Health, Safety & E Nvironment (HSE) Manual: Doc No.: HSE/01 Rev No.: 00
Health, Safety & E Nvironment (HSE) Manual: Doc No.: HSE/01 Rev No.: 00
Health, Safety & E Nvironment (HSE) Manual: Doc No.: HSE/01 Rev No.: 00
(HSE)
MANUAL
INDEX
Procedure No.
CONTENT
Page No.
1.6
1.7
1.8
1.9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
56
60
66
71
77
84
88
92
95
102
3.1
3.2
3.3
3.4
3.5
CHAPTER-3 ENVIRONMENT
Water Discharge Control
Air Emission Control
Waste Management
Conservation of Soil & Ground water
Water Supply & Conservation
107
110
112
115
117
1.1
1.2
1.3
1.4
1.5
1
2
4
6
10
22
24
26
33
35
42
52
118
Chapter 1
HSE MANAGEMENT
Introduction
Balmer Lawrie & Co. Ltd (BL) is a Public Sector Enterprise under the administrative control of
Ministry of Petroleum & Natural Gas, Government of India. It is engaged in a number of
diverse businesses spanning manufacturing and services sectors, with operations spread
across the country. Whereas the company is a leading player in Industrial Packaging,
Greases & Lubricants, Performance Chemicals, Tours & Travel, Logistics Services & Logistics
Infrastructure, it also has presence in Refinery & Oil Field Services.
The Company is committed to highest standards of corporate conduct towards its various
stakeholders and the environment in which it operates. Towards this, the Company
recognises its responsibility to ensure safety and protection of health of its employees,
contractors, visitors and neighbourhood in all its operating sites, which include
manufacturing, sales and distribution, research laboratories and offices.
This Policy document defines the vision, mission, aim, scope of application and required
actions of the policy as well as the responsibility for its execution.
HSE Vision
Our vision is to be an organization which neither causes or nor provides any opportunity to
cause any harm or injury to people in general and/or cause any damage, of whatsoever
nature to the environment.
HSE Mission
Health, Safety & Environment (HSE) shall be of topmost priority to the operation of our
organization and will constitute an integral part of our business process. We will realize our
HSE Vision by adopting an integrated approach to the management of Health, Safety &
Environment by focusing on People, Processes, Systems, Technology and Facilities. HSE in
the organization will be driven by the leadership and will be demonstrated through
employee commitment at all levels.
Implementation Responsibility
The Management of BL at all levels is responsible for the implementation of the HSE Policy.
Every Unit, Workplace, Site shall prepare a responsibility matrix with respect to this Policy.
Such HSE responsibilities shall form an integral part of the overall job responsibilities of all
employees. All Standards, Rules and Procedures on HSE, including those that may be specific
to a site are integral to this Policy. All employees are required to strictly adhere to them and
ensure their proper implementation.
HSE GOVERNANCE
1.0 Purpose
The purpose of the HSE Governance structure is to define the policy & principles of the
HSE Management System and to provide guidance & directions in implementing the
requirements of HSE Policy and its deployment
2.0 Scope
Covers all SBUs/Corporate Functions and/or Sites in which BL operates.
3.0 HSE Organisation & Responsibilities
3.1 Chairman & Managing Director
The C&MD shall approve the HSE policy and will Head the HSE Steering Committee.
3.2 Directors (Manufacturing & Service Businesses)
As Operational Directors they will define and approve the HSE systems & procedures
for SBUs under their control.
3.3 Director (HR&CA)
The Director (HR&CA) will assist C&MD and the Operational Directors in setting and
monitoring the HSE policy and its implementation and ensure HSE training.
3.4 Director (Finance)
The Director (Finance) will ensure that all financial resources required for the proper
implementation of the HSE Policy are made available.
3.5 SBU / Corporate Function Heads
The SBU / Corporate Function Heads shall ensure that:
i) HSE at workplace is strictly adhered to in respect of all Units/Branches/Sites
under their control.
ii) HSE Review Meetings are conducted as laid down for their Business/Function
iii) HSE Objectives and targets are set for their respective SBU/Function.
iv) Resources, as required for proper implementation of HSE is made available
3.6 Unit/Branch/Site Heads
The Unit/Branch/Site Heads, as the case may be, will ensure that:
i) The HSE policy & procedure is fully and properly implemented as laid down
ii) Suitably trained and experienced HSE Representative(s) are in place
iii) Appropriate HSE training is carried out
3.7 Corporate HSE Resource
The Corporate HSE Resource shall assist the Directors and the SBU/Function Heads in
proper implementation, monitoring and review of the HSE policy and processes,
including HSE Audit and Management Review.
3.8 Unit/Branch/Site HSE Representative
The Unit/Branch/Site HSE Representative shall assist in proper implementation of all
HSE regulations at workplace and report incidents and/or deviations, if any, with
respect to HSE policy & practice.
Following information related to Health & Safety to be captured month wise from all
units--HSE & Sustainability Monthly Information System
SBU :
UNIT:
Month:
Direct
employee
Indicator
Indirect
personnel
Cumulative
for the
year
Remarks
Cumulative
for the year
Remarks
Number of Employees
Man Hours Worked
Fatalities
Loss Time Injury(LTI)
Injury Frequency Rate(IFR)
Lost days
Injury Severity Rate(ISR)
First Aid Case
Near Miss
Property Damage Case
Spillage of Oil
HSE training conducted (man- hrs)
Environment Data:
Category
ENV01
ENV02
ENV03
ENV04
ENV 05
ENV06
ENV07
ENV08
ENV09
ENV10
ENV11
For the
Month
Indicator
Water Consumption
Waste Water Discharged
HSD consumption in MT
LDO consumption in FT
FO consumption in MT
Gas(LPG, Natural gas) consumption in MT
Hazardous waste Generated in MT
Hazardous waste disposed in MT
Non Hazardous waste generated in MT
Non Hazardous waste disposed in MT
Electricity consumption from Grid in MWH
Specify if any special event like Mock Drill, Specific HSE audit, Health Camp, safety
promotional events organized in the month:
Definitions
1. Direct Employee: Employees who are on Companys pay role.
2. Indirect Personnel: Personnel who may be engaged for and/or in connection with
the operation/activity of the Company but are not on Companys pay role
3. Lost Time Injury (LTI): Any work related injury which results in a person being unfit
for work for a period of 48 hours or more immediately following the occurrence of
the occupational injury (as per the Indian Factories Act,1948) The period of 48
hours includes rest days, weekend days, leave days, public holidays or days after
ceasing employment.
4. IFR (Injury Frequency Rate):
Ie (LTI X 1000000) / Total Man hours worked (Own + Contract).
Definition as As per IS 3786
5. ISR (Injury Severity Rate):
Ie (Lost days X 1000000) / Total Man hours worked. (Own + Contract).
Definition As per IS 3786
6. Lost Days: The number of days lost beyond the day of injury to the employee , who
was away from work due to an occupational Injury
7. First Aid Case: Number of Occupational minor injuries suffered by Balmer Lawrie
employee or contractor where first aid was administered & injured person resume
work as usual.
8. Near Miss: An incident where no injury, ill health or fatality occurs, but which could
have easily resulted into an accident.
9. Hazardous waste: Any waste by means of its characteristics may cause danger to
health or environment. Example: used oil, waste oil, oily soaked jutes, filters, paint
sludge, paint/oil contaminated barrels, sludge from wet scrubber.
SBU:
Feb
1
2
3
4
5
6
Leading Indicators
HSE Training(man Days)
HSE Inspections
Safety Committee Meetings
Tool Box Talk
Job Safety Analysis
Near Miss
1
2
3
4
5
6
7
Lagging Indicators
Fatality
Loss Time Injury
First Aid Incidents
Loss days
IFR(Injury Frequency Rate
ISR( Injury Severity Rate)
Spill in Lts
1
2
3
4
Environmental performance
Water intensity
Electrical intensity
Carbon Intensity
Waste generated
Reporting Manager:
Jul
10
4.4 Employees
All employees must participate in any identified training, to ensure the effective
implementation of risk control measures
5.0 Process
5.1 Workplace Risk Assessment
5.1.1 Risk Assessment
An identification of the hazards present in a workplace and an estimate of the extent
of the risks involved, taking into account whatever precautions are already being
taken, involves:
i.
ii.
iii.
iv.
v.
11
All activities together with methods and systems of are to be subjected to a hazard
survey. The extent and depth of this survey will be dependent on the potential
outcome arising from the activity. Important criteria to be considered include:
a. Exposure of people (both the workforce and the public) to any dangers that
may arise
b. Legal requirements
c. The value of the plant or equipment in financial and economic terms
d. Any inherent toxic, explosive or fire risk associated with any stage of the
activity / process
II. Based on received information identify the significant risks that have potential
impacts on OH&S.
III. Hazards can result in different forms of harm. It is useful to record both the hazard
and the harm so that it is easier to identify the correct precautions to take. Hazard
identification can be helped by:
a. Viewing a situation or activity
b. Discussing it with those involved in the activity
c. Referring to:
i. Manufacturers or suppliers manuals or data sheets
ii. A checklist of hazards as an aide-memoir
iii. Accident/incident reports
d. Reviewing legislation and legislative guidance notes
IV. Hazard Analysis
The hazard identified must be analyzed. The main elements of this are probability,
frequency and severity.
V.
Control Measures
If the risk assessment has determined that something needs to be done then the
following two questions must be considered and appropriate control measures
implemented:
i. Can the Hazard be removed altogether?
ii. If not, how can the risks are controlled so that harm is unlikely?
12
13
6.0 References
6.1 Clause 4.3.1 of OHSAS18001
14
(Annexure 1)
GENERAL RISK ASSESSMENT
Probability & Frequency
Score
Negligible
Low
Moderate
High
Definite
1
2
3
4
5
Severity
Minor
Moderate
High
Major
Catastrophic
Score
1
2
3
4
5
Definite
10
15
20
25
High
12
16
20
Moderate 3
12
15
Low
10
Negligible 1
Minor
Moderate
High
Major
Catastrophic
Severity
Risk Level
Risk Priority
Negligible
Tolerable
Low
Medium Priority
Medium
High Priority
High
Immediate
NOTE : Abbreviations
R
Routine Activity
NR
Non Routine Activity
N
Normal Condition
AB
Abnormal Condition
E
Emergency Condition
15
16
SL. NO.
4.2.0
4.2.1
4.2.2
4.2.3
4.2.4
4.3.0
4.4.0
4.4.1
4.4.2
4.4.3
4.4.4
4.5.0
4.6.0
4.8.0
a)
b)
c)
ACTIVITY
RESPONSIBILITY
Collect periodic information about various environmental aspects Operational
and their impacts related to activities, products or services during Managers & MR
normal, abnormal and emergency situations.
Use environmental impact analysis format (Annexure 1) for
gathering information from the concerned employees in the
department.
The identification of significant environmental aspects are covered
where relevant:
a) Emission to air; b) Discharge to water
c) Waste stored; d) Contamination of land
e) Impact on communities; f) Use of raw material and natural
resources; g) Concerns of interested parties
The identification also to cover applicable legislative and
regulatory requirements.
Identify all aspects with any impacts, whether beneficial or
adverse.
Consider any accidents, minor or reportable as well as potential All concerned
emergency situations and assist the HOD in its review
personnel
Based on the received / validated information, identify the aspects Operational
that have an impact on the environment.
Managers & MR
The identified impacts be evaluated by discussion between HODs
where necessary
The criteria for evaluation are:
1. Legal Concern; 2. Probability; 3. Severity
4. Resource Savings Potential; 5. Interested Party Concern
6. Existing control measures
The environment impact rating should be achieved utilizing values
for the above six criteria, as provided in the Environmental
Impact Analysis Format (Annexure 1)
Based on the above evaluation, the impacts be classified 1, 2 , 3, 4,
5, 6. The ranking of impacts can be done based on the product of
1, 2, 3, 4 & 5 of all aspects.
Compile the information and validate the information by visit to
MR(HSE)
the site as applicable
Record the significant aspects in the Significant Environmental
MR(HSE)
Aspects register
Maintain and review the environmental impacts register under
following circumstances
When there is new information regarding environmental Aspects/
Consequent impacts during audits or in the case of amendments
to the legislative requirements.
MR(HSE)
New process/ Activity introduction and/ or amendment to the
existing process / activity
Change in ranking due to effective implementation of
programme(s) related to an impact(s).
17
5.0
On establishing a new site, location or service contract (or an any existing site where a
review has not been performed), the Site HSE Representative or nominee, must
conduct a review of environmental aspects associated with BL activities on the site /
location, as described below. The results of the review must be recorded.
1. The site or location to be evaluated should be broken down into manageable areas
for examination.
2. Identify as many environmental aspects of the activity, product or service as
possible. (See Table 1)
3. Identify as many environmental impacts (See Table 2) as possible associated with
each identified aspect, taking into consideration normal, abnormal and emergency
conditions.
TABLE- 1 (Identification of Environmental Aspect)
Environmental Aspect
Noise/ vibration
General Aspects
Size/ appearance of plant/ chimney/ building etc.
Road use
Discharge to ground
Releases of
Leaching (migration of liquid to the ground)
substances onto/ into
Leakage of oil/ chemical/ fuel/ process liquid
the ground
Spillage of oil/ chemical/ fuel/ process liquid
Discharge to sewer
Discharge to surface water body
Releases of
substances to water
Leakage of oil/ chemical/ fuel/ process liquid
Spillage of oil/ chemical/ fuel/ process liquid
Release of asbestos
Release of Carbon Monoxide
Release of dusts/ particulates
Release of HCFC/ HFC
Release of SF6
Release of Nitrogen oxides
Releases of
Release of Odour
substances to air
Release of other hazardous substance
Release of ozone depleting substances (CFCs etc.)
Release of radiation/ radioactive particles
Release of sulphurous oxides
Release of visible plume
Release of VOCs (Organic solvents)
Generation of difficult waste
Waste resulting from an
Generation of general non-hazardous waste
activity, product or service
Generation of special waste
Incineration
Waste disposal
Recovery of energy
Recycling/ re-use
Use of energy/ fuel
Use of land
Resource use
Use of raw material
Use of water
Category
18
6.0 Reference
6.1 Clause 4.3.1 of ISO 14001:2004
7.0 Record
7.1 Environmental Impact Analysis Register
7.2 Significant Environmental Aspects Register
7.3 Impact Control Plan Register
19
(Annexure 1)
ENVIRONMENTAL IMPACT ANALYSIS
Legal Concern
SCORE
1
2
3
CRITERIA
Full Compliance
Half Compliance
Zero Compliance
Probability
SCORE
4
3
2
1
CRITERIA
High
Moderate
Low
Very Low
Severity
SCORE
4
3
2
1
NOTE:
N
AB
E
EMP
Normal Condition
Abnormal Condition
Emergency control
Environment Management program
20
CRITERIA
High
Moderate
Low
Very Low
Resource Savings
Potential
SCORE CRITERIA
4
High
3
Moderate
2
Low
1
Very Low
Interested Party
Concern
SCORE CRITERIA
4
High
3
Moderate
2
Low
1
Very Low
Unit following Integrated Management System (IMS) can use a combined Risk and
Environment Aspect Impact register as follows:
Scoring
5
4
3
2
1
Definite
High
Moderate
Low
Unlikely
Severity
Environment
Permanent Damage to
Environment
Major Damage to
environment
Moderate damage to
environment
Low damage to
environment
Negligible damage
Scoring
Safety
Catastrophic/
Multiple fatality
Single Fatality
5
4
3
2
1
Scoring
5
3
1
Scoring
5
1
21
Residual risk/Impact
Control by
Elimination/substitution/E
ngineering Control/Admin
control
Compliance to legislation
Severity
Likelihood
Existing Control
OHSAS/EMS
Concern
D/I/R/NR/Abnormal
Activity
Sr No
22
5.2.4 Where changes in legislation have a significant impact on the business the appropriate
register must be revised in line with the periodic reviews
Legislation-specific checklists may be developed for assessments and / or
inspections.
Sample Legal Register
Applicable
Law
Requirement
(Rule no.)
License no/
Submission
of Forms
Date of
expiry
23
Frequency of
renewal
Remarks /
Compliance
status
24
4.0 Process
4.1 Performance Improvement
Each Site must consider the following when defining objectives and setting targets:
i. Corporate, Business and Operational objectives and targets.
ii. The review of new, current or revised legislation.
iii. Environmental aspects Impact and risk assessments.
iv. The results of Site HSE inspections and audits
v. Accidents, incidents, near misses and dangerous occurrences
vi. HSE non-conformance reports including complaints from stakeholders
vii. Lessons learnt
viii. Existing objectives and targets, which have not been achieved
4.2 Performance Measurement
4.2.1Performance improvement to be measured by continuous monitoring and
measurement of following parameters.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Management Commitment
Cost of HSE
Training
Communication
Reporting of Accidents & Incidents
Audit, Inspection
Procurement
Waste Management
Water Conservation
Conservation of Energy
25
26
10. Immediate Cause: Is the direct reason why an incident has occurred. It can
encompass unsafe conditions (which are not under the control of the person in the
workplace), as well as unsafe acts (which are under a person's control).
11. Incident: Incident includes Accident and Near Miss; An Incident is an event or a
chain of events that has caused, or could have caused fatalities, injuries, and/or
damage to assets, the environment, or third parties.
12. Job Factor: Any circumstance that may cause or contribute to the development of
an unsafe condition.
13. Lost Time Injury (LTI): Any work related injury which results in a person being unfit
for work for a period of 48 hours or more immediately following the occurrence of
the occupational injury (as per the Indian Factories Act,1948) The period of 48
hours includes rest days, weekend days, leave days, public holidays or days after
ceasing employment.
14. Medical Treatment Case (MTC): Medical treatment case is not LTI but requiring
medical treatment from a professional physician or qualified medical person and
MTC case is more than a First Aid.
As a guide a "yes" answer to any of the following questions (due to work related
injury) would be a medical treatment case:
i. Treatment of infection?
ii. Antiseptic during second or subsequent visits to medical personnel?
iii. Treatment for second or third degree burns?
iv. Application of sutures (stitches)?
v. Application of butterfly adhesive dressing?
vi. Removal of foreign body embedded in the eye?
vii. Complicated removal of foreign bodies from a wound?
viii. Use of Prescription medications?
ix.
Cutting away of dead skin (surgical debridement)?
x.
Application of heat therapy during second or subsequent visits?
xi.
Positive X-ray diagnosis (fractures, broken bones, etc.)?
xii. Admission to a hospital for treatment (more than observation)?
15. Loss of Consciousness: If one loses consciousness as a result of a work-related
injury, even for a short period, the case must be considered as an MTC.
16. Near Miss: A Near Miss is an unplanned event, which under slightly different
circumstances could have resulted in harm.
17. Risk: Product of the chance that a specified undesired event will occur and severity
of the consequences of the event.
18. Spills/ leaks: Any loss of containment of hazardous, flammable or toxic gas, liquid
or solid. There is no difference between a leak and a spill. The type of containment
shall not determine whether to report or not - A spill even in a bounded area on
concrete floor shall be reported even though there is no environmental impact.
Spills are classified into Major Spills and Minor Spills as below.
a. Major Spill: A spill of 500 litres / kg or more & needs to be reported.
b. Minor Spill: A spill less than 500 litres / kg but more than 5 litres / kg, needs to
be recorded for investigation
19. Release / seepage reaching outside plant boundary: Accidental release of liquid
hydrocarbons, contaminated / saline water or effluent which can cause negative
impact on company reputation should be considered as spills.
27
20. Work Related Activity: A work related activity is an activity in a work environment,
which is or ought to be subject to management controls. All incidents that occur in
work related activities are reportable.
4.0 Responsibilities
4.1 Site Manager
a. Initiating the investigation of reported incidents
b. Ensuring that accident / incidents are reported within BL, as required
c. Ensuring the implementation of any corrective and / or preventative measures
4.2 HSE representative
a. Coordination of accident and incident reporting and investigation
b. Maintenance of accident and incident records
4.3 Employees
All employees have a responsibility to report accidents and incidents occurrences to
the Site Manager or HSE Representative.
4.4 Unit Head has the overall responsibility to ensure implementation of this Table 1
(TABLE 1) Reporting of Incidents (in Format I)
Report
Fatal, Serious Accidents,
Major Fire or any incident
resulting in disruption of
Operation for more than
2 days
LTI (Loss Time Injury).
Work related injury which
results in a person being
unfit for work for a period
of 48 hours or more
Fire/Spillage (Greater
than 200 lts) / Toxic
release
Incident leading to
property damage of more
than INR 20,000/High potential near miss
(event which could have
lead to major accident)
Responsibility
Unit/Establishment
Head
Unit HR head
Unit Head
Report to
C&MD, D(HR&CA), Director
(I/C), SBU Head, RHR (Head)
and Sr Manager (HSE)
All relevant Statutory
Authorities
C&MD, Director (I/C), SBU
Head, RHR (Head) and Sr
Manager (HSE)
Factory Inspector
Unit HR head
Time Line
Immediate
Immediate
Within 24 hrs
After 48 hrs of
the accident
but within 72
hrs
Within 24 hrs
Unit Head
Within 24 hrs
Unit Head
Within 24 hrs
Unit Head
Investigation Report in
case of fatality & serious
accident
Investigation Report for
all other incidents
reported
Unit Head
Unit Head
28
Within 7 days
of the incident
Within 7 days
of the incident
Annexure- A1
Initial Incident Notification:
Form No:
Medical
Case:
Fatality:
HIPO incident:
Oil Spill:
Chemical Spill:
Treatment
Fire / Explosion:
Site/Location/Area/Plant:
Name of Injured
Sex
M/F
Age
Years of
Experience:
Name of Reporter:
Name of Supervisor:
Position:
Position:
29
Designation
Annexure- A2
Summary Analysis Report/ Investigation Report
Form No:
Plant/Location of Incident:
______________________
Type of Incident:
Near Miss:
Minor Fire /
explosion
Name of Contractor:
Others including
minor traffic
accidents
Employee / Contractor:
Incident Details:
Immediate causes:
Sr. No.
Corrective Action
Responsibility
Prepared by:
Name: __________________________
Designation: _____________________
Target Completion
Date
Approved by:
Name: ____________________________
Designation: _______________________
30
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Immediate Causes
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Unsafe Acts
Operating equipment
without authority;
Lack of planning;
Lack of warning/failure to
observe warning;
Inappropriate
speed/mistiming;
Bypassing or removing
safety devices;
Using faulty
tools/equipment;
Lack of or inappropriate
PPE;
Failure to
secure/improper loading;
Incorrect lifting methods;
Incorrect position for
task;
Not following
procedures;
Inattention / poor
judgments /decision
making;
Working on operating
equipment;
Impaired ability;
Horseplay /Taking
shortcuts;
Unsafe Conditions
Inadequate or defective
guards/barriers or safety
devices;
2. Unprotected height;
3. Inadequate or incorrect
isolations;
4. Damaged Tools/Equip;
5. Congested workplace;
6. Lack of warning system;
7. Inadequately controlled
Fire and explosion
hazards;
8. Poor housekeeping;
9. Poorly controlled
chemical, electrical or
radiation hazards;
10. Inadequately controlled
1.
31
Job Factors
Inadequate
Leadership/Supervision/Standar
d setting;
2. Lack of training;
3. Inadequate engineering;
4. Inadequate purchasing;
5. Lack of Maintenance/or wear
and tear;
6. Lack of routine inspections or
hazard Identification;
7. Incorrect equipment;
8. Inadequate tools/equipment;
9. Inadequate work standards or
procedures;
10. Confusing/out of date or
procedures with missing steps;
11. Lack of employee input to
procedure development;
12. Ineffective communication;
1.
Events
25. Fire & explosion;
26. Event leading to
reputation damage;
Immediate Causes
temperature extremes;
11. Adverse weather
conditions;
12. Noisy workplace;
13. Inadequate ventilation;
14. Inadequate /excessive
light;
15. Inadequate or defective
PPE;
32
33
Training Title
Safety Leadership Training
Target Group
All executives
Remarks
Once in every 3
years
Once in every 3
years
One time
Work at Height
Once in every
two years
Every Year
Every year
Every year
S3
S4
Every year
Every year
Every year
Every year
Waste Management
Every year
M2
M3
M4
S1
S2
S5
S6
S7
E1
E2
Environment Management
System
Every year
34
Purpose
To ensure that robust, clear and tested emergency plans exist and that suitable
persons are trained to implement them.
2.0 Scope
All business locations under BL control
3.0 Definitions
Emergency Organization: The personnel, systems and procedures put in place to
ensure that emergency conditions are managed efficiently and effectively.
4.0 Responsibilities
4.1 Unit Head
Unit Head will ensure that adequate and appropriate resources are provided to ensure
that the requirements of this procedure are applied.
4.3 Site HSE Representative
The Site HSE Representative will ensure that the requirements of this procedure are
implemented within the scope of the Site organization
5.0 Process
5.1 Development of a Site Specific Emergency Plan
A Site Specific Emergency Plan must be developed for each BL business location & new
construction site. It will be based upon the generic emergency plan included as
Appendix 1 of this procedure and developed according to the methodology described
within this procedure.
5.2 Emergency Plan Scope
In most instances the scope of the emergency plan will be limited to fire related
emergencies; however, depending upon the geographic location of the Site other
types of catastrophe must be taken into consideration and emergency arrangements
made proportionate to the identified risk
Consideration should be given to the following:
Flooding
Earthquakes Risk
Lightning
Wind
35
Further guidance and preventative measures associated with these risks is included in
the Generic Emergency Plan see Appendix 1
5.3 Preparation of the Emergency Plan
The Site Manager or nominee will ensure the preparation of the emergency plan, using
the generic plan in Appendix 1.
5.4. Review and Approval Process
5.4.1 The emergency plan must be prepared, checked and approved as indicated below.
The same person must not do more than one of these functions.
Prepared by: The Site HSE Representative
Checked by: BL Organization HSE Representative
Approved by: Site Manager / Organization Manager
5.4.2 The Site HSE Representative will control this document
Emergency Plan Implementation
5.5.1 The Site HSE Representative is responsible for the implementation of the emergency
plan at site. This includes:
i. Ensuring all personnel on site are aware of the emergency arrangements and
receive an induction detailing its requirements. In addition, the emergency plan
must be posted in areas where all BL employees and contractors can have access
to it
ii. Ensuring necessary persons involved in the emergency team are appropriately
trained and that such training is upgraded, as required
iii. Other methods by which emergency arrangements may be tested / simulated
include audits, inspections and desk top reviews
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37
Police Station
Local Hospital Emergency Department
Customer
Government Authorities
Local Doctor
etc..
4.0 Responsibilities
A Trained Emergency response team is set up as described below.
(Insert emergency organization and responsibilities; this will generally include the
following
The person raising the Alarm
The Emergency Communication Co-ordinator e.g. Security Guard
The Emergency Response Team
The Site Nurse
5.0 Evacuation Arrangements
The Site has made the following arrangements in case of evacuation:
i. Responsibilities as per the clause 4.
ii. Muster points have allocated and are indicated on the attached site plan.
(provide the site plan)
iii. An alarm has been installed (if more than one alarm is present state sound of
alarm if different for each type of emergency e.g. gas leak, fire)
iv. An Evacuation Notice has been appended to the site notice boards
v. Simulation Exercises shall be conducted every (define intervals). (If alarm is also
periodically tested also state time, day etc)
6.0 Containment
6.1 Spill kits are available at locations shown on the attached site plan for chemical/oil
spills and include the following items:
a.
Oil/chemical absorbent material (mats, booms, sand etc)
b. Hand pump
c.
Electric pump
d. Empty drums
e. Chemical resistant gloves
f.
Chemical resistant overalls
g.
Chemical resistant calf length boots
h. Chemical resistant face shield
i.
Respirators with cartridges suitable for chemical mist
j.
Hazard warning tape
38
6.2 Spill kits shall be inspected weekly to ensure that the inventory of the kit is as it should
be and to ensure that the location of the spill kit is appropriate to the site activities
such as storage, offloading and use of materials. Outfalls and interceptor pits shall be
inspected daily as part of the daily site inspection system.
7.0 Emergencies
7.1 Medical
Contact the site medical staff and if casualty is in an obscure location or is trapped
alert emergency response team. Casualty must not be moved until examined by site
medical staff except where casualty is in further danger by not being moved e.g., likely
collapse of nearby structure etc. In case of multiple casualties summon Statutory
Emergency Services and where applicable notify the Regulatory Authority.
7.2 Fire
Call for assistance from the trained Emergency Response team. If a minor fire, try to
extinguish using fire extinguisher but ensure escape route away from the fire is
available at all times. Hand the situation over to the emergency response team on
their arrival
7.3 Environmental
(i) Oil Spills
a) Call for assistance from the trained Emergency Response Team.
b) Use appropriate Personal Protective Equipment from the emergency spill kit
and ensure oil cannot enter storm water drains, rivers or run into the sea.
c) Bund area of spill as quickly as possible using sand, oil booms or other
suitable material.
d) Use hazard-warning tape to cordon off the area and establish as no smoking,
no source of ignition zone, position foam filled fire extinguishers close to the
area.
e) Arrange tanker if large spill or transfer to oil drums as soon as possible. Soak
up remaining oil with absorbent material and excavate contaminated soil.
f) Treat used absorbent material and contaminated soil as hazardous waste and
dispose of through a licensed contractor to a licensed facility.
g) Recovered oil should be considered for recycling.
h) At any time during this action that the emergency response team arrives,
hand over to that team informing them all that you know about the incident
and what you have done in preparation for their arrival. Stay available for
investigation purposes.
(ii) Chemical Spills
a) Call for the emergency response team and take only that action required to
prevent further damage only if certain of the chemical, its toxicology and if
you have appropriate PPE.
39
40
secured secondary steel work, pipes, pipe supports, scaffolding etc, (the structure
should have been designed to withstand an earthquake) crouch down and keep your
hard hat in position. If outside stay outside, move away from buildings, structures and
overhead power lines.)
41
42
5.2.2 Medical fitness certificate to be submitted for all contract workman engaged high risk
activities
5.2.3 The Site Manager must review planning, progress and performance on site activities
and initiate appropriate actions to ensure timely completion of the activities.
5.2.4 Contractors will be represented at HSE meetings and progress meetings where they
will be consulted regarding reciprocal risks associated with ongoing activities in order
that they can be minimized.
5.2.5 Pre-Qualifying The Potential Bidder
Pre-qualification Criteria: To ensure consistent pre-qualification response from all
Contractors, the Contract Manager shall enclose the pre-qualification questionnaire
to all potential bidders, along with expression of interest.
The set of standard questionnaire for prequalification criteria is enclosed in
Annexure- A1. The Manager shall evaluate the response to pre-qualification
questionnaire from all the potential bidders and provide feedback to Contracts
Manager.
If required, Manager may contact the potential bidder for additional information
and the potential bidder is allowed to visit the site.
If requested, the Contract Manager shall arrange meeting between Manager and
potential bidder for clarifications. The minutes of meeting shall be documented.
6.0 Contract Scope & Specific Contract Requirements
The Contracts Manager shall forward the scope of work to Manager to develop
Contract Specific Requirements.
6.1 The Standard Contract Requirements are enclosed in Annexure- A2. While formulating
the Contract Specific requirements, the Contract requirements shall be considered in
addition to the following factors,
a. nature of work activities (civil works, mechanical, material handling, maintenance
etc);
b. location & surroundings;
c. mobilisation/ demobilisation;
d. personnel competency requirements;
e. potential risks;
f. security threats & arrangements;
g. standards of equipment used;
h. regulatory requirements;
i. raw materials & consumables;
6.2 Techno-Commercial Bids & Standards
The Manager shall evaluate standards of each Contractor separately, against
requirements mentioned in tender enquiry and if required, on-site audit may also be
carried out. A complete report shall be forwarded to Contracts Manager along with
short falls and recommendations. This shall help the potential Contractor to improve
and make the management more effective.
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44
6.6.1 Annexure - A1
Pre-Qualification Questionnaire for Contractor
Guidelines for Completion of Questionnaire
i. The potential bidder is to ensure that the answers provided are focussed against
the activities indicated in the pre-tender document.
ii. The information is supplied in the same format and sequence in which they
appear in the questionnaire. A minimum of 12 has to be obtained in the HSE prequalification questionnaire.
iii. Failure to supply information that accurately and fully covers the material
requested may result in an individual Contractor failing to meet minimum
expectations and therefore being disqualified.
iv. Contractor shall provide information that is authentic and documentary evidence.
v. Even after getting pre-qualified, if it comes to the notice that non-authentic
documents are provided, the Contractor may be disqualified and if any Contract
is in place, it may be terminated immediately.
vi. BL shall have right to audit Contractors records to verify the authenticity of the
documents, during any phase of the Contract.
Questionnaire for HSE Pre-Qualifications of contractors:
Contactor Details
Company Name
Contact Person for HSE
Name
Telephone Number
E-Mail Address
Question
1 Do you have a signed and dated HSE Policy?
2 Do you confirm that you will comply with BL HSE
Policy in as much as it is applicable to your scope
of work?
3 Do you have a Health and Safety System
certified by an accredited body to a recognized
standard? (Eg : OHSAS 18001)
4 Do you have an Environmental Management
System Certified by an accredited body to a
recognized standard? (Eg : ISO 14001 )
5 Have you identified, documented and
maintained your Health and Safety risk
assessment of your activities?
6 Have you identified, documented and
maintained your Environmental Impact
Assessment of your activities?
7 If you use subcontractors, will you assess them
in terms of HSE?
Response
Yes
No
Evidence Required at
bidding Stage
Attach HSE Policy
Weightage if
complied
1
None
Provide Current
Certificate
Provide Current
Certificate
None
None
None
45
Question
8 Have you produced project/contract HSE plans
for recently completed work?
9 Is HSE Covered in your companys organization
chart?
10 Have HSE roles and responsibilities been defined
in your company?
11 Have your employees received documented HSE
training appropriate to the task they will
undertake?
12 Do you identify and monitor compliance with
HSE Legislation?
13 Do you carry out regular medical examination
for your employees?
14 Is your company free from any charges or
notices served by the regulatory authorities in
relation to HSE in the last 3 years?
15 Do you have any procedure of reporting HSE
Incident and investigation?
16
17
18
19
20
Response
Yes
No
Evidence Required at
bidding Stage
None
Weightage if
complied
2
None
None
None
None
None
I confirm that the above information is correct and that further evidence to support this will be provided to
BL on request.
Name
Position
Company
Date
Signature
6.6.2 Annexure A2
HSE Requirements BY CONTRACTORS (To be a part of contract documents)
Housekeeping
Contractors shall ensure that their work area is kept clean tidy and free from debris.
The work areas must be cleaned on a daily basis. Any disposal of waste shall be done
by the Contractor.
46
All equipment, materials and vehicles shall be stored in an orderly manner. Access to
emergency equipment, exits, telephones, safety showers, eye washes, fire
extinguishers, pull boxes, fire hoses, etc. shall not be blocked or disturbed.
Confined Space
Before commencing Work in a confined space the Contractor must obtain from BL a
Permit to Work, the Permit to Work will define the requirements to be followed.
As minimum Contractors must ensure the following:
i. Confined spaces are kept identified and marked by a sign near the entrance(s).
ii. Adequate ventilation is provided
iii. Adequate emergency provisions are in place
iv. Appropriate air monitoring is performed to ensure oxygen is above 20%.
v. Persons are provided with Confined Space training.
vi. All necessary equipment and support personnel required to enter a Confined
Space is provided.
Tools, Equipment and Machinery
The Contractor must ensure that all tools & equipment provided for use during the
Work is:
suitable for its intended use;
safe for use, maintained in a safe condition and where necessary inspected to
ensure this remains the case (any inspection must be carried out by a
competent person and records shall be available);
Used only by people who have received adequate information, instruction
and training to use the tool or equipment.
Provided with Earth leakage circuit breaker (ELCBs) at all times when using
electric power cords. Use of electrical tape for temporary repairs is
prohibited.
Working at Height
Any Work undertaken where there is a risk of fall and injury is considered to be
working at height.
For any Contractor Personnel working at height, Contractors shall provide fall
prevention whenever possible and fall protection only when fall prevention is not
practicable. Before commencing Work in a height the Contractor must obtain from BL
a Permit to Work, the Permit to Work will define the requirements to be followed.
Supervisor must be present at all point of time, to ensure no deviation occur during
the course of work.
Fall Prevention System
Fall prevention systems (e.g. fixed guardrails, scaffolds, elevated work platforms) must
provide protection for areas with open sides, including exposed floor openings.
47
i.
ii.
iii.
iv.
v.
Only approved full body harness and two shock-absorbing lanyards are used,
Prior establishment of a rescue plan for the immediate rescue of an employee in
the event they experience a fall while using the system,
Anchorage points must be at waist level or higher; and capable of supporting at
least the attached weight,
Lifeline systems must be approved by BL before use.
Use of ISI marked industrial helmet at all point of time.
Scaffolding
All scaffolds shall subject to a documented inspection by a competent person and
clearly marked prior to use. The footings or anchorage for scaffolds shall be sound,
rigid and capable of carrying the maximum intended load without settling or
displacement. All scaffolding materials should be of MS tubular type.
Guardrails and toe-boards shall be installed on all open sides and ends of scaffold
platforms. Scaffolds shall be provided with an access ladder or equivalent safe access.
Contractor Personnel shall not climb or work from scaffold handrails, mid-rails or brace
members.
Stairways and Ladders
Ladders should only be used for light duty, short-term work or access in line with the
below and the Site Requirements.
a. Fabricated ladders are prohibited.
b. Ladders will be secured to keep them from shifting, slipping, being knocked or
blown over.
c. Ladders will never be tied to facility services piping, conduits, or ventilation
ducting.
d. Ladders will be lowered and securely stored at the end of each workday.
e. Ladders shall be maintained free of oil, grease and other slipping hazards
f. Ladders will be visually inspected by a competent person and approved for use
before being put into service. Each user shall inspect ladders visually before using.
g. Ladders with structural defects shall be tagged "Do Not Use," immediately taken
out of service, and removed from the Site by the end of the day.
Roof Work/Access
Roof work and access to roofs must not be undertaken without prior authorization
from BL.
Overhead Work
48
49
50
Spills
The Contractor is responsible for the provision of adequate spill kits/protection and
the clean up and disposal costs arising from such spills.
Emissions
The Contractor shall identify and quantify any emission sources associated with the
Works. The control measures associated with these emission shall be subject to the
approval of BL. Emissions include but are not limited to noise, dust, fumes, vapours.
6.6.3 Annexure A3
POST CONTRACT HSE EVALUATION
Answer
Remarks
(Yes / No)
Question
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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52
until corrective action has been taken. The Inspector must also notify the Balmer
Lawrie Site Manager at the earliest opportunity, who will monitor, advise and assist
with any outstanding action.
4.3 Senior Managers HSE Observation Tours
4.3.1 HSE observation tours are to be undertaken by all Senior Managers when visiting a
site. The aim is to observe behaviors or conditions on the site and to provide feedback
on what has been observed to enable improvement.
4.4 Site Manager Weekly HSE Tour
The Site Manager must perform a site HSE tour on a weekly basis. The inspection
consists of a walk around the site (typically not exceeding 1 hour). The Site Manager
must be accompanied by the Site HSE Representative who will note any observations.
Hazards must be dealt with quickly and on the spot, wherever practical.
4.5 General Planned Inspections
4.5.1 General Planned Inspections (GPI) should be conducted:
Monthly in offices
Weekly at site / manufacturing facilities.
4.5.2 The responsible manager for each area of work must conduct an HSE Inspection of the
work area. Opportunity should be given for worker representatives to be involved.
These inspections must as a minimum, address the topics on the GPI standard
inspection checklists, however, it is preferred that the site should create a checklist
specific for their own needs.
4.5.3 Details of the inspection must be recorded on a Site HSE Inspection Report. The extent
of the inspections may vary from site to site depending on the complexity.
4.5.4 The Site HSE Representative will support the area supervisors/workers representatives
in this task. The Site EHS Representative must collate all the inspection reports after
the inspection and review them.
4.6 Detailed HSE Assessment
The HSE Audit Protocol has been developed by Balmer Lawrie to evaluate the
performance of HSE for all its sites. (Annexure A attached at the end of the Manual)
The Audit Protocol is broken down into 3 Chapters:
I.
HSE management
II.
Health & Safety
III.
Environment
which are broken down into several procedures.
53
Assessor should have reasonable confidence that required processes are in place.
It is the auditors role to recognize if missing information is not highly significant
or if a criterion is missing due to a gap in the system.
Themes which are NOT ASSESSED shall be scored as N/A.
The score given for each chapter is the average of the themes scores.
Utilization & Frequency of Audit
The HSE audit protocol has been developed with the objective that it will become a
tool for self-assessment as well as formal Assessments and a management tool for the
improvement of the HSE, performance.
Each Unit will be assessed by an external evaluator at least once a year. Each unit
should also make a self evaluation at least once a year as per Annexure A attached at
the end of this manual.
Significance of the HSE audit score:
The score obtained by the unit/establishment will have a direct link to the overall
performance of the unit & SBU.
5.0 Records:
1. Internal assessment records.
2. External assessment records.
3. GPI records.
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Chapter 2
OCCUPATIONAL HEALTH
&
SAFETY
55
INDUSTRIAL HYGIENE
1.0 Purpose
To ensure that all employees, indirect personnel and others who may be affected by
BL activities are adequately protected from chemical, biological and physical hazards
2.0 Scope
The procedure is applicable to BL facilities to fulfill the general and also the legislative
requirement.
3.0 Responsibilities
3.1 Operational Manager
Ensure that appropriate workplace risk assessments are performed
Ensure adequate maintenance of protective equipment
3.2 Medical Officer
Maintain a register of persons who may be potentially exposed and to review that
register at appropriate intervals
Maintain appropriate documentation for twenty years.
4.0 Description
4.1. Definitions
4.1.1 Industrial Hygiene: The discipline of anticipating, recognizing, evaluating and
controlling a broad spectrum of biological, chemical, and physical hazards that can
affect an employee's health. Typically these may include: vapours, gases, mists, dusts,
fumes, smoke, aerosols, high frequencies of sound and light, ionizing and non-ionizing
radiation and noise and vibration
4.1.2 Physical Agents: Sources of energy that may cause injury or disease e.g. noise,
vibration, radiation, and extremes in temperature and pressure
4.2 Risk Assessment
4.2.1 A workplace risk assessment must be carried out on all sites in order to identify
potential chemical, biological or physical hazards, detrimental to human health and
the risk of exposure.
4.2.2 Risk assessments can be made as part of, or as an extension of a more general risk
assessment i.e. if a substance hazardous to health present in the workplace is also a
56
risk to the safety of employees, e.g. they are flammable, unstable etc, it may be
beneficial to perform a combined risk assessment.
4.2.3 The risk assessment must include consideration of:
i. The hazardous properties of the substance or physical agent
ii. How the hazard arises i.e. produced or given off, e.g. as fumes, vapour dust etc
by a process or an activity or as a result of an accident or incident
iii. Information on health effects provided by the supplier, including information
contained in any relevant material safety data sheet
iv. The level, type and duration of exposure
v. The circumstances of the work, including the amount of the substance involved
vi. Activities, such as maintenance, where there is the potential for a high level of
exposure
vii. Any relevant workplace exposure limit or similar occupational exposure limit
viii. The effect of preventive and control measures which have been or will be taken
ix.
The results of relevant health surveillance
x.
The results of monitoring of exposure
xi.
In such cases, it is necessary for BL to carry out ambient air and work zone
monitoring and / or measurements to determine exposure, particularly where
operations are complex or specialized and the substances involved have an
occupational exposure limit
4.2.4 The risk assessment must be reviewed regularly (at least annually) or if:
i. There is reason to suspect that the risk assessment is no longer valid
ii. There has been a significant change in the work to which the risk assessment
relates
4.3 Hierarchy of Control
4.3.1 The following principles are adhered to in order to reduce the risk of exposure:
i. Remove any potential hazard through risk mitigation
ii. Substitute any known high-risk substance for a less hazardous substance
iii. Contain the hazard by separating the hazard from the person or by enclosing the
person from the risk
iv. Organize the work to reduce the exposure to the hazard
v. The use of personal protective equipment (PPE)
4.3.2 Control measures must be periodically reviewed, particularly where exposure level are
near to exposure limits subject to regulatory controls, which may change.
4.4 Monitoring of Exposure at the Workplace
Monitoring is done when any of the following circumstances apply:
i. When failure or deterioration of the control measures could result in a serious
health effect, either because of the toxicity of the substance or because of the
extent of potential exposure, or both
57
ii.
iii.
iv.
58
5.0 Records
1. Records of Ambient Air and Work Zone Monitoring
2. Records of Health check-up
3. Pathological Test Reports
59
Working at
Height
Definition
Person trained, experienced and authorized to carry out a particular
function
Equipment typically consisting of a Double hook full body harness, a
lanyard not exceeding 2 meters in length and a deceleration device.
The system needs to be attached to an anchor point capable of
withstanding a load of at least 2270 kg
All working at height is above 2 m height where there is a risk of
falling and a person can become injured as per Factory Act. All high
works which are not regular in nature should to be covered under
work permit system i.e. a work permit is to be issued and verified and
checked by authorised persons prior to start of work
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4.2 Process
4.2.1 Elimination or Minimization Programme for Work at Height
I. Minimization of work at height via:
a. Elimination of the need to perform work at height
b. By eliminating the risk of fall (i.e. implementation of fixed barriers, scaffolds,
mobile elevated work platform etc.)
II. Where reasonably practical as much work as possible will be done at ground level
to minimize working at height e.g. sections of steel work can be bolted together,
pipes welded, radiography carried out and the items painted before being lifted
into position.
4.2.2 Actions Prior to Starting Work at Height
I. Prior to any person working at height a risk assessment must be carried out to
identify the risks and the safety measures necessary to eliminate or reduce the risk
II. Collective protection measures must always be considered in preference to
individual protection measures
III. Where it is not reasonably practicable to provide a safe working platform and a
person has to rely on the use of a double hook full body safety harness, life line
with fall arrestor, a suitable rescue plan must be considered along with the safety
measures.
IV. A Competent Person must verify that the contents of this procedure have been
implemented before the commencement of any work at height. Work may only
commence with the written approval of the Competent Person.
4.2.3 Verification of Procedure Implementation
I. For all work of more than 1 day in duration, a systematic verification of the
satisfactory implementation of this procedure must carried out by Competent
Person, at a frequency appropriate the duration and risk of the task.
II. On completion of the work it must be formally verified by a Competent Person,
that the work place has been left in a satisfactory condition and that all persons
have safely returned from the workplace.
Note: Many accidents occur because floor gratings have been removed and not
replaced, or superfluous materials are left in elevated positions causing slip, trip and
fall hazards
4.3 General Precautions
4.3.1 Fall Prevention
I. The first consideration must always to provide a safe working platform.
II. The sides of all stairways, floors/platforms, walkways, buildings, etc, from where a
person can fall and suffer injury or from where articles could fall and injure
61
someone must be protected with double guard rails and toe boards of at least
150mm in height.
III. With regard to permanent structures such as stairways and platforms, as much of
the permanent handrails as is reasonably practicable should be installed while the
structure is at ground level. Where this is not possible then handrails/guard rails
must keep place with construction.
4.3.2 Floor Openings
I. All openings, through which a person can fall and suffer injury, must be covered
and secured using material that is sufficiently strong to support any forces that it
may be subjected to. The word Hole or Opening must be printed on the
topside. If a cover is not used the opening must be protected by rigid guardrails of
adequate strength and toe boards.
II. When floor gratings are removed for fitting instrument cables etc, the area must
be physically fenced off and signs put in place. Rope or warning tape is not
considered as being adequate. Fences must not be removed before the floor is reestablished and inspected.
III. Collective safety measures, such as a safety net suspended beneath the area of
work, must be adopted for persons installing floor panels and the floor panels
locked/bolted in position as each one is fixed.
IV. Persons not connected with the works must be prevented from inadvertently
walking into the area until all panels are fixed and work complete. Double
guardrails must be used for closing off such areas and notices clearly displayed
prohibiting unauthorized access.
4.3.3 Hand Tools
I. Precautions must be taken to ensure that portable tools, hand tools etc, used in
elevated work areas cannot fall onto people below. Safety nets and/or toe boards
are suitable for this purpose.
II. So far as is reasonably practicable, barriers must be erected below to prevent
person walking below such areas.
III. If none of the above is practical, then some form of protection from falling tools
must be implemented e.g. use of straps/ropes attached to the tools and some
appropriate anchor
4.3.4 Fall Protection Equipment
I. Fall Protection Equipment must be inspected by the user & trained person daily.
II. Double hook full body Safety harnesses that have been used in a fall arrest
situation must be withdrawn from service and not reused/issued until after a full
examination.
III. Records of the results of thorough examinations must be kept on site
IV. Lifelines fall arrestor used for the attachment of Double hook full body Safety
harnesses must be:
a. Horizontal lifelines must be made of steel rope 12 mm diameter (min)
b. Installed at waist height or above
c. Tensioned by use of a turnbuckle or similar
d. Designed to support the maximum number of workers
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V.
VI.
e. Securely anchored at both ends with triplicate wire rope clamps at points
able to withstand the dynamic load generated by a fall
All lanyards must be made of flame resistant materials. Inertia reels may be used
to enable more safe movement around certain areas.
Safe access and egress must be provided to all places of work including access to
lifelines, fall arrestor.
63
III. Inspections must also be carried out when a scaffold is substantially altered and
after any event or incident likely to have affected the stability of the scaffold such
as strong winds or being struck by a crane.
IV. Inspection reports must be kept until the work is completed. All other records of
inspection must be kept until the next inspection has been carried out.
V. A notice with warnings such as scaffold under construction/dismantle - do not
use or a scaf-tag showing that it has been inspected and passed safe for use or
condemned as unsafe do not use must be affixed at all scaffold access points.
Scaf-tags must include the name of the inspector and the date of inspection.
4.5.3 Scaffold Erection
A. Scaffolds of special or non-typical design and any scaffold greater than 10metres in height must be designed by a suitably qualified engineer.
B. Persons erecting scaffolds, steel erectors and any other person likely to work in an
area or in circumstances where the provision of a work platform is not practical
must use fall protection equipment.
C. All work platforms must have a top guardrail fixed at a height of 1.1 m, an
intermediate guardrail and toe boards to all sides from where a person or articles
can fall.
D. Work platforms made from loose planks or boards are forbidden.
E. Gangways must have guardrails and toe boards on all sides from where a person or
articles may fall.
F. Scaffolds erected around a structure, which may have electrical services, and
where electrical equipment is to be used for work must be earthed to protect
persons from electric shock. The earth cable must be routed to avoid damage from
work equipment.
4.6. Roof Work
4.6.1 All persons required to undergo medical test & vertigo test.
4.6.2 All new persons required to safety training before start the job.
4.6.3 Every day before start the job required work permit checked & sign by safety person &
to be serve toolbox talk.
4.6.4 Persons use permanent ladder / temporary ladder with use life line, fall arrestor &
double hook full body harness for prevent fall arrest to climb up & get down.
4.6.5 Persons working on sloping roofs must use proper roof ladders designed to gain
anchorage from the opposing slope or must be connected to a double hook full body
harness with fall arrestor to lifeline positioned so that the person(s) cannot fall from
the roof.
4.6.6 Persons working on fragile roofs must use crawling boards of sufficient length to span
roof trusses. Buildings with fragile roofs must have a notice clearly displayed at all
access points with the wording or similar Danger Fragile Roof
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4.7
65
66
using appropriate equipment and tools; remote cameras can be used for internal
inspection of vessels)
5.2 Confined Space Register
A written inventory of all confined spaces must be established and maintained for the
site. A register of all staff and contractors who are trained to perform work in confined
spaces must also be established and maintained.
5.3 Training
I. Everyone involved with preparation of confined spaces for entry; those required to
enter a confined space, Watchers and those that may have to enter in the event of
an emergency must be given appropriate training.
II. The person responsible for the completion of a confined space entry permit and /
or the Authorized Person must be suitably trained and competent within the
permit system, confined space entry requirements and the hazards associated with
the work
III. Training must provide details of the risk assessment and will include as a minimum:
i. Confined space entry permits
ii. Use of barriers to prevent unauthorized entry
iii. Emergency entry and exit procedures
iv. Use of respiratory equipment.
v. Use of Safety Equipment
vi. Communication, including marking / identification of confined spaces
vii. Rescue drills
viii. Fire protection
5.4 Risk Assessment
If entry to a confined space is unavoidable a safe system of work and adequate
emergency arrangements must be in place before the work starts. The first step will be
to perform a suitable and sufficient Risk Assessment in order to identify any hazards,
assess the risk and determine precautions.
The following must be taken into consideration:
a. The task being performed
b. The working environment
c. Working material and tools
d. The suitability of those carrying out the task
e. Arrangements for emergency rescue
5.5 Hazards to be Considered
5.5.1 If the atmosphere in the confined space contains toxic, flammable/explosive
substances, carbon monoxide gas, corrosive substances and/or low/ high oxygen
levels, the confined space must be emptied and flushed or purged. Fresh air (normal
air in sufficient quantity to make the atmosphere safe) must be provided. If this cannot
be achieved, or if there is a risk that an inappropriate atmosphere could evolve during
the work, self contained breathing apparatus or air hoods must be used along with
other protective measures such as ensuring that ignition sources or materials that may
67
inadvertently cause ignition are not taken into the confined space or the vicinity of an
opening to the confined space
Note: respirators must not be used if there is a risk of oxygen deficiency.
5.5.2 When providing fresh air, it must be ensured that the fresh air intake is not
contaminated by smoke, exhaust fumes from generator sets, etc. and that the intake is
protected from interference. Open vents must be prevented from being closed or
obstructed and air blowers/extractors must be safeguarded against disconnection.
Forced ventilation such as air blowers must be fitted with an alarm that will activate in
the event of a breakdown of the equipment or alternatively the equipment doubled up
or a person on standby close to the equipment. In the event of hearing the failure
alarm or being alerted by the person on standby, the confined space must be
immediately evacuated.
5.5.3 Under no circumstances must oxygen be used to provide breathable air or to sweeten
the atmosphere. An oxygen-enriched atmosphere presents a serious risk of fire and
explosion and can cause normally stable materials to become highly combustible e.g.
grease can become liable to spontaneous combustion when oxygen-enriched.
5.5.4 If welding or burning must be conducted in the confined space consideration must be
given to the fact that the process could seriously reduce the breathable air and
introduce toxins.
5.5.5 Flammable substances and substances liable to give off gases, vapors or fumes
including substances being used in the confined space e.g. paints, resinous compounds
etc, must be continuously monitored to ensure that the OEL and LFL are not exceeded.
5.5.6 Gas/oxygen cylinders must not be taken into a confined space. If gas e.g. acetylene/
oxygen is required for welding or burning, the gas must be conveyed by a hoses of
continuous length with the cylinders on the outside of the confined space. When not
in use the gas/oxygen supply must be turned off at the nozzle/torch and cylinders and
the hoses disconnected from the cylinders or completely removed from the confined
space after each shift.
5.5.7 Consideration must also be given to the tools, plant and equipment being taken into
the confined space e.g., if a flammable atmosphere, all electrical
equipment/appliances must be explosive proof or intrinsically safe, tools will need to
be non-metallic and all other sources of ignition prohibited. Smoking is prohibited in
all confined spaces
5.5.8 Consideration must also be given to noise that may be generated from the work inside
the confined space and any work taking place on external surfaces of the confined
space or adjoining plant/apparatus. Noise in a confined space tends to reverberate
and intensify. Therefore noise that sounds to be at an acceptable level outside could
be unacceptable inside. When considering what action to take with respect to
protecting persons inside a confined space from a noise source, it must be appreciated
that ear protection may make it difficult for them to communicate with persons on
standby duty on the outside.
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viii. Buildings and structures shall be protected against lightning as per IS 2309 1989.
ix. During lightning, everyone working in open areas must be advised to come under
shades which are protected by lightning arrestors.
7.2 Secondary Protection through Residual Current Circuit Breakers (RCCBs) & Earth
Leakage Circuit Breakers (ELCBs):
RCCBs / ELCBs of adequate current rating shall be provided for:
i. All socket outlets in plants and office buildings including 3 phase socket outlets
(e.g., welding socket outlet)
ii. Movable/portable, electrical/electro-mechanical equipment e.g. welding
machines, movable plant & equipment etc.
iii. Air circulators and temporary construction power and lighting power distribution
board.
7.3 Testing the RCCB: RCCB should be tested once in six month
Failed RCCBs shall be replaced promptly. In the event the RCCB cannot be replaced
immediately, the said connection should be isolated immediately & made inoperative.
Similarly, in the event of the RCCBs failing at the time of periodic audits, root cause
would need to be ascertained as the period between failure & detection of failure of
RCCB is a risky proposition & should clearly deal with any emergent environmental
reasons for premature failures.
8.0 Working on or in the vicinity of live conductors
The risk associated with working on live conductors is extremely high. As a rule, no
work shall be done on live conductors.
Only in extremely rare and unavoidable circumstances may 'live-working' be justified,
these being limited to situations where the risk resulting from electrical isolation is
greater than the risk from working on the live conductor (e.g. where the isolation
would result in the shutdown of a critical safety system(s). Such situations should be
covered by PTW to be authorized by the Maintenance Head only. For trouble shooting
on individual circuits, it may be necessary from time to time to work on control circuits
which are live.
PCC/MCC panels/equipment panels where control circuit is 240V to identify such
locations & draw up a comprehensive program for phasing out such circuits in favour
of 110V control circuits wherein the winding of the transformer is center tapped and
earthed. Such control supplies shall be protected by an ELCB of 30 mA sensitivity.
The decision to work on or near any live conductor must not be made on the basis of
business exigency or on economic grounds.
9.0 Modifications to Electrical Systems or Equipment:
I. In general, electrical systems or equipment shall not be tampered with (including
PCCs / MCCs / transformers etc.) and no unauthorised connections shall be
permitted.
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VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
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IV. The operational state of electrical switchgear and control gear must be clearly
shown by indicators, except when the main contacts can clearly be viewed.
15.0 Records
Earth Pit test records.
ELCB test records.
Transformer oil test records.
PTW.
LOTO register.
Relay test records
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iv.
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iii.
iv.
v.
is then responsible for the lifts. However, the operator shall obey a stop
signal at all times, no matter who gives it.
The operator must be familiar with the equipment and its proper care. If
adjustments or repairs are necessary, the operator must promptly report
this to the Appointed Person, and must also notify the next operator.
The operator prior to a new lift must test all controls. If any controls fail
to operate properly, they will be adjusted or repaired before operations
are begun.
Where applicable, the manufacturer's balancing bar and lifting
procedures must be followed. Any deviation from the manufacturer's
procedure must be promptly reported to the Appointed Person
Records
1. Records of testing of Lifting Tools and Accessories
2. Training Records.
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Excavations less than 1.2 meters in depth need not have a rigid barrier as long as they
are highlighted with warning tape at a distance of at least 1.5 meters from all edges of
the excavation.
4.2.4 Protection from Water Accumulation Hazards
Among the additional hazards stemming from water in an excavation are undermining
the sides and making it more difficult to get out of the excavation. Employees are
prohibited from working without adequate protection in excavations where water has
accumulated or is accumulating. If water removal equipment is used to control or
prevent water accumulation, a competent person shall monitor the equipment and its
operation to ensure proper use. Diversion ditches, dikes, or other suitable means shall
also be used to prevent surface water from entering an excavation and to provide
adequate drainage of the adjacent area. A competent person shall inspect excavations
subject to runoffs from heavy rains.
4.2.5 Inspections
I. Work must not be carried out in an excavation where any supports or battering and /
or the excavation are more than 1.2 meters deep unless:
The excavation and any work equipment and materials which affect its safety, have
been inspected by a Competent Person:
a. At the start of the shift in which the work is to be carried out
b. After any event likely to have affected the strength or stability of the
excavation, and
c. After any material unintentionally falls or is dislodged; and
II. Inspection reports must contain the following:
i. Organization and person on whose behalf the inspection was carried out
ii. Location of the place of work inspected.
iii. Description of the place of work or part of that place inspected (including any
work equipment and materials)
iv. Date and time of the inspection
v. Details of any matter identified that could give rise to a risk to the health or
safety of any person
vi. Details of any corrective action taken and any further action considered
necessary.
vii. Name and position of the person making the report
4.2.6 General Precautions around Excavations
I. As a minimum requirement, material including spoil and backfill must not be
stored within 1 meter of the edge of excavations. The actual distance necessary
related to the particular excavation and must be calculated at site considering the
depth of the excavation and the weight of the material.
II. Vehicles and construction plant must not be allowed to come within 2 meters of an
excavation unless working in connection with the excavation.
III. Vehicle / plant working in connection with the excavation must have a person
controlling the vehicles tipping material and their movement to prevent them from
going so close to the edge that it shall cause damage to the excavation.
86
IV. Persons are not allowed to work or stand under loads being loaded or unloaded.
V. All persons in excavations must wear safety helmets, safety boots and any other
personal protective equipment as defined by the risk assessment.
VI. Persons entering bore holes or similar restricted excavations must do so in a safety
cage, the end of which must be attached to a winch or similar hoisting appliance at
the top of the borehole with a Watcher on emergency standby
4.3 Training
All persons required to work in an excavation deeper than 1.2 meters must be given
appropriate training. The level of training will depend on the complexity of the
excavation but basic training must take account of the following:
i. Induction training for new persons
ii. Details of the risk assessment
iii. The dangers of working in excavations
iv. The safety arrangements
v. Daily inspections
vi. Who to contact in the event of emergency
vii. Fire protection
5.0 Records
Excavation Work Permit.
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4.0 Description
4.1 Definitions
Contractors: Any third party employee executing works on the BL premises or sites
under BL supervision
Personnel:
PPE:
Lanyard:
4.2 Process
Assessing PPE requirement
Risk assessment is carried out to find out the requirement of PPEs and an effort is
being made to prevent workers from coming in contact with the hazards by
guarding suitably at source. When it becomes impractical to eliminate the cause of
accident by engineering revision, dependence on PPEs is being chosen as the last
resort.
Selection of PPE is based on,
(a) Degree of protection which a particular PPE might afford,
(b) The ease with which it may be used.
Basic requirement - The Company ensures that:
i.
ii.
iii.
iv.
v.
vi.
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Breathing
Eyes
Feet and
Legs
Hands and
Arms
Head
Hazards
Options
4.3 Inspections
4.3.1 General Inspection of PPE
PPE users are responsible for inspecting issued PPE before each use and reporting any
damage to their Supervisor, who must arrange to replace or repair replacement of
PPE, as appropriate, if it is not functioning as required.
4.3.2 Inspection of Safety Harnesses and Lanyards
I. Inspection Regime
The following minimum inspection regime will be adopted for safety harnesses and
lanyards:
a. User Inspections - each time the equipment is used
b. 6-monthly Inspection - by Safety Representative
II. Identification
All items of fall arrest equipment are indelibly and permanently marked with a
unique identification number, so that they can be readily associated with the
respective documentation. If marking is not evident, or obscured by dirt, the item
of equipment must be withdrawn from service immediately and referred to the
safety representative who is responsible for the six-monthly inspection.
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7.0 Training:
The Person authorized for carrying out LOTO must undergo requisite training to make
him enable to carry out the job. Refresher Training for Authorised Person to be
conducted at least once in every three years. General Awareness Training to be
extended to the person performing work with LOTO. Record for the training to be
maintained by the concerned agency in addition to H.R. Dept.
Specimen for Lock out Tag out
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However it is essential that the persons carrying out these tasks are adequately
trained and fully aware of hazards in their operating area. Untrained persons should
never be put on such tasks.
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4.0 Definitions
Permit to Work (PTW):
Issuing Department:
Issuer:
Permit Approval
and Authorisation:
Acceptor:
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6.0 Procedure
6.1 Responsibilities
6.1.1 Unit Head shall.
i. nominate managers (department or functional heads) who have authority to
appoint persons who may issue or accept PTW in their areas of responsibility
ii. define the plant area boundaries within which their teams will issue PTW
iii. issue a register of any specific tasks exempted from this procedure in their areas of
iv. responsibility, after consultation with the Safety representative and concerned
managers
v. carry out random checks on PTW issued
6.1.2 Nominated Managers (department / functional head) shall
i. ensure that persons are appropriately trained as Issuers and Acceptors of PTW
prior to appointment, and maintain up to date lists of such appointed personnel
ii. carry out random checks on PTW issued on a daily basis and ensure that the PTW
system is operated effectively.
6.1.3 The Safety Representative shall
i. be responsible for imparting the training on PTW system and upkeep of the
training packages. The training packages must be based on this Standard.
ii. conduct internal system audits on PTW at least once two months and report
findings to the management team at site.
6.1.4 Issuer of PTW shall
i. be responsible for determining the nature and extent of the job to be carried out,
possible hazards and the necessary precautionary measures to be taken prior to
issuing the permit
ii. ensure that necessary isolations are carried out
iii. provide acceptor with necessary Method Statements / Risk Assessments (where
applicable)
iv. take assistance of maintenance manager/officer in carrying out above
responsibilities in case of an engineering job
v. ensure that necessary precautionary measures are taken prior to authorising the
permit.
vi. For jobs directly under charge of the Issuer, the Issuer of PTW shall
a) select competent people for the job
b) be responsible for explaining the safe Work Method to the persons
carrying out the job provide them with proper tools / PPE
c) be overall responsible for the job.
6.1.5 Competent person for certifying isolation shall
i. be responsible for checking and certifying isolations as relevant
ii. be the electrician for electrical isolation
iii. be the issuer or operator for process / services isolation.
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iv) acceptor has the responsibility to ensure that all the other people doing the
work are familiar with the contents of the Permit to Work, that the specified
precautions are observed and that a new Permit to Work is obtained if the
nature of the work changes.
v) Work Completed
The acceptor (i.e. the contractor supervisor or own employees on the job) must
detail on the Permit to Work and describe to the issuer the precise state of the
equipment when the task is finished, and confirm the area has been left clean
and tidy. He will confirm this by signing the permit.
vi) Energisation and Permit Closure
The issuer shall then arrange for the de-isolation and restoration of energy as
required which will be recorded in the permit. Permit shall be closed (both
original & the copy)
7.0 System Audit
7.1 The Site Safety representative shall conduct formal audit of PTW system covering all
defined areas at site, at least once in a month, to confirm its appropriateness and full
compliance to all provisions of this Standard.
7.2 The audit shall be carried out using a checklist developed based on this Standard
7.3 Formal audit reports shall be prepared and appropriate corrective actions identified
7.4 The Unit Head and Department Head shall personally carry out daily random checks of
Work permits
8.0 Records
The following documentation / records shall be regularly updated and retained for the
times indicated.
Records Retention Time Location
Closed PTW - 3 month
System Audit Reports & Action Reports of last 2 years.
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Sample PTW
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5.0 Process
5.1 Key Principles
All sites must implement fire prevention and protection methods specific to hot work
operations as applicable such as:
a) Eliminating/minimizing fire hazards in the vicinity of the hot work process
b) Providing a fire watch when hazards cannot be adequately minimized
c) Completing and approving work permits and associated requirements prior to
beginning the cutting or welding process
d) Prohibiting hot work in designated, high-hazards areas
e) Cutting and welding equipment care and use
f) Training affected personnel
5.2 General Requirements
I. Hot work must only be performed in areas proven by risk assessment to have fire
hazards adequately controlled.
II. All combustibles must be relocated, where practicable, a minimum of 6m from
the work site. Where relocation is impractical, combustibles must be protected
with flame proof covers, guards or curtains.
III. Ducts and conveyor systems that could carry sparks to distant combustibles must
be suitably protected or shut down.
IV. Where hot work is done near combustible walls, partitions, ceilings or roofs, fire
resistant shields or guards must be provided to prevent ignition.
V. If hot work is to be done on non-combustible walls, partitions, ceilings or roofs,
precautions will be taken to prevent ignition of combustibles on the other side,
due to conduction or radiation, preferably by relocating combustibles. Where
combustibles are not relocated, a fire watch on the opposite side from the work
must be provided.
VI. Hot work must not be attempted on a metal partition, wall, ceiling or roof having
a combustible covering nor on walls or partitions of combustible sandwich-type
panel construction.
VII. Cutting or welding on pipes or other metals in contact with combustible walls,
partitions, ceilings or roofs must not be undertaken if the work is close enough to
cause ignition by conduction.
VIII. Floors must be swept clean of combustible materials for a radius of a minimum
of 6m. Combustible floors must be kept wet, covered with damp sand, or
protected by fire-resistant shields. Where floors have been wet down, personnel
operating arc welding or cutting equipment will be protected from possible shock
e.g. insulated blankets.
5.3 Welding
I. No welding, cutting, or other hot work must be performed on used drums, barrels,
tanks or other containers that were used for holding flammable/ combustible
materials until they have been cleaned. Cleaning must remove all flammable
materials present, as well as any substances such as grease, tar, acids, or other
materials that might produce flammable or toxic vapours when subjected to heat.
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II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
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Chapter 3
ENVIRONMENT
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Discharge Consent:
Storm Water:
Water Pollution:
4.0 Responsibilities
4.1 Site Manager
The Site Manager must ensure that a detailed knowledge of the functioning of the
site's storm water and wastewater drainage systems is gained. This is to ensure that
foul and surface waters are discharged correctly to the right drainage system.
4.2 Site HSE Representative
i. Monitor implementation of this procedure
ii. Co-ordination of emergency response in the event of a spillage
iii. Ensure that any environmental incidents are reported
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5.0 Process
5.1 Site Drainage
5.1.1 The locations of any Site water discharge points must be identified before any work is
undertaken. This will involve:
i. Mapping of the wastewater and storm water networks on site, including the
sources of all discharges and the discharge points
ii. Identification of discharge points for these networks
5.1.2 Drains must be identified as to whether they are storm (surface) water drains or foul
(wastewater) drains to aid identification of where a spill will leave the site.
5.2 Consented Discharges to Controlled Waters
5.2.1 For all water discharges to controlled waters, it must be ensured that:
i. No water is discharged without consent.
ii. Discharge is monitored and recorded, taking samples where necessary.
iii. All conditions of the consent are met / none of the conditions are breached.
iv. If conditions are breached, the breach must be reported firstly to the
regulatory authority and secondly, internally using the Accident / Incident
reporting procedure
5.2.2 Storm water that is essentially "clean" water can be allowed to enter controlled
watercourses without the need for Consent.
5.3 Planning for Spill Emergencies
I. An emergency plan must exist for the control of spills. This plan will be simulated at
least annually to ensure its effectiveness.
II. An adequate number of personnel will be trained in spill containment. This could be
all site personnel but may be a dedicated emergency response team.
III. Spill kits must be inspected weekly to ensure completeness of the inventory and to
ensure that the location of the spill kit is appropriate to the site activities such as
storage, offloading and use of materials.
IV. Arrangements must also be in place to ensure that spill kits are replenished if items
have been used in the event of a spillage
V. Outfalls and interceptor pits will be inspected daily as part of the daily site as
inspection system.
5.4 Unplanned Discharges and Spillages
5.4.1 Identification of Substance
All unplanned discharges or spillages must be reported to the site HSE Representative,
who will evaluate the spillage or release and determine the required response.
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iii.
iv.
v.
vi.
vii.
viii.
B. All spillages as identified above will be investigated and reported in line with
procedure of Accident and Incident Reporting.
6.0 Records :
Consent to operate
Layout of waste water & storm water.
Records of discharged water parameters.
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II.
III.
Obtaining and reviewing information for each waste stream relating to the
relevant legislative requirements and confirming validity with the relevant
authorities
Ensuring that waste control documentation is completed and retained as per
procedural/ legislative requirements.
Planning, conducting and reporting of waste audits.
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4.0 Description
4.1 Wastes have been categorized as:
1.
2.
3.
4.
Bio-degradable waste
Non-Biodegradable waste
Contaminated waste
Hazardous Waste
a. Industrial
b. Biomedical
III.
IV.
V.
Biodegradable waste like paper, cotton waste, wood will be kept in green bins
which will be transferred to identified area in Scrap Yard for further disposal.
Non-Biodegradable waste include plastic, polythene, rubber, concrete debris, fire
bricks, glass and welding slugs are to be kept at blue bins and to be disposed to
identified place at Scrap Yard for further disposal.
Welding slugs are to be collected and used for land filling
Oil Contaminated wastes are to be collected in one red bin which will be
transferred to identified area in Scrap Yard for further disposal.
Industrial hazardous wastes in liquid form (used lubricant and used coolant oils)
are to be collected in empty oil drums & to be kept under shed and lock and key
and the floor must be made of concrete with non permeable membrane below
ground. The content must be labeled.
Biomedical wastes are to be sent to Medical Centre for disposing by deep burial
method.
4.3 Disposal
I.
Biodegradable waste includes paper waste, wood waste, cotton waste, and
cardboard packets--- can be used for landfill or sold to vendor through auction.
II.
III.
IV.
Metallic Waste include off-cuts of steel tubes, plates and turning and borings of
tubes and bars, and also nonferrous metallic scrap like aluminum, copper and
bronze coming out of maintenance. These wastes are to be sold through auction.
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V.
Old machinery list which is approved are disposed off through open auction.
VI.
Hazardous waste include empty paint containers, paint sludge, empty dye
penetrant cans, used lubricants, used cutting oil, used transformer oil ,ETP
sludge & asbestos waste , generated out of shop floor roof sheets and rain
water pipes of roof sheds. These are to be disposed through approved recyclers
or approved disposers of Central/ State Pollution Control Board. The vendors
must be able to provide all legal documents prescribed in legal register.
5.0 Records:
Hazardous waste generation, storage & disposal authorsation.
Manifest (Form-13) of disposed hazardous waste.
Annual return (Form-iv) to SPCB by 30th June each year.
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obvious sign of contamination - particular care must be taken when the stored
substance is water-soluble. If contamination is suspected a sample must be taken for
analysis and the results approved by a competent person before the bund is drained.
On completion of drainage, the drain valves must be locked in the closed position. Any
water found to be contaminated must be disposed of in accordance with procedure of
Waste Management.
4.1.5 Temporary Storage
When it is necessary to have temporary fuel or chemical storage facility the most
appropriate method of containment must be applied
4.1.6 Prepared Bund
A bund must be fabricated on a level (as far as practicable) base; using materials that
will ensure that the walls and base are impermeable to the substances stored and to
water. The height of the bund must be calculated to hold at least 110% of the volume
of the largest container or 25% of the total capacity of all the containers, whichever is
the greater. It is recommended that the minimum height of the walls be 150mm.
4.2 Underground Storage
4.2.1 The use of underground storage tanks and pipework is to be avoided wherever
possible. Where such facilities do exist, an action plan must be drawn up for their
elimination (unless the underground storage system incorporates technology capable
of providing the same degree of control as that for above ground storage).
Until such time as they are removed the following precautions must be taken:
i. The locations of the tanks and pipework must be recorded, as far as is practical,
preferably on a map and by physical markings / signs above ground.
ii. Records must also be kept as to the volume, method of construction (i.e. single or
double skinned, in a pit, pipework in ducts) and the nature of the product
contained (at present or in the past)
iii. Measures taken to protect tanks and pipework from physical damage, such as that
caused by excessive surface loading, ground movement or ground disturbance
iv. Some form of monitoring of contents employed to ensure that leaks are readily
detected
v. Regulatory testing must be performed
4.2.2 To avoid the risk of pollution, underground tanks that will not be used again must be
removed. All remaining product and residues removed, tanks and pipework must be
disposed of in accordance with local regulatory requirements.
4.2.3 Once the tank has been removed, samples of soil and groundwater (if present) should
be taken to check for subsurface contamination. The samples must be analyzed for the
parameters appropriate to the type of product stored.
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118
HSE MANAGEMENT
1
An HSE co-ordinator has been appointed at each site, or the responsibility has been clearly
assigned to a certain person and documented.
HSE roles and responsibilities of the Operational managers have been cascaded down through
the organization and documented.
3
4
5
The sites management team has been given documented HSE training within the past 3 years.
A management review on HSE KPIs is held and documented at least once a year
Site, Unit or Project Management team members to do documented Safety Observation Visits
The site has identified all of its routine and non routine activities requiring risk assessment
For each activity, the site has identified environmental aspects/impacts generated during
normal, abnormal and emergency conditions
Identified significant risks should be controlled through appropriate procedures and workinstructions.
Regulation Monitoring
10
Regulation Monitoring
11
HSE Objectives to be framed for each year & targets have been defined for each of these
objectives
12
Cost Control
All investments associated with accident prevention must be identified and cost of treatment &
compensation to be documented.
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Remarks
Final Score
Points to be audited
Maintained at per
BL std
Excellent & Best
Practice
Theme
2
Maintained below
BL std
Sr
No
1
Lack of awareness/
no initiative
Scores
HSE MANAGEMENT
13
Training
14
Training
15
Communication
16
Communication
17
Communication
18
19
20
21
22
All the site personnel including contractors are made aware of the sites HSE policy, relevant
health and safety hazards and risk Assessments, environmental aspects and associated impacts
and applicable HSE objectives and targets set by the management,
A process has been established that ensures that all new employees and sub-contractors are
identified and trained upon arrival at the site. All trainings to be documented.
All HSE topics (policy, objectives, results, assessments, reviews, reports, etc.) shall be a subject
of regular information. (such as team briefings or tool box talks for example).
HSE posting is visible and understandable,
HSE communication involves as a minimum:
communication of HSE rules to visitors to the site,
appropriate involvement of workers in hazard identification, appraising on MSDS of all
chemicals used in premises, risk Assessments and determination of controls,
appropriate involvement of workers in incident investigation,
involvement of workers in the development and review of objectives,
HSE roles and responsibilities are clearly defined and communicated accordingly
The analysis of all the incidents is conducted annually.
Each accident with & without Lost time injury are recorded , investigated & reported as per
reporting protocol.
A process is in place to ensure that near misses are recorded & high potential near misses are
investigated.
The site has identified equipment types and installations being subject to regulatory controls;
Procedure for alarm and evacuation are trained and known by employees.
120
Remarks
Final Score
Points to be audited
Maintained at per
BL std
Excellent & Best
Practice
Theme
2
Maintained below
BL std
Sr
No
1
Lack of awareness/
no initiative
Scores
HSE MANAGEMENT
23
Emergency Preparedness
24
Emergency Preparedness
25
26
27
28
Emergency Preparedness
Emergency Preparedness
Emergency Preparedness
Housekeeping
29
Housekeeping
30
31
32
33
34
35
36
37
38
39
40
Emergency equipment is tested and controlled periodically (at least once a year).Mock Drills
are conducted at least 3 times a year.
Site Emergency team members (first aid & fire fighters) & important contact numbers are
displayed at strategic locations.
Tie up with external hospitals, for immediate treatment in case of serious accidents.
Adequate safety shower & eye wash stations are in place
Adequate First aid box are available & contents are inspected frequently
The site has established a daily cleaning program and the work area is tided after each shift;
All the walkways, driveways, workstation, lay-down areas, storage area, loading and unloading
area are properly marked;
Site carry our daily safety inspection by a checklist & proactively address the HSE deviations.
Inspection carried out by executives of various departments including Unit heads &
documented.
Register of periodical regulatory monitoring and controls are maintained.( Pressure Vessels ,
Cranes , Slings etc)
Safety Organisation & safety committee reports of each month to be documented.
First aid & Near Miss reports are maintained.
Analysis of all Emissions.( Air , water etc)
Hazardous waste disposal agreements with authorised vendors
fire License
work accident reports,( Lost time accidents)
employer insurance certificates,
raw data (energy consumption, water, etc..), Management programs taken in HSE for
continual improvements.
121
Remarks
Final Score
Points to be audited
Maintained at per
BL std
Excellent & Best
Practice
Theme
2
Maintained below
BL std
Sr
No
1
Lack of awareness/
no initiative
Scores
HSE MANAGEMENT
41
42
43
44
45
122
Remarks
Final Score
Points to be audited
Maintained at per
BL std
Excellent & Best
Practice
Theme
2
Maintained below
BL std
Sr
No
1
Lack of awareness/
no initiative
Scores
Industrial Hygiene
Industrial Hygiene
Medical Surveillance
Medical Surveillance
Confined Spaces
Confined Spaces
Confined Spaces
Electrical Safety
Electrical Safety
10
Electrical Safety
11
Electrical Safety
12
Lockout Tagout
The site has identified workshops and processes required to carry out regulatory exposure monitoring
and/or which are considered to have potential for high risk exposures according to risk assessment.
the immediate control measures of the personnel have been implemented in case of exposures
greater than these standards;
Medical check-ups as legally required for all relevant employees have been:
1. planned, and/or
2. Completed.
Pre employment medical records of the contract staff are also in place.
Training on confined space hazards have been conducted to supervisors & people exposed to confined
spaces.
All confined spaces in the site are identified & confined space PTW (Permit to work) are issued for all
work in confined spaces.
Oxygen level & LEL (lower explosive limits) are continuously monitored & maintained when someone
enters inside confined space. Oxygen level should never be less than 19.5 %.
A suitable resource of trained and competent individuals have been appointed (in some cases subcontracted) to carry out electrical activities.
All electrical staff are appropriately trained, have a formal statement of their competencies and
knowledge of the extent of their personal authority to carry out the required electrical tasks, at their
competency level. Those carrying out operations, maintenance, testing and commissioning works on
the systems, equipment, must be competent and have knowledge of general electrical hazards.
All critical electrical equipments like Relays, Circuit breakers, tripping devices are tested & certified by
an competent authority at least once a year.
Entire earthing system to be checked & earth pits are tested once a year & documented.
Trained and formally authorized person approves the isolation prior to work starting through Permit to
Work system
123
Remarks
Final Score
Points to be audited
Maintained at per BL
std
Excellent & Best
Practice
Theme
Maintained below BL
std
Sr
No
Lack of awareness/
no initiative
Scores
2
3
Portable Equipment
14
Portable Equipment
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
124
Remarks
Final Score
Points to be audited
Maintained at per BL
std
Excellent & Best
Practice
Theme
Maintained below BL
std
Sr
No
Lack of awareness/
no initiative
Scores
2
3
Excavation
Lifting Operations
Lifting Operations
Lifting Operations
People involved in excavation & trained in the associated hazards & documented.
All lifting accessories & equipments are tested as per the legal requirements.
All crane operators & riggers have undergone training on safe lifting operations.
Working below suspended load is strictly prohibited
Lifting Operations
Machine guarding
38
Machine guarding
If rotating parts are protected with wiremesh guards the wire mesh openings are not larger than
inch
39
40
41
42
43
44
45
Machine guarding
Personal Protective equipments
Personal Protective equipments
46
Air receivers are tested & labeled on the body as per statutoru requirements
47
125
Remarks
Final Score
Points to be audited
Maintained at per BL
std
Excellent & Best
Practice
Theme
Maintained below BL
std
Sr
No
Lack of awareness/
no initiative
Scores
2
3
Points to be audited
ENVIRONEMENT
1
Waste
2
3
Waste
Waste
Water Supply
Water Supply
Energy Consumption
8
9
10
11
Energy Consumption
Energy Consumption
Greenhouse Effect Gas
Greenhouse Effect Gas
Underground Storage Tank &
Piping
Underground Storage Tank &
Piping
12
13
All the types and the nature of wastes generated at the site have been identified & documented in
Form- 3.
Waste transfer& disposal documentations are maintained as per Form -13.
regulatory compliance for the disposal of the waste can be proven;
the storage areas of Chemicals & Petroleum products are subject to planned inspections in order
to ensure their good management sound secondary containment.
The site has knowledge of the source or sources of the water that it uses (local city supply system,
pumping from the water table etc.);
the site has quantitative data of its water consumption for each of its means of supply;
the site has quantitative data on various types of energy consumption and for each of its means of
supply;
an annual report on its consumption has been drawn up.
the site has defined a program for the reduction of energy consumption (objectives and targets);
the site identifies all the activities that generate greenhouse gases;
the site identifies the sources of the emissions of these gases;
The site has located (on a map if possible) all of its underground storage tanks, reservoirs and piping
present on the site;
for each of the tanks, reservoirs and piping subject to regulatory testing, the test results file is upto-date.
Remarks
Theme
Final Score
Sr
No
Lack of awareness/ no
initiative
Maintained below BL
std
Maintained at per BL
std
Excellent & Best
Practice