l. LPG cylinders or inflammable liquids such as petrol shall not be stored in trenches. LPG

is heavier than air and does not leave a confined space easily.

m. Do not allow heavy vehicles near the edge of excavation to prevent the ground from

breaking away under the weight of the vehicle.

4.5 Scaffolding

a. Scaffolding must be provided for all work which cannot be safely done from the ground or

part of a building or other permanent structure.

b. Scaffolding must be erected, altered and dismantled under supervision of a competent

person & by people with adequate experience.

c. Scaffolding must be constructed of sound, strong steel tube material.

Tubes/pipes used should not be not corroded, bent or distorted.

Use only proper steel scaffoldings

Wooden planks used for working platform should be of uniform size & strength to

support the load & workers, free from nails, screws, cracks, oil and grease.


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Fittings & clamps free from worn threads or damaged bolts and excess oil which may

reduce friction grip.

d. Vertical posts or standards of the scaffolding can be placed directly over concrete or steel

floor although generally preferable to use base plates. On other surfaces, use base

plates & sole plates on a soil that is levelled & properly compacted. Do not use bricks or

odd timber pieces under sole plates. Cut steps on a sloping ground to accept base plate

& sole plate.

e. Working platforms or decks for persons & material movement should be provided at all

levels where the work is to be carried out. The floor of the platform should be made of

closely packed boards/planks (each board not less than 225mm wide and space between

two boards not more than 25mm)

Overhang of the boards on bearer pole should be minimum 50mm. Width of the platform

must be 440mm if used by men only & 640mm if movement of material is also there.

Space between platform & wall must not be more than 300 mm.

f. Guard rails of height 910mm to 1150mm should be provided on platforms but not more

than 765mm above the toe board. They should be fixed inside the standards/posts.

g. Toe boards should accompany the guard rail and should be at least 150mm high above

platform. They should be fixed inside the standards/posts.

h. Structural diagonal & cross bracing should be provided to impart stability to the

scaffolding structure.

i. No one should climb on the diagonal or cross bracings.

j. Ladder should be provided at angle of 75 deg. to access the working platform. Ladder

should be properly supported. It should be secured at the top & bottom to prevent

swaying or sagging and should extend at least 1.05 meters above platform. The vertical

height between landings should not exceed 9 metres. No material should be stored on

the landings.

k. Scaffolding must be inspected once in 7 days of use and also after exposure to adverse

weather conditions which may have affected its strength & stability. It should also be

inspected after any substantial modification or alteration.


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l. Illumination to be provided if work is carried out on scaffoldings at night.

m. Do not fix tarpaulins on the scaffolding unless it has been specifically designed for the

same.

n. Keep scaffoldings clear of overhead electrical wires or transmission lines.

A typical Tube & Coupler type of Scaffolding


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4.6 Ladders, Height & Roof work

a. Ladder as a means to access should be provided at angle of 75 deg. it should be

properly supported and secured at the top & bottom to prevent from slipping and should


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extend at least 1.05 meters above platform. The vertical height between landings should

not exceed 9 metres. Ladder with missing or defective rungs should not be used.

b. Rope/detachable ladder to be used for chimney erection works.

c. Ladders and stepladders must be maintained in good condition at all times. Joints shall be

installed tight, all hardware & fittings be securely attached and movable parts must

operate freely without bending or buckling. The unnecessary sideward/backwards

movement should be prevented.

d. Secure ladders placed in areas such as passageways, doorways, or driveways, or wherethey can be displaced by workplace activities or traffic to prevent accidental movement.Or use a barricade to keep traffic or activity away from the ladder.

e. Face the ladder when moving up or down. Use at least one hand to grasp the ladderwhen climbing.

f. Ladders must not be tied or fastened together to create longer sections unless they arespecifically designed for such use.

g. Two or more separate ladders used to reach an elevated work area must be offset with aplatform or landing between the ladders, except when portable ladders are used to gainaccess to fixed ladders.

h. If a person is liable to fall more than 2 metres, the landing place must be provided with

handrail of between 910mm & 1150mm height. The toe board should be at least 150mm

high. The space above toe board & handrail must not exceed 765mm.

i. If on a flat roof there is no parapet or barrier against falling, edge protection must be

provided in the form of guardrail and toe board.

j. On a sloping roof (pitch more than 10 deg.) made of asbestos, plastic or brittle sheet,

work should be done using crawling boards. Always use two boards one to support the

workman and other is moved to a new position. A firmly fastened life line of adequate

strength should be strung beside each crawling board throughout its length while using

such crawling boards.


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k. Wherever impractical to erect a platform & guard rail, use safety belts or harness that

should be always worn and safely anchored. The lanyard of the harness can also be

attached to a horizontal lifeline on roofs.

l. Maximum distance that a person may fall before arrest is 2 metres.

m. Use safety nets only where it is practical to support or fix them. Erect the nets as close to

the working level as possible. The max. recommended distance a person should fall


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before encountering the net is 6 metres. Personnel nets are 100mm mesh, intended to

catch a person falling from above. Material or debris protection nets are smaller mesh

12mm 19mm size intended to protect those below from falling objects.

n. Carry out weekly inspection of safety belts & harness & replace immediately if found

faulty.

o. Do not use body harness to hoist material.

p. Provide barricades around see-through (brittle & weak) sheets on the roof.

q. Never pile up sheets on the roof; they can fly off by wind and cause accidents.

r. Working involving handling of sheeting requires extra care in windy conditions when a

sheet may act like a sail causing a person holding it to loose balance.

4.7 Electrical Safety

a. Do not insert wires directly into the sockets. Use suitable plugs.

b. Metallic industrial sockets should be used instead of bakelite sockets.

c. Ensure that all electrical appliances and current carrying equipment are adequatelyearthed. All temporary electrical circuits should be provided with an earth leakage circuit

breaker (ELCB)

d. Do not be complacent having installed the ELCB. Test it periodically for performance.

e. Check plans to establish cable routes, depth & voltages before undertaking excavationsnear underground cables.

f. Regard all buried cables as live. Do not assume pot ended cables are dead or disused.

g. Resort to hand digging when nearing assumed line of cable.

h. Do not use excavators and power tools within 0.5 metres of assumed line of cable.


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i. Do not use exposed cables as hand and footholds.

j. Main switch boards shall in installed in enclosures.

k. Main switches shall be located at a height not exceeding 1.5 metre so as to be accessiblein emergencies.

l. Support the cables connected to switches such that no mechanical force is exerted onthem.

m. Do not permit defective wiring & faulty terminations.

n. All distribution cables to be festooned loops or cleated along the walls of a permanentstructure or on poles. The height of the cables shall not be less than 2 metres and shallbe at least 5 metres when run along or across the road.

o. Assume all overhead lines to be live unless advised otherwise by the owner / customer.Precautions to be taken to prevent contact of ladders, poles, crane jibs etc. with overheadlines while working / passing beneath them.

p. Never give direct supply to equipment (such as welding machine) without provision forisolation.

q. Place rubber mats in front of electrical panels.

r. Use only insulated tools such as pliers. Use screw drivers which are sleeved with PVCand not exposed at the user end. Preferably use double insulated tools.

s. Do not store any flammable material in the electrical appliances area or clutter the vicinityof any switchgear.

t. While testing, ensure that all men & material are removed & busbar chamber closedbefore meggaring. Ensure proper earthing before meggaring or high potential test.Cordon off the area and display warning boards before commencing testing.

u. Panel manufacturers provide barriers between busbar chambers to avoid accidentalcontact with live parts, when the doors are opened. Ensure that all barriers are in placebefore testing.


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v. When grounding devices are removed from equipment for testing purposes, they must bereplaced immediately after the tests are over.

w. Do not permit damaged cables running to welding machines, power tools etc.

x. Do not use pipelines or equipment as a ground return circuit. Keep a separate earthingcable connected to work piece.

y. When working on de-energized equipment, safety barriers shall be provided to preventaccidental contact with adjacent lines or equipment.

z. Lockout & Tagout: These are positive isolation methods and shall be followed asfollows:

Lockout: Putting a padlock on an energy isolating device while the equipment hasbeen shut down. This ensures safe maintenance work. The keys of the padlock

should be in custody of the Wartsila supervisor.

Tagout:

Before the Electrician works on electrical circuits or electrically powered equipment ina position such that he could be endangered either electrically or mechanically, theelectrical power source shall be turned off and disconnected in accordance with thefollowing tag-out procedures: The Electrician shuts the equipment down. The Electrician shall turn the main disconnect switch to the OFF position and tag it

with the "DO NOT OPERATE" tag The Electrician shall inform accordingly the Site Manager/Commissioning

Manager/ Commissioning Engineer about the tag out. Electrician working on the equipment shall de-energize the unit being provided

with "DO NOT OPERATE" tag on which he will write his name and date. It is theresponsibility of this person to assure his own safety by keeping this tag on thedisconnected equipment while he works on the equipment

Upon Work completion Disconnecting and "DO NOT OPERATE" tag shall be removedas follows: As the Electrician finished his work, he shall remove the tag He shall advise the

Site Manager/ Commissioning Manager/Commissioning Engineer that the system/equipment can be energized

Guards and protective items removed during the repair of electrical equipment are

to be replaced immediately after the repair work has been completed.


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"DANGER" notices and signs shall be posted on all installations, circuit andequipment.

Before energizing any electrical systems and equipment, supervisor in question,shall make sure that necessary warning signs and notices are installed and that all

parties concerned are informed.

4.8 Confined spaces

a. Confined space means a space that: Is large enough and so configured that an employee can bodily enter and perform

assigned work; and Has limited or restricted means for entry or exit (for example, tanks, vessels, silos,

storage bins, hoppers, vaults, and pits are spaces that may have limited means ofentry.); and

Is not designed for continuous employee occupancy.

a. Entry & work inside a confined space (such as tanks) shall be restricted and shall be

allowed only after issue of Work Permit by concerned Wartsila supervisor / Site

Manager. (See 4. Work Permit for procedures)

b. The confined space shall be kept adequately ventilated. Pure oxygen shall not be

used to ventilate the tank.

c. Compressed gas tanks & welding machines shall not be kept inside the tank.

d. Hand lamps of only 24V shall be allowed inside metallic storage tanks.

b. Before the workers enter the confined space they should be instructed to take the above

precautions.

c. While working inside the tanks, easy accessibility to the manhole opening to be ensured.

Station one attendant outside the exit / manhole at all times when the work is in progress.

d. Post a sign board outside the confined space entry point:

-DANGER-

PERMIT REQUIRED CONFINED SPACE


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DO NOT ENTER

e. Inlet valves / pipe connections to the confined spaces shall be blanked or locked &

tagged out before entry into the confined space & shall be opened only after the work iscompleted and Work Permit closed.

f. After the work period is over, the Work Permit shall be closed only after inspection by

contractors supervisor / Wartsila supervisor to ensure that no one is inside the confined

space.

4.9 Tools

4.9.1 General

a. Accidents arising from the use of hand and power tools are frequently caused by humanerror, misuse of tools, or using a defective tool. Hence, all personnel shall select and usethe correct tool for the job.

b. As the poor quality hand and power tools increase the risk of accidents, high or bestquality available tools shall be used

c. After site mobilization, Wartsila site in charge & contractor should jointly carry out a pre-

use inspection.

d. Contractor should carry out periodic maintenance of tools.

e. Workmen must use the correct PPE while operating the tools.

4.9.2 Hand Tools

a. Personnel shall use tools and equipment which are in good condition and are right sizeand type of tools for the job.

b. Tools and material shall not be thrown or tossed from one person to another.

c. Tools and material shall not be placed or permitted to remain on narrow pathways or onscaffolding where they can become stumbling hazards or be placed in a position wherethey may fall.


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4.9.3 Electric & Pneumatic Power Tools

a. Tools shall be regularly inspected so that they are safe for use.

b. Tools shall be used only by personnel who have been instructed to use tools safely.

c. Metal body of the portable electric tools shall be grounded when connected to electriccircuits.

d. Portable extension cords shall be maintained and kept in safe condition.

e. Lamp sockets shall be adequately insulated and equipped with suitable guards.

f. Hose and hose connections for the compressed air tools shall be maintained and kept insafe condition.

g. All tools shall be disconnected from the power supply before cleaning and changing thebits, blades, discs etc. or when not in use.

h. Tag the damages electric tools Do not use

i. Use grinding wheels of proper RPM only. Always check date of expiry before mounting.Never store grinding wheel in damp place. Never keep the grinding machine on groundwhen the wheel is spinning.

4.9.4 Jacks

a. Never use a jack to support a lifted load. Once lifted, support with blocks etc.

b. If the lift surface is metal, place a 25mm thick hardwood block or equivalent in between toreduce danger of slipping.

c. Ensure the following: The base of the jack should rest on a firm level surface. The jack should be correctly centred. The jack head should bear against a level surface The lift force should be applied evenly


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d. Never use a leaking hydraulic jack.

4.10 Material Handling

a. If required to lift material manually the following must be adhered to: Get as close as possible to the load. Avoid picking up heavy objects placed below your knees or above your chest. Keep your back straight. Never twist or turn the body while lifting. Tighten stomach muscles while lifting. Always push an object rather than pull it.

b. All the lifting tools and tackles like Slings, Jacks, and Cranes should have valid testcertificates. This should be submitted for approval/inspection before mobilising to thesite/before starting the work.

c. According to the nature of work win in charge shall decide whether to do by manually orwith crane.

d. The usage of slings shall be as per the standard instructions given in the below charts


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e. Ensure supervision during lifting/handling of materials.

f. All the sleepers, packing used for unloading & leading to be in good condition and shouldhave the approval of the Site in Charge.

g. All defective/damaged lifting equipment and tools to be kept separately tagged.

h. Lifting or hoisting Gear & Tackles shall never be attached to scaffolding for lifting ordragging.

i. Blocking of road is forbidden. Roads shall not be used as storage or work area.

j. Prior to usage of crane the manufacturer recommended chart/SWL shall be ensured. Theusage of crane shall be as per WI/S.O.P.Crane / Hydra / forklift operator must hold validdriving licence for heavy motor vehicle.

k. All lifting and transportation of equipment should be done with prior intimation/permission

from the Site in Charge.


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l. Hoisting of workmen by crane and other means should be done with approval from Site inCharge.

m. A gap of minimum 600mm must be maintained between a travelling crane and a fixture(guardrail, adjacent building)

n. Any chain or sling if altered or repaired by welding must be examined and retested beforeuse.

o. Never use a wire rope if more than 5% of the wires are broken (1 in 20)

p. Take special care while handling unbalanced loads since such loads may increase strainon one leg of the rope, dramatically.

q. Dog ropes or tag lines must be used when handling large loads to direct the loads intoposition and prevent it from spinning.

r. The angle between sling legs should be less than 90 degrees. At angles higher than this,the strain on each leg increases rapidly where they may break because of overloading.

s. Chain blocks of proper lifting capacity supported by test certificates should be used forlifting known loads.

t. Chain block must be lubricated before every use.

u. Never leave the pulling rope of winch or chain block tensioned when stopping work duringbreaks. Support the object being handled & lock it with wedges or stops.

v. While hauling an equipment such as EG set or alternator on rails or roller skids, controlthe movement of the load by a tag line (gentle release of rope kept tensioned in directionopposite to the movement of the load)

4.11 Welding & Cutting

a. Leather safety shoes, welding helmets, gloves, sleeves, aprons, shields, & goggles shallbe used when welding and cutting operations are being done.

b. Usage of flame arresters in regulator (D.A) & gas cutting torch to be ensured.

c. Special attention to be paid for connecting the grounding cable. Grounding over theengines or equipment may cause major damages on the bearings, instrumentation, etc.Separate earthing cable should be used and direct earthing to be given to the work.

d. Never use loose rods, damaged cable, angles and other structure for earthing purpose.

e. Damaged cables should never be used for welding- Holder should be properly insulated.


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f. Contractors, Fire Watch Person/Supervisor with necessary Fire Extinguishers should bedeployed wherever welding, cutting and grinding work is in progress. Fire watch must bemaintained for at least 30 minutes after work ceases.

g. Acetylene cylinders should always be stored upright (Valve end up).

h. Store Oxygen & Acetylene cylinders separately.

i. All the cylinders valve should be kept closed when not in use and during transportation.

j. Hoses should be fitted by proper hose clamps -Joints are allowed only if the lengthexceeds 20 metres.

k. Leaking/damaged cylinders and valves should be tagged and kept separately.

l. Empty cylinders should be marked

m. The International colour coding for the Hoses to be followed. Never interchange. Oxygen -Blue/Black

Acetylene -Red

Argon -Grey

k. Oxygen shall never be used as a substitute for Compressed Air.

l. The power point for welding, grinding and other applications is to be properly made andprotected.

m. While doing over head cutting, grinding and welding necessary covering to be provided toprotect the men and machine below.

n. Use guards (fire blankets etc.) to protect equipment, cables, flexible bellows etc. fromsparks & molten metal drops of welding & cutting.

o. Welding cables and hoses must be kept clear of passageways, ladders & stairways.

p. Gases should be turned off at cylinders, electrodes to be removed from holders whenaway from work and welding machines to be switched off during breaks.

q. Never shift a welding machine when it is ON.

r. Do not use cylinders as rollers, jacks or work supports.

s. Oil & grease must not come in contact with cylinder valve assembly or regulator. Do notlubricate cylinder valve threads.

t. Keep the nozzle tips clean always to prevent backfire.


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u. Do not store cylinders under direct sun or on wet soil. Do not allow them to come incontact with live wires.

v. Reserve clearance enough for removing cylinders out of the building in case of fire.

w. Ensure proper ventilation in welding area.

x. Ensure proper earthing

y. Use of ELCB and reduce welding exposure time.

4.12 Chemical cleaning, Pickling

a. During pickling operation the persons involved should wear appropriate goggles, masks

and Rubber/PVC gloves.

b. Material safety data sheet (MSDS) for the chemicals used in the pickling should be made

available at site.

c. All the chemical substances should be clearly labelled.

d. Used Acid/Alkali should be neutralised (check with Ph paper) and to be dumped into thedrainage system.

e. All Hoses should be tightly secured.

f. Water Hoses with cut off valve should be available always near the pickling area.

4.13 Pressure testing of pipes & tanks

_WARNINGHydraulic pressure test are normally carried out with water or approved liquid.Never use compressed air or any other gas for pressurizing a large pipe system or a vessel.

a. When testing the pipes and tanks with positive pressure, strictly follow test instructions.Never exceed the maximum testing pressure required.

b. Use only dependable and calibrated pressure gauges.


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c. If pipes or pressure vessels for pressure test are provided with flexible hoses and steelbellows, inspect these carefully for correct length, alignment and proper supporting andthat hoses are not left twisted.

d. Before the test check bellows and hoses carefully for maximum allowable pressure.Pressure tests shall be carried out only by experienced and authorized personnel.

4.14 Fire Prevention

EVERYONE IS OBLIGED TO PAY A SPECIAL ATTENTION TO FIRE SAFETY

4.14.1 Types of Fires

Fires are classified by their fuel types

Class A typically combustible solids that leave an ash - including wood, paper, textiles.

Class B typically inflammable liquids including gasoline, oil, grease, paint, etc. Class C Electrical fires Class D reactive metals including sodium, potassium, magnesium etc.

4.14.2 Types of portable fire extinguishers

Sr.No.

Type of FireExtinguisher

AWood,Paper,Cloth,Plastic

BPetrol,Oil,Paints

CLPG,Acetylene,Industrialgases

DReactivemetals Sodium,Potassium

LiveElectricalFire

Caution!

1 Water Good No No No NoDo not use onlive electrical

equipment & oil.

2 Foam (AFFF) Fair Good No No NoDo not use onlive electricalequipment.

3Dry ChemicalPowder (ABC)

Fair Fair Good No Fair

Do not use invery confinedspaces aspowder mayreduce visibility.

4Dry ChemicalPowder(BC/TEC)

No Fair Fair Good Fair

Do not use invery confinedspaces aspowder may

reduce visibility.


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5CarbonDioxide

No Fair Fair No GoodVentilate areaafterextinguishing fire.

4.14.3 Measures to be taken in case of fire

a. Rescue injured and persons in danger.

b. Raise fire alarm.

c. Extinguish fire or try to limit fire by removing flammable material, liquids or gases to safeplace.

d. Guide fire department to place of fire.

4.14.4 Regulations for fire prevention

a. Site must have sufficient amount of fire extinguishers for first extinction.

b. Accumulation of trash, oily rags, combustible materials or fire hazards of any nature willnot be permitted. The area around welding and cutting operations must be kept free offlammable material of all kinds (wood, paper, cardboard, flammable liquids, etc.)

c. Fire extinguishers must be easily accessible and standby for use at each welding, cutting,burning or other such operations. It is contractors responsibility to obtain required fireextinguishers and to arrange the recharging and resealing of the fire extinguishers

immediately after use.

d. All tarpaulins used in, or in the near vicinity of welding, cutting, burning, or other suchoperations shall be fireproof. Fireproof blankets such as fibreglass are acceptable.

e. Flammable or explosive type material such as fuel, oil, cleaner, etc., must be properlycontained, clearly identified, separately stored and kept clear of work areas. Appropriatewarning signs must be posted in such storage areas.

f. Welding or any spark or flame-producing operation must be stopped within radius of 10meters during the refuelling operation.


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g. Contractors shall ensure that employees, especially those assigned for hot work, arefamiliar with the use and operation of fire extinguishers.

h. Check the location of fire extinguishers beforehand and study for the use by reading the

instructions. Do not move extinguishers from their marked places

i. Fire extinguishers shall be checked by an expert for correct operation at least once a year

4.15 Initial start-up of EG set

a. Before starting a generator set, ensure that exhaust pipes are properly insulated and noleakage was noticed in the fuel or gas supply system.

b. Place the fire extinguishers at either side of the generator set for initial start-up.

c. Stop the fuel booster pumps or close the main gas valve immediately in case of fire on

the EG-Set

4.16 Radiography

a. Every Radiation Worker/Supervisor should be familiar with the basic principles orradiation hazards and protection and should be a qualified person.

b. Only authorised agencies/persons should be allowed to carry out the radiography tests.

c. As the radiography is a high-risk health hazard, all the people are to be intimated of itbefore starting any RT testing. The safety officers of the contractors, WARTSILA and thecustomer should be informed in advance and his prior approval should to be obtained.

d. The area where the radiography testing is conducted should be cordoned off-dependingon the source of radiography & its strength. A warning board to be displayed and also anorange blinking light to be used.

e. RT should be done preferably during night wherever possible.

f. All radiation dosages should be kept below the recommended dose limits.

g. Agency doing 'RT' should have all the safety monitoring devices viz. Area monitoringdevices (Minirod Survey Meter) and Personal monitoring devices (Film Batch, PocketDosimeter)


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h. All the calibration certificates and instructions or operating methods of all the instrumentsmust be readily available.

i. All defective instruments should be repaired without delay and recalibrated after repair.

4.17 Dress code at site

a. Loose clothing must not be worn when working around machinery and rotary hand tools.

b. Long hair is dangerous. A good head cover, covering of long hair is obligatory.

c. Necklaces and wrist rings should not be used, especially when working with live electricalequipment or assembling / overhauling of engines and mechanical equipment.

4.18 Housekeeping

a. A large part of the accidents can be prevented by good housekeeping. For this reason,good housekeeping is and shall continue to be a important part of this Safety Program. Itis the responsibility of all employees.

b. Cleaning up before and after the job is better than cleaning up after the accident.

c. Working and storage areas shall be cleaned at regular intervals; rubbish left on thejobsite may provide good starting point for fire.

d. All waste - packing materials, wood material, oily rags, and other unwanted materialshould be stored out of the construction premises.

e. The work place should be cleaned of all debris daily at the end of work. There should be

a box/place where all these debris can be collected and discarded.

f. All scrap materials should be stored in a separate identified place. The scrap should notbe deposited under an overhead work area.

g. Closed trash cans shall be used for waste disposals and shall be emptied daily.

4.19 Traffic on site

a. Trucks, excavators, dozers, vehicles and equipment are allowed to be driven and

operated only by nominated and trained personnel.


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b. Dragging or skidding of materials and objectives along the roadways is prohibited.

c. Fuel tanks on motorized equipment must not be filled while the engine is running or while

welding or other hot work is being done nearby.

d. Motorized equipment such as trucks, dozers, cranes, graders, etc. must not be leftunattended while the engine is running.

e. Co-riding on cranes, winch trucks, etc. is not permitted

f. Driving a dumper truck with lifted bed is strictly forbidden.

g. Drive with speed that you can control your vehicle and load in every condition and everysituation.

h. The WIN Incharge according to the site conditions shall inform customer/provideproperly levelled ground for vehicles/crane movement wherever required.

i. Speed limits set up by customer or by the WIN shall be followed.

j. Be careful when backing.

k. Always use safety belts when driving a car, also outside the site.

l. Blocking of roads is forbidden. Roads shall not be used as storage or work area

5. SAFE OPERATING PROCEDURE

5.1 Working at heights

1. Decide on the job to be carried out

2. Working at height means any work carried out at or above 2mtrselevation.

3. The Engineer-in-charge (either WIN or Contractor) should give a tool box talk to theworkmen emphasising the need for the use of PPEs and the possible hazards involved.

4. Visual inspection of PPEs shall be carried out before usage by the user. All workmenworking at heights should use Safety belts, Shoes, and Helmets (Helmets should be worn

with chin straps fastened correctly)


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5. Scaffolding must be provided for all the height works which does not have permanentplatform/building.

6. A firmly fastened life line of adequate strength should be strung beside each crawlingboard throughout its length while using such crawling board.

7. Ladder as a means to access should be provided at an angle of 75 Deg. It should beproperly supported at the bottom and secured at the top to prevent from slipping and theladder top should extend at least 1.05 Mtrs above the platform.

8. Placements of ladders obstructing the door movements, passageways, vehicle movementetc., to be avoided.

9. On a roof work where no parapet or barrier against falling down is available guardrail, toeboard etc to be provided at the free ends of the roof.

10. On a slope roof made of asbestos, plastic or brittle sheet, work should be done usingcrawling boards. A firmly fastened life line of adequate strength should be fastened.

11. Wherever impractical to erect a platform & guardrail, use safety belts or harness thatshould always be worn and safely anchored.

12. Use safety nets where it is practical to properly support or to fix them.

13. Erect the nets as close as possible to the working level.

14. Avoid working below when work is being done at elevations. Barricade the area with

barricading tapes.

15. Ensure effective communication system to give instructions to the workmen working atelevations (like walkie talkie etc).

16. The safety belts/harness, fall back arrester, life line etc. are to be inspected periodically.

17. Adequate work break to be provided while working at height.

5.2 Pickling


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1. Insist on supply of MSDS (Material Safety Data Sheet) from the supplier for all chemicals,such as hydrochloric acid, sulphuric acid, formaline inhibitor, caustic soda, etc.

2. Store each chemical in places identified for the storage. Ensure that the containers are

properly labelled.

3. Containers of acids that are partly used should be kept labelled and closed.

4. Workmen employed for `Pickling should use suitable PPEs Face shields, Goggles,Hand Gloves, Apron etc.

5. Always keep enough quantity of fresh water to wash spillages and accidental flashes. Incase of flashes on the body or eyes, wash with abundant quantity of fresh water(continuous free flow of water is preferred).

6. Remember never add water to acid. It will spurt dangerously. Always add acid to water.

Add acid in thin stream, slowly stirring the solution with a long glass rod.

7. Never use antidotes on the affected area before cleaning and diluting with water

8. Check the PH of the solution and neutralise with Acid / Alkali or with water and maintain aPH 7 before disposal.

9. Do not use other chemical containers for storing different chemicals.

5.3 Use of Cranes

1. Before using crane, it should be inspected to ensure safe operation. The `InspectionCheck List will be available at site.

2. Operate, Cranes, Hoisting Lifts, Fork Lifts etc. only with trained operators. The machinesshould be properly maintained.

3. While employing crane do not lift loads beyond the SWL, marked in the crane.

4. Employ only trained persons for signalling and operating the cranes.

5. Only one person should give signals.


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6. Before lifting a load, proper slings, with valid test certificates, and of the required capacity,should be made available.

7. The `Braking system of the crane should be checked.

8. Use only approved slings, tools and tackles.

9. Ensure that the crane moves in level surfaces

10. The load should always be tied with a rope and held firmly to prevent fluctuations.

5.4 Excavations

1. For excavations in an area, where underground pipes and cables are installed, the work

needs continuous supervision.

2. To avoid any damage to pipes or cables, etc. exposed during excavations, sufficientsupports. Must be provided under them.

3. Excavation works shall be kept illuminated

4. Proper barricading shall be done around the excavated area.

5. Adequate & suitable warning signs shall be put in conspicuous places at excavation workto avoid any person falling into the excavation.

6. Excavations such as ditches, trenches, etc. shall be sloped sufficiently to prevent cave-insor slides.

7. Excavated materials such as heap of soil, should not be stored less than 0.65 metresfrom the edge of excavation.

8. Where the depth of excavation is more than 1.5 metres, suitable means of access &egress, such as ladder, ramp, staircase etc. as the case may be, shall be provided.

9. For trenches 1.2 mtrs deep, no timbering, or shoring is required, unless there is a dangerof any material collapsing & falling. For trenches upto 4.5 mtrs. Deep, a survey isrequired to determine requirement of timbering and shoring


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10. Where banks of an excavation are undercut, adequate shoring is to be provided tosupport the material or article over hanging such bank.

11. Safety helmets should be worn at all times.

12. LPG cylinders or inflammable liquids such as petrol, kerosene shall not be stored intrenches, LPG is heavier than air and does not leave a confirmed space easily.

13. Do not allow heavy vehicles near the edge of excavation to prevent the ground frombreaking away under the weight of the vehicle.

5.5 Working in confined spaces

Confined Space means a space that:1. Is large enough and so configured that an employee can bodily enter and perform

assigned work and

2. Has limited or restricted means for entry of exit (eg. Tanks, vessels, silos, storage bins,hoppers, vaults, and pits are spaces that have limited means of entry) and

3. Entry and work inside a confined space (such as tanks) shall be restricted and shall beallowed only after issue of work permit by concerned Wartsila supervisor / site manager.

4. The confined space shall be kept adequately ventilated.

5. Compressed gas tanks & welding machines shall not be kept inside the tanks.

6. Before the workers enter the confined space they should be instructed to take the aboveprecautions.

7. Post one attendant outside the exit / manhole at all times when the work inside confinedspace is in progress.

8. Post a sign-board outside the confined space entry point like:

DANGER - PERMIT REQUIRED CONFINED SPACE DO NOT ENTER

9. Inlet valves / pipe connections to the confined spaces shall be blanked or locked & taggedout before entry into the confined space & shall be opened only after the work iscompleted and work permit enclosed.


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10. After the work period is over, the work permit shall be closed only after inspection bycontractors supervisor / Wartsila Engineer to ensure that no one is inside the confinedspace.

5.6 Grinding, Gas cutting & Welding

1. Leather gloves, Sleeves, Aprons, Face shields and Goggles shall be used when grinding,gas cutting and welding operations are being done.

2. Special attention to be paid for connecting the grounding cable. Grounding over theengines or equipment may cause major damages on the bearings, instrumentation etc.separate earthing cable should be used and direct earthing to be given to the work.

3. Never use loose rods, damaged cable, angles and other structures for earthing purpose.

4. Contractors fire watch person / supervisor with necessary fire extinguishers should be

deployed wherever welding, cutting and grinding work is in progress. Fire watch must bemaintained for at least 30 mts. After the work is completed.

5. Acetylene cylinders should always be stored upright (valve end-up)

6. Store oxygen and acetylene cylinders separately.

7. All the cylinders valves should be kept closed when not in use and during transportation.

8. Hoses should be fitted by proper hose clamps Joints are allowed only if the lengthexceeds 20 mtrs.

9. Leaking / damaged cylinders / valves should be tagged and kept separately.

10. Empty cylinders should be marked and kept separately.

11. The colour coding for hoses to be followed. Do not inter change hoses.

Oxygen Blue / Black

Acetylene - Red

Argon Grey

12. Oxygen shall never be used as a substitute for compressed air

13. The power point for welding, grinding and other applications are to be properly made

protected.


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14. While doing overhead cutting, grinding and welding necessary covering to be provided toprotect the men and machine below

15. Use guards (Fire blankets etc.) to protect equipment cables, flexible bellows etc. fromsparks && molten metal drops of welding and cutting

16. Welding cables and hoses must be kept clean of passage ways, ladders and stairways.

17. Gases should be turned off at cylinders, electrodes to be removed from holders, whenaway from work and welding machines to be switched off during breaks.

5.7 Superstructure / Masonry work

1. Make the surrounding area to firm for providing scaffolding

2. Scaffolding must rest on proper / standard base plate with adequate support

3. Necessary hand rails and staging to be provided for safe working platform.

4. Work persons must wear PPE like, safety belt, helmet, safety shoe, hand gloves etc

5. Warning tape must provide for avoid trespasses.


1. Do not insert wires directly into the sockets. Use suitable plugs.2. Metallic industrial sockets should be used instead of Bakelite sockets.3. Properly levelled approach to be made (for example to cross a cable trench) while shifting

the panel to the place of erection.

4. Precaution to be taken to avoid tilting of panel while shifting.5. Ensure that all electrical appliances and current carrying equipment are adequately

earthed.6. All temporary electrical circuits should be provided with an earth leakage circuit breaker

(ELCB)7. Periodically test the ELCB for its performance.8. Check existing cable routing drawing to establish cable routes, depth & voltages before

undertaking excavations.9. Consider all buried cables as live cables.10. Do not assume open end cables as dead or unused.11. Do not use piercing metal tools such as crow-bar & pick-axe etc. when nearing the

assumed depth of cable.


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12. Use excavators and power tools at a clearance of 0.5 mtrs away from the assumed cableroute.

13. Use roller for heavy cables pulling.14. Precaution to be taken while pulling the cable on the over head cable tray from falling

down.15. Do not misuse Electrical cables. (as hangers for materials, hanging on the cable or

walking on the cable etc.)16. Provide weather proof Main switches in out door usage or provide the power isolation

switches under a shelter.17. Main switches shall be located at a height not exceeding 1.5 mtrs so as to be accessible

in emergencies.18. Support / Clamp the cable connected to any terminal such that no mechanical force is

exerted on the terminals.19. All distribution cables to be properly looped or cheated along the walls of a permanent

structure or on poles. The height of the cables shall not be less than 2 mtrs and shall beat least 5 mtrs when run along or across the road.

20. Assume all overhead lines to be live unless advised otherwise by the owner / customer.Precautions to be taken to prevent contact of ladders, poles, crane jobs etc. withoverhead lines while working or passing beneath them.

21. Never give direct supply to equipment (such as welding machine) without provision forisolation.

22. Place rubber mats in front of electrical panels.23. Use only insulated tools for connection of batteries to avoid shorting of terminals.24. Use only insulated tools such as pliers. Use screw drivers which are sleeved with PVC

and not exposed at the user end.25. Do not store any flammable material in the switch gear and control rooms.26. Ensure that all unauthorised men & material are removed & bus bar chamber closed

before testing. Ensure proper earthing before meggaring or high potential test. Barricade

the area and display warning boards before commencing the test.27. Ensure that all the protective covers are in place for bus bar chambers before testing to

avoid accidental contact with live parts, when the panel inspection doors are opened.28. Reconnect the grounding devices which are removed from the equipment for testing

purposes, immediately after the tests are over.29. Do not permit damaged cables running to welding machines, power tools etc.30. Do not use pipelines or equipment as a ground return circuit. Keep a separate earthing

cable connected on the working piece.31. When working on de-energised equipment, safety barriers shall be provided to prevent

accidental contact with adjacent lines or equipment.32. Barricade & keep sign board in the area where the HI-Pot testing is carried out to avoid

person coming in contact with the live parts.


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33. `Lock out & `Tag out. These are positive isolation methods and shall be followed asfollows.

i. Lock out: Putting a pad lock on an emergency isolating device while theequipment has been shut down. The keys of the pad lock should be in the

custody of the Wrtsil Engineer / Customer Engineer.ii. Tag out: Before the electrician works on electrical circuits or electrically powered

equipment in a position such that he could be endangered either electrically ormechanically, the electrical power source shall be turned off and disconnected inaccordance with the following tag out procedures.

iii. The Electrician shuts the equipment down.iv. The Electrician shall turn the main disconnect switch to the `OFF position and tag

ir with the `DO NOT OPERATE tag.v. The electrician shall inform the site manager / commissioning engineer about the

tag.vi. The electrician working on the equipment shall de-energise the unit being provided

with `DO NOT OPERATE tag on which he will write his name and date. It is the

responsibility of this person to assure his own safety by keeping this tag on thedisconnected equipment which he works on the equipment.

vii. Upon work completion `DO NOT OPERATE tag has to be removed as follows:viii. As the electrician finishes his work he shall remove the tag. He shall inform the

SITE MANAGER / WARTSILA ENGINEER / CUSTOMER ENGINEER that thesystem / Equipment can be energised.

ix. Guards and protective items removed during the repair of electrical equipment areto be replaced immediately after the repair work has been completed.

x. DANGER notices and signs shall be posted on all installations, circuit andequipment.

xi. Before energising any electrical system and equipment, the supervisor in questionshall make sure that necessary warning signs and notices are installed and that all

parties concerned are confirmed.


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6. ON SITE EMERGENCY PLAN

1. The site manager is the `Main controller of the emergency plan. He controls the safety ofmen, machinery and material.

2. In the absence of Wrtsil representative, Contractors supervisor will assume theresponsibility, depending on the discipline of work, such as Civil / Mechanical / Electrical.

3. In the absence of the site manager at site, the site engineer / contractor representativewill take charge.

6.1 Declaration of an Emergency

1. In case of an existing plant, the customer emergency plan will be used.

2. Any employee / workman who come across an emergency at site such as Fire, Explosion,

Gas release, Roof collapse, Major accidents etc should inform the site manager/engineer

immediately.

3. All the employees / workmen should be asked to assemble at the pre-determined

Assembly points at site and await further instructions from main controller.


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4. The site manager on the spot of emergency shall decide on the further action plans and

arrange for the mobilisation of rescue operations, fire and ambulance services, the

services of doctors, evacuation of personnel, head count of workmen etc.

5. After the emergency is over, the main controller decides on declaring All Clear signal for

resumption of the routine operations.

6. The site manager will assess the extent of damages to men & materials and communicate

with the Head of the department.

7. A list of local hospitals, and doctors available should be prominently posted at the site

office. The land line Telephone numbers of hospitals, ambulance services, doctors, and

mobile contact numbers should be easily available.


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7. Work Permit System

7.1 Introduction

The relevant Customers General Instructions/ Wrtsil `s Safety Instructions on Work Permitwill be complied with and in accordance with current regulations for the Work Permit Systemas required by the customer.The work permit incorporates procedures commonly used in construction sites and powerplants to ensure that the necessary communication takes place and hazards are controlled.Work permit shall be obtained to work in restricted and hazardous areas.

7.2 Definition of Restricted & Hazardous areas

The following are examples:

Storage Tanks (during hydrotest)Confined workChimney erectionPicklingSand blastingRadiographyHot work in the live system and or hot work during pre-commissioning and commissioning.Work on roof (during dg building roof work)Major excavationsDismantling/demolishingTesting, charging and shutdown activities pertaining to electrical works

The Site Manager & Site Engineer shall identify such work areas & inform contractors to carryout work in such areas only on Work Permit Basis.

7.3 Authorised Issuer

Authorized issuers are those employees such as site Manager or Site Engineer designatedand certified by the customer or Wrtsil to issue and approve Work Permits in restrictedareas under their supervision.

7.4 Authorised Receiver

Authorized receivers are those workers, craftsmen or supervisors who have been authorized

by the customer or Wrtsil to sign and receive Work Permits.


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7.5 Issuance & approval

The authorized receiver has to request a work permit from a certified issuer before doing any

work in a restricted / hazardous area.

7.6 Handling of issued work permit

a. Validity of the work permit will be as long as possible to avoid multiplication of requestsfor the same work.

b. The receiver of the work must keep the permit posted at the work location at all timesc. When receiver leaves the site temporarily, he shall give the permit to a responsible

person, having also certified receiver of work permit to keep the permit until he returns.The issuer must be notified and approves the transfer of the work permit.

d. When the work is completed the work permit shall be closed by both, issuer and receiver.

7.7 Guidelines for Work Permita. Issuer and receiver shall inspect the work area together before signing the work permit.b. The work with used equipment shall be clearly stated on the work permit.c. Proper tagging fixed with chains, padlocks, etc. must be used.d. The work permit shall be issued for the period required to complete the work.e. When the work is extended from shift to another, the oncoming shift issuer must inspect

the work area, write the extended time and sign the work permit.f. The work permit shall be in a visible place while work is going on.g. The work permit must be closed after the work is completed.h. The issuer and receiver must inspect the work area and sign off.

8. Formats & Checklists

The following Formats & Checklists shall be used:

a. Tool Box Talk Form Doc. No. 2500 F200

b. Spot Safety Observation Form Doc. No. 2500 F201

c. Site Safety Audit Report Doc. No. 2500 F202

d. Work Permit Doc. No. 2500 F204

e. Incident and Analysis Report Doc. No. 2500 F064

f H t k it D N 2500 F073

Documents

Annexure 11 - Safety Handbook