SAFETY REQUIREMENTS : HEALTH, SAFETY & ENVIRONMENT

1.0 HEALTH, SAFETY & ENVIRONMENT POLICY OF BPCL.

The objective of this document is to provide and establish safe & environment
friendly work practices at all construction sites as per our corporate health, safety
and environment policy given below.
Commitment
Together, we have the highest concern and commitment for protecting the Health
and Safety of all employees, contractors, customers and the communities in
which we operate and for conservation of the Environment.
We will comply with all Statutory Regulations and may even go beyond these for
the benefit of our environment.
We consider Health, Safety and Environmental aspects are an integral part of our
business planning and operation processes.
Policy
Based on these guiding principles, we shall :
Demonstrate our commitment by ……
Providing and maintaining safe facilities and working conditions.
Recognising that all employees have responsibility for their own safety and
actions which could affect the safety of others.
Adoption of appropriate technologies to minimise the impact of our activities
on the Environment.
Establish clear objectives and targets to ……
Improve continuously for prevention of accidents & occupational illnesses and
minimising any impact of our activities on the environment.
Promote learning through training and sharing of experiences and best
practices; including with contractors, customers and the public, wherever
required..
Inculcate values and attitudes conducive to achieve excellence in Health,
Safety and Environmental performance.
Provide means to achieve our mission by ……
Assigning clear roles and responsibilities at all levels and periodically
reviewing and recognising contribution to HSE objectives.
Allocating adequate resources.
Fostering a spirit of participation by all employees in Health, Safety and
Environmental conservation efforts.
Creating appropriate forums for deliberations on Health, Safety and
Environmental issues.
Monitor performance by …..
Periodically auditing work processes, systems & practices and promptly
correcting deficiencies.
Incorporating HSE performance as a parameter for assessing the overall
performance of Employees, Business Units, Contractors and Business
Associates.
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Commensurate with above corporate HSE policy, policy of E&P to ensure health,
safety and environmental protection at every construction site is as under:
i. Adopting sound and safe engineering practices for each project at design and
construction stage.
ii. Taking due care to not cause any intentional damage to the environment
during process of construction or material handling or both.
iii. All major projects shall be audited by a multimember team. The time gap
between two consecutive safety audits at long duration project sites shall be
around six months.
iv. Every audited construction site and material warehouse shall conform to audit
recommendations through compliance report to HQ.
v. Every near miss and accident at construction site shall be reported
immediately on-line by official present at incident location.
vi. Investigation of any accident at construction site shall be done by a
multimember team to determine root cause of accident and to recommend
necessary changes in ground condition to prevent repetition of similar
incident.
vii. Workshop for contractors on Factory act, Minimum wages act, ESI & EPF
acts, Contract labour and Building workers acts.
viii. Workshops for contractors on industrial first aid procedures.
ix. Increasing awareness through holding competitions among all categories of
staff and contract workers on safety slogan, safety suggestions and detection
of unsafe conditions and near misses.
x. Delivering safety talks and holding safety committee meetings periodically
with active participation from workers.
xi. Observing National Safety Week and Fire Service week and World
Environment day appropriately.
1.1 IMPLEMENTATION OF SAFETY & ENVIRONMENTAL REGULATIONS
The contractor shall at his own expense arrange and comply with all safety
provisions as stipulated by BPCL / Bureau of Indian Standards / Electricity act /
OISD / Andhra Pradesh State Pollution Control Board and other acts as
applicable in respect of all personnel, directly or indirectly employed by contractor
for the work. The contractor shall ensure that he, his sub-contractor and workers
employed by him shall comply with all safety / environmental regulations issued
from time to time by BPCL.
The contractor shall also be liable for any pecuniary liability arising on account of
any violation by him of the safety & environmental requirements. If any injury to
workers or loss or damage due to accident and / or environmental pollution to
any property or a portion thereof occur as a result of failure on part of the
contractor to comply with such regulations, the contractor shall be held
responsible for the consequences thereof and shall keep BPCL harmless and
indemnified.
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2.0 OISD & BIS CODES OF PRACTICES
The contractor shall abide by the following OISD codes:
i. OISD – STD -105 Work Permit System
ii. OISD – GDN – 192 Safety Practices During Construction
The contractor shall abide by the following BIS codes:
1) IS:3764-1992- Excavation work-code of safety.
2) IS:4014(Part 1&2)-1967-Safety regulations for steel tubular scaffolding.
3) IS:3696(Part 1) -1987-Safety code for scaffolds.
4) IS:3696(Part2)-1987 –Safety code for Ladders.
5) IS:7293-1974-Safety code for working with construction machinery.
6) IS:4081-1986-Safety code for blasting and related drilling operations.
7) IS:3016-1982-Code of practice for fire precautions in welding and cutting
operations.
8) IS:4130-1991-Demolition of buildings-Code of safety.
9) IS:5216(Part 1&2)-1982-Reccommendation on safety procedures and
practices in Electrical work.
10) IS:5121-1969-Safety code for piling and other deep foundations.
11) IS:10667-1983-Guide for selection of industrial safety equipments for
protection of foot and leg.
12) IS:1989(Part 2)-1986-Leather safety boots and shoes for heavy metal
industry.
13) IS:6994(Part 1)-1973-Specification for safety gloves: Part1-Leather and
cotton gloves.
14) IS:2925-1984-Specifiation for industrial safety helmets.
15) IS:3521-1983-Industrial safety belts and harnesses.
3.0 LEGISLATION ON ENVIRONMENTAL POLLUTION CONTROL
The contractor shall abide by the following legislation:
1) Water (Prevention & Control of Pollution) Act 1974 & Rules.
2) Air (Prevention & Control of Pollution) Act 1981 & Rules.
3) Environment (Protection Act) 1986 & Rules
4) Hazardous Wastes (Management & Handling) Rules 1989
5) Public Liability Insurance Act 1991 & Rules.
6) Noise Pollution (Regulation & Control) Rule, 2000
4.0 BPCL’S OBILIGATIONS ON SAFETY & ENVIRONMENT
The layout planning of the site shall be done by BPCL. Suitable and adequate
space shall be provided to the contractor for his site office and storage of
materials / equipment. However, approach to work spot and road around it, if
required for movement of men and machineries for construction purpose, shall
be made by contractor at his own cost. Electric power source and drinking water
facilities at one point of site shall be provided by BPCL. Disaster Management
Plan for the site shall be prepared by BPCL wherein the contractor shall be
assigned a role, which shall be obligatory.
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5.0 CONTRACTOR’S OBILIGATIONS ON SAFETY & ENVIRONMENT
Any safety & environmental impact mitigation action plan prepared by BPCL shall
be binding on contractor and the contractor shall adhere to the same.
The following practices shall be mandatory on part of contractor::
6.0 SAFETY POLICY OF CONTRACTOR
The contractor shall have a safety policy, which shall deal with the following
issues:.
Arrangements for training at all levels with particular attention to key workers
such as workers working at height, crane operators etc, whose mistakes can
be especially dangerous to other workers.
Safe methods or systems of working in hazardous condition.
The duties and responsibilities of supervisors and key workers.
System to circulate all information / instructions / policies.
Arrangements for setting up of safety committees.
The selection and monitoring of sub-contractors (if any).
The upkeep and maintenance of tools/machineries/safety appliances in
perfect working condition.
Feed back system and corrective measures wherever required.
7.0 ENVIRONMENT POLICY OF CONTRACTOR
The Contractor shall have a environmental policy, which shall deal with following
matters
 Commitment to not to cause adverse impact on ecologically sensitive areas.
Environmental Impact mitigation measures.
Feed back system & corrective measures, wherever required.
8.0 ROLE OF SAFETY CUM ENVIRONMENT IN-CHARGE
The contractor shall designate a person possessing required experience and skill
in safety and environmental issues as “Safety cum Environment In-charge”. His
main duties shall consists of :
Observance of safety action plan for the work and conditions stipulated in the
tender/agreement.
Providing and maintenance of safety facilities like access roadways,
pedestrian routes, barricades and overhead protection.
Providing and installation of safety signs.
Circulating safety practices for each trade.
Testing of lifting machineries such as cranes and goods hoists and lifting
gears such as ropes and shackles and obtaining certification from competent
authority.
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Inspection and maintenance of access facilities such as scaffolds and
ladders.
Inspection and cleaning of welfare facilities such as toilets, clothing,
accommodation and canteens.
Explaining the relevant parts of the safety plan to each worker group.
Playing role in Disaster management plan.
Identifying unsafe practice / equipment and rectifying the same.
Dissemination of information on safety and environment protection
Attending safety committee meetings and implementing all decisions taken by
safety committee.
Ensuring proper use of personal protective equipment.
Delivering Safety talk to workers.
Implementing all Environmental Impact Mitigation measures.
9.0 ROLE OF SUPERVISOR
Good planning and organization at work site and assignment of clear
responsibility to supervisors are fundamental to safety and environment
protection. Each supervisor shall ensure within his field of competence and
domain the following:-
Working condition and equipment are safe.
Workplace safety is ensured.
Workers are trained for the job they are supposed to do.
Workplace safety measures are implemented.
The best alternative to ensure safety and environment protection is adopted
within available resource and skill.
Necessary personal protective equipments are available and used by
workers.
Safety caution boards are displayed at right place.
Unsafe practices are eliminated.
Arranging rescue of workers, in case of accident.
Playing his role in disaster management plan.
Arrange tool box safety meeting frequently.
Informing safety cum environment in-charge in case of any violation of safety
practices.
Informing safety cum environment in-charge in case of any violation of
Environmental Impact Mitigation measures.
10.0 ROLE OF WORKER
Every worker shall follow safety practices and environmental impact mitigation
measure conveyed to him by the contractor’s supervisor. He shall take care of
his tools and use personnel protective equipment in accordance with safety
practices.
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11.0 SAFETY COMMITTEE AT SITE
The safety committee shall include representative of BPCL, representative of
contractor identified as safety cum environment in-charge and representatives of
various trades from workers. Ratio between BPCL representatives and that of
contractor and various trades taken together shall be 1:1.
Model code of practice:
Safety committee is a key part of safety in the workplace. They shall accomplish
the following::
a) Central focus : Overall look at safety requirements and to foresee problems
that might otherwise cause difficulties.
b) Sounding board. The committee is a visible and approachable body for
safety or environmental complaints, suggestions, and the like.
c) Central coordination. The coordination of safety training activities shall be
accomplished by the safety committee.
An effective safety committee encourages safety awareness, gets a large
number of employees actively involved in the safety program over time, helps
motivate employees to follow sound safety practices. An effective employee
safety structure provides a feedback mechanism to identify and correct new
safety hazards at the earliest stage. Once the safety committee structure is in
place and working well, it is a natural vehicle for employee involvement,
preparation and introduction of new safety rules, new preventative practices, and
safety procedures on new equipment.
Primarily safety committee shall look in to following:
a) Detection of Hazard and determination of risks to workers, equipment,
property and environment.
b) Deciding actions to mitigate risks
c) Drawing Disaster Management Plan
d) How the committee can help management to enforce safety rules and
environmental Impact mitigation measures.
e) How to implement safety suggestions
f) How to ensure compliance from workers.
Ideally safety committee members should play following roles:
a) Set a good example. Committee members must set a good example. They
must be above average in their safe work habits and their positive attitude
about safety and environment..
b) Be visible. Names of safety committee members should be posted
prominently in their departments.
c) Conduct safety inspections. Safety committee members should perform
safety inspections. Members know the safe—and the unsafe—way to perform
the jobs. Hence, they are right men to correct unsafe situation.
d) Investigate accidents. Safety committee should investigates all lost work day
accidents and record the findings.
e) Hold regular meetings. Safety committees must meet at least once a month,
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and for their meetings to be effective the following matters must be
considered:
Safety cum environment in-charge shall in general act as chairperson cum
secretary
Preparing agenda & issuing in advance of the meeting to:
— keep discussions on track
— allow members to prepare for the meeting
Issuing Minutes within two days containing:
— written summary of proceedings
— names of attendees
— number of absentees
— responsibilities for implementation assigned
— timing of implementation assigned
— cost of implementation
— any approvals required
— completed recommendations
— uncompleted recommendations
— accident review (if any)
— safety training activities
Duties of Safety Committee members shall be as under:
Work safely yourself—set the example in the site.
Attend and actively participate in safety committee meetings.
Speak to your fellow workers if you believe that they are engaged in an
unsafe work practice; report things which you feel you can't handle.
Listen to employee suggestions about safety and bring those that appear to
have merit to the notice of safety committee.
Before each safety committee meeting review minutes and open items
affecting your section of job and have answers or a progress report on each
item for the meeting.
Model code of practice for Safety Talks:
Safety talks should be delivered by any one of Safety Committee members by
rotation. Duration could be anything depending on interest of audience and
capacity of speaker to deliver oration.
The speaker may like to use this opportunity to convey various decisions taken in
Safety Committee to workers. He may prepare talk on following suggested topics
or any topic of his choice but of relevance. Political or human relation related
topic must not feature in Safety talks.
i. Housekeeping
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ii. Use of Safety Shoes
iii. Use of Safety Helmet
iv. Wearing of Safety Harness
v. Safety from Cement and stone dust.
vi. Checking scaffold before climbing
vii. Right use of ladders.
viii. Use of materials and tools while on scaffold.
ix. Fall protection, i.e. toe boards, anchoring of safety harness, positioning of
safety net.
x. Handling of Asphalt
xi. Precautions during excavation.
xii. Electrical faults.
xiii. Safety from hanging live wires and high tension lines.
xiv. Entering confined space.
xv. Safety from toxic materials and fumes.
xvi. Right posture for lifting weights.
xvii. Slipping, tripping, drowning and falling hazards.
xviii. Eye protection from arc welding and dust.
xix. Precautions during operation of lifting appliances.
xx. Safety during erecting shuttering.
xxi. Safety during stripping of shuttering.
xxii. Safety during use of concrete mixers and pouring of concrete.
xxiii. Precaution during demolition of any structure.
xxiv. Right storage of safety belts and other PPEs.
xxv. Working on steep roof.
xxvi. Safety from vehicles.
xxvii. Need of communication and looking for safety of one another.
xxviii. Look around safety.
xxix. Air and water pollution.
xxx. Nearby medical facilities.
xxxi. Sun stroke and remedies
xxxii. First aid in case of injury.
xxxiii. Protection from AIDs.
xxxiv. What to do if accident happens.
12.0 WORKING CONDUCT
No one shall enter any part of the worksite other than for the purpose of carrying
out the work. Contractor’s personnel shall abide by all rules and regulations
stipulated, including the following:
Smoking inside the premises of a working location is strictly prohibited except
in the designated areas.
No source of ignition shall be taken to job site unless covered by a Hot Work
Permit.
Personnel must also strictly adhere to the approved protective clothing and
equipment requirements.
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It is essential that good house keeping is practiced at all time to keep the
work area neat and clean. No material on any of the site of work shall be so
stacked or placed as to cause danger and inconvenience to any person.
Consumption of liquor, drugs or any other intoxicating substances shall be
totally banned.
13.0 SITE PLANNING AND LAYOUT
Proper advance planning shall be done in all matters including the following:
Details regarding location of workshop / fabrication yard/ quality control
laboratory / store yard / electrical installations / construction machineries,
medical and welfare facilities, lighting etc. shall be decided and identified.
The working sequence.
Clear access to work location.
 Identifying and providing emergency exit.
Displaying warning notices at vulnerable locations and routes for vehicles..
14.0 HOUSE KEEPING
Maintain tidiness during construction by cleaning up rubbish/scrap/spilled oil
and grease.
Keeping gangways, working platforms and stairways clear of equipment and
material not in immediate use. Removing or hammering down any nails
projecting from timber etc.
Arrange all machinery such as welding machine, generators, cutting machine
etc. in such a way that equipment are segregated and protected.
Check all machines at periodic intervals.
Do not accumulate saw dust and other combustible waste to avoid fire.
15.0 LABOUR ACTS:
The Contractor shall comply with all provisions of applicable Labour Acts, such
as
(a) The Minimum Wages Act 1948.
(b) The Factories Act 1948
(c) The Contract Labour (Regulations & Abolition) Act 1970
(d) The Building & other Construction Workers Act 1996.
(e) The Employees State Insurance Act 1948
(f) The Employees Provident Funds & Miscellaneous Provisions Act, 1952.
(g) Any other applicable Act.
16.0 LABOUR WELFARE MEASURES:
The contractor shall extend all welfare measures to his workmen in line with
provisions given in labour acts mentioned in previous clause 15. Some of those
are reproduced below:-
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First Aid box
Treating injuries by a qualified and experienced medical practitioner.
Arrangement for hospitalization, if needed.
Payment of wages / PF / ESI etc. as per relevant labour act and maintaining
proof of the same.
Ensuring fitness of workers and maintaining hygiene.
Arrangements for clean & cold drinking water.
Separate toilet and washing and resting facilities for male and female
workers.
Canteen facility, if obligatory under contract labour act..
Crèche, if obligatory under contract labour act.
17.0 ROLE OF SUB-CONTRACTORS
It shall be responsibility of the contractor to ensure that all sub-contractors
engaged by him in accordance with terms of agreement with BPCL, comply with
all safety practices and environment protection measures mentioned here and
conveyed to him subsequently.
18.0 PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment shall be of approved make and are essential for
avoiding injuries to workers on the job. A register showing stock and issue of
PPE shall be maintained by the contractor. The most common personal
protective equipment are described below.
18.1 SAFETY SHOES
Suitable safety footwear conforming to relevant BIS code shall be worn by
personnel, considering the nature of works and hazards such as:
Risk of crushing by heavy objects.
Penetration by sharp objects.
Penetration by chemicals or harmful liquids.
Weld spatter.
Leather safety shoes with steel toe caps shall be used for all heavy manual work
and general construction. Shoes shall be abrasion resistant and suitable for wet
and muddy conditions. Soles shall be slip resistant type.
Light low-cut leather safety shoes with slip resistant soles shall be used for
climbing job. Gum boot shall be used while working with bitumen, chemicals,
mud and muck etc.
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18.2 HAND GLOVES
Hand gloves are mainly used to protect the hand from hazards of material
handling, heat, electrical shock. etc. Various types of hand gloves are available.
Some of those are described below:
Flame-resistant gauntlet gloves made of leather or other suitable material.
They may be insulated for heat.
Rubber gloves suitable for working in low voltage, medium voltage and high
voltage.
Hand gloves made of asbestos for handling hot bitumen and other hot work.
Hand gloves made of special material for protection against chemicals.
Hand Gloves shall conform to relevant BIS code.
18.3 SAFETY HELMETS
Safety helmets shall be of yellow colour with chin strap. All workers are expected
to wear safety helmet while inside the construction site. Sufficient number of
safety helmets shall be kept at site for visitors. Safety helmets used by helpers
of excavators shall have suitable arrangement to carry load on head. Safety
helmet shall conform to relevant BIS code.
18.4 SAFETY JACKET
All workers shall wear yellow colour jackets made of good quality cotton with
trade name printed on back and front in bold letters. Safety cum Environment incharge
and supervisors shall jackets of green colour made of good quality cotton
with designation printed on back and front in bold letters.
19.0 PROTECTIVE CLOTHING DURING WELDING AND HANDLING
TOXIC/HAZARDOUS MATERIALS
Welders shall wear aprons or overalls and gloves made of flame resistant
material. Hand held welding face shield shall be used for any welding job. Full
face shield with respiratory filters shall be used for specialized welding jobs. For
handling toxic or hazardous materials proper impervious overalls, gum boots,
gloves; facemask and respiratory equipment like canister masks shall be used.
All equipment shall conform to relevant BIS code.
19.1 GOGGLES
Goggles shall be used to avoid risk from:
- Flying particles / dust ingress.
- Chemical splash – Radiation glare.
- Hot sparks or metal splatter.
- Harmful vapours.
- Sand / grit blasting.
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Goggles shall be single piece constructed of clear impact resistant plastic and
fitted with adjustable elastic straps. Goggles shall conform to relevant BIS code.
20.0 HEARING PROTECTION
Hearing protection shall be worn by personnel involved with works in areas
where noise level exceed 85 dB (A noise level beyond which normal
conversation becomes difficult) on a continuous or regular intermittent basis.
Protection is available in two basic types; 1) an external cup type defender which
fits over the outside ear and 2) internal disposable type of ear plugs usually made
of compressible foam, which fits inside ear. Whenever practicable, equipment
generating high noise levels shall be fitted with sound mufflers and located at
maximum possible distance away from any work place .
For overhead welding ear protection in the form of wool or rubber plugs shall be
done.
All equipment shall conform to relevant BIS code.
21.0 WARNING SIGNS AND BARRIERS
The contractor shall arrange necessary material to secure the work site and to
warn the general public or other workers of hazards. This shall include
- Warning signs.
- Warning lights and signs in traffic control zone.
- Barricades around excavations including illuminating warning signs.
22.0 RESPIRATORY PROTECTION / MASK
Whenever there is doubt about the presence of toxic substances or the gases
injurious to health, a respirator must be worn. The type of respirator to be used
shall depend upon the hazard and work conditions.
The simplest masks are disposable paper types. These are only effective against
nuisance dusts. There are three types of half-face masks with filters.
For protection against airborne particles, e.g. stone dust, with a coarse filter
fitted in the catridge (these filters have a specific lifetime and should be
changed as necessary).
For protection against gases and fumes, e.g. when using paints containing
solvents, with a filter containing activated carbon.
A combination filter containing both a dust and gas filter. Catridge must be
replaced regularly.
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A full facemask could be fitted with the same types of filter, and it also protects
the eyes and face.
Self-contained breathing apparatus with a full-face mask fed with air at positive
pressure is another alternative and it must be used in confined spaces and
whenever supply of air or oxygen is insufficient.
Users must be trained in the use of self-contained breathing apparatus and must
know the manufacturer’s specifications.
All equipments shall be thoroughly checked prior to use to ensure:
Oxygen Cylinders are full and gauges function correctly.
All connections are proper
Facemasks are in order.
All equipment shall conform to relevant BIS code.
23.0 SAFETY BELTS / HARNESSES
The majority of fatal accidents in construction sites are due to fall from height.
There are many types of safety belt and safety harness available depending on
nature of work. A full safety harness should always be used in preference to a
safety belt.
Safety belts / harnesses shall conform to relevant BIS code and worn by all
workers working at a height greater than 2 mts above ground level.
Details of Safety Belts / Harnesses are given in 26.5 “Working at Height”.
24.0 LIFE JACKET AND LIFEBUOYS
For working over or near large and deep-water body this life saving device
should be used. Life Jacket shall be tested for leak and usefulness before start of
work. It shall conform to relevant BIS code.
25.0 RAIN COAT
Rain coat shall be provided to workers during rainy season. The colour of rain
coat shall be yellow. It shall conform to relevant BIS code.
26.0 SAFE CONSTRUCTION PROCEDURES / PRACTICES
26.1 EARTH EXCAVATION
i) The site of the excavation or trench should be sloped or battered back to a
safe angle of repose usually 45 degree or be supported with shoring by
timbering or other suitable means to prevent collapse. The type of support
necessary will depend on the type of excavation, type of soil, the nature of
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ground and the ground water condition. Adequate timbering or sheeting shall
be provided where excavation is deeper than 1.5 M. 100 mm wide “Safety
tape” of yellow colour with one meter long phosphorescence band after every
three meter shall be used to encircle excavated pit of any depth. For any pit
of depth one meter or more, one meter high fence with a mid rail made of
bamboo or steel pipes shall be provided for preventing people / animals from
slipping into the pit. If the pit is by the side of vehicular drive way, in addition
a prominent board shall be put up saying “Excavation in Progress”.
ii) Pumping out of accumulated water from pit is to be done at regular intervals.
Run-away water shall be prevented from entering the excavated area, as
such water can cause erosion of soil and sudden collapse of earth.
iii) If the excavation is carried out without shoring, necessary angle of repose
shall be maintained at all times.
iv) Labourers shall not be allowed to sleep or take rest inside the pit. Protection
against insects / poisonous snake shall be provided.
v) Excavated earth shall be stacked at least one meter away from cutting edge to
avoid collapse of trench and sliding of heaped earth into trench.
vi) Contractor shall ensure that the excavation does not damage any existing
underground cables, pipelines, foundation of adjoining buildings or structures
etc. Wherever excavation is near any adjoining building or structure, proper
precaution shall be taken.
vii) Before working / entering inside an existing excavated pit it shall be ensured
that it is free from any toxic gasses or explosive gases. The underground
water present in the pit shall be checked for acid content, if there is possibility
of seepage of industrial affluent.
viii) Adequate access to and escape from the excavated trench in the form of
ladders provided at every thirty meters or less shall be ensured. Crossovers
over excavated trench shall be provided at suitable interval for movement of
workers.
ix) If the excavated trench is adjacent to any parking space for vehicles,
adequate and well-anchored stop blocks shall be provided on the surface to
prevent vehicles from falling in to trench while reversing.
Relevant BIS codes shall be followed for safe practices.
26.2 PILING AND OTHER DEEP FOUNDATIONS
The following precautionary measures shall be taken:
 Piling machine operators shall be over 18 years of age and properly trained.
Prior to piling, all underground services shall be located and made safe
There shall be a firm level base for the crane. If necessary crane mats shall
be provided.
The workers shall use necessary personal protective equipment.
All cranes, lifting appliances and lifting gear must have appropriate
certificates of testing and shall be of capacity required for the job.
Particular attention shall be provided to the risk of damage to lifting gear from
sharp edges.
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Cranes used for lifting or lowering workers, must be fitted with a dead man’s
handle and lowering shall be done under power.
Relevant BIS Safety Code for piling and deep foundations shall be followed.
26.3 WORKING IN BASEMENT / UNDERGROUND TANK
.
Fatal and serious accidents could occur if proper precautions are not taken
before entering confined space like basement or underground tank.. The
following precautions shall be taken:
i) Entry into the confined space shall be allowed only against Hot work permit.
ii) Air circulation shall be ensured. Hot work in such places shall be taken up
only after ensuring that ample supply of fresh air is available using additional
blowers etc.
Proper ventilation shall be ensured by opening manholes (either ends if
available) and fixing a wind sail or forced circulation of air. Old tanks shall be
filled with water and washed with water before entering into it. Sludge shall be
cleared / removed from outside of the confined space, to the extent possible,
before entering.
iii) Workers shall be allowed entry in the confined space, only after ensuring
absence of toxic and explosive gases. Purging of gases may be done by
filling the underground confined space with water.
iv) Everyone inside the confined space shall wear rescue harness, with lifelines
attached to a point outside the confined space. Whenever workmen are
allowed to enter a vessel or underground tank or confined space, it is
necessary to keep one person (alert and trained) at each manhole or entry
point. The person should keep watch through manhole and offer rescue
assistance so as to ensure prompt pulling out of the workers from confined
space in case of emergency. Proper communication system between
confined space and outside shall be maintained.
v) A proper procedure for rescue in an emergency shall be laid down, with
specific duties allocated to specific persons.
vii) An experience supervisor shall supervise the entire operation.
viii) Monitoring of air supply must continue while work in progress.
ix) Only trained workers shall be allowed entry into confined space..
x) The following equipment shall be provided.:
Toxic gas meter, Oxygen meter and Explosive meter
Rescue harnesses with adequate length of rope taking into account the
location of work site.
Hand torches or lamps safe for use in a flammable atmosphere.
Appropriate self contained breathing apparatus.
First aid equipment.
 Fire fighting equipment.
An audible alarm for summoning help.
Resuscitation equipment.
Means of communication between confined space and outside.
Boards & barricades.
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26.4 DEMOLITION
Demolition is a dangerous process and workers shall use requisite personal
protective equipment.
Demolition must be supervised by supervisor with thorough knowledge not
only on demolition procedure, but also on the principles of structural
construction.
A survey of the physical characteristics and design of the structure to be
demolished must be carried out in order to choose a safe method of
demolishing. The demolition action plan shall be drawn by the contractor
including drawings or sketches showing the sequence of operations, the
machinery and equipment to be used, personal protective equipment required
etc. Before demolition begins, all service connections to the structure shall be
disconnected. Arrangements must be made to erect a fence of height two
meter encircling the structure under demolition
It is dangerous to leave isolated walls or parts of a wall standing alone, as
those are liable to collapse from the effect of high winds and hence
necessary supports should be given in such cases.
Debris should not be allowed to build up against walls or floors with the
consequent risk of the structure getting overloaded.
Vapour present inside the structure must be checked for toxic nature before
starting demolition work.
Protective measures should be taken against dust, fumes, chemical deposits,
asbestos, glass wool etc. while carrying out demolition work.
Disposal process and pit / yard should be identified for safe disposal of
debris.
Relevant BIS safety code for demolition of structures shall be followed.
26.5 WORKING AT HEIGHT
Scaffolds accidents occur primarily to the following reasons:
Faulty design
Faulty erection
Weak foundation
Inadequate strength of structural members
Inadequacy of platforms, guard-rails and toe-boards.
Scaffolds are designed for live loads of workers and building materials, besides
their own dead weight. However, a scaffold is usually designed only in case of
important structures, like bridge girder/slab, very long beam/very large slab in
buildings etc. In case of day today scaffoldings for general civil constructions /
colour washing / painting / plastering etc., scaffolds are usually not designed, but
erected based on experience.
Scaffolds may be constructed of either timber, sal ballies, bamboo, or metal.
Those may be single scaffold or double scaffold for light duty or heavy duty, as
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the case may be. Single scaffolds are recommended for carpenter, painter and
similar trade. Double scaffolds are recommended for masons and similar trade.
All scaffolds should conform to IS:3696(Pt.1)-1987. As bamboo and metal
scaffoldings are used, salient features of those scaffoldings are given below:
Single Pole Bamboo Scaffolds :
Single scaffold consists of one row of upright poles or standards, placed not
more than 1.8mt centres, fixed at suitable distance from the wall and connected
horizontally by ledgers (bamboo placed horizontally ) spaced vertically at 1.5 to
1.8mt centres. Cross members (putlogs), supported on ledger on one side and
hole in the wall on other side, are provided at 1.2mt centres.
Double Pole Bamboo Scaffolds:
It consist of two rows of up-rights or standards. The inner row is placed next to
wall and other row placed 1.2 to1.5mt away from the wall. As in earlier
case,ledger is provided every 1.5 to 1.8mt vertically. However, in this case ,
putlogs shall rest entirely on ledgers at both ends.
Every single or double pole scaffolds, shall be effectively tied with adjacent
structure. Diagonal face bracing or zig zag face bracing shall be provided on
single pole scaffold and outer row of double pole scaffold. The maximum
distance between braced bays in any lift of scaffold shall not exceed 10mt.
Quality of Bamboo
Bamboo should be reasonably straight, sound, free from splits, knots dry rot,
worm holes and any other defect, which tend to reduce strength of bamboo. The
mean diameter shall not be less than 80mm in case of single pole scaffold and
100mm in case of double pole scaffold, subject to minimum diameter of 50mm at
thinner end. The slenderness ratio, i.e.L/d ratio shall not exceed 50, where L is
the legnth of up-right or standard between putlogs. The diameter of bamboo shall
not be measured at knot points.
Where it is necessary to extend a up-right, the overlapping distance between two
up -rights shall not be less than 600mm.
Maximum Height of Bamboo Scaffolds
IS:3696(Pt 1) has recommended use of Bamboo Scaffolds for heights upto 18mt,
subject to conforming to provisions given there-in.
Platform Width for Working on Scaffolds
_ Where platform is not more than 2mt above ground or floor:
For Painters,Decorators etc 300mm (min)
For other types ,i.e., mason etc. 500mm (min)
_ Where platform is more than 2mt above ground floor:
For Painters,Decorators etc 900mm (min)
For other types ,i.e., mason etc. 1200mm (min)
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Railings & Toe Boards
Railings consisting of top rail at a level of around 1000mm above platform and an
intermediate rail halfway between top rail and platform shall be provided for all
working platforms higher than 2mt above ground or floor.
The platform edges shall be provided with 150mm high toe board to eliminate
hazards of toolbar or other objects falling from platform. Where scaffolds are
erected over areas, where people work or pass, the space between top rail and
toe board shall be enclosed by tarpaulin or PVC sheets.
Means of Access
A safe and convenient means of access shall be provided to all platform level of
scaffolds. Conventional means of access are the following:
Ladder
Stairway
 Ramp
Ladder:
To ensure safe use of ladder, the following steps should be followed:
Erecting ladders in the "four up-one out position" (i.e 75 degree angle
between ladder and ground)
Lashing ladder securely with the structure.
Using non-slip devices, such as, rubber shoes or pointed steel ferrules at the
ladder foot, rubber wheels at ladder top, fixing woollen battens, cleats etc.
When ladder is used for climbing over a platform, the ladder must be or
sufficient length, to extend at least one meter above the platform, when
erected against the platform in "four up-one out position".
Portable ladders shall be used for flights not more than 4mt. Above 4mt
flights, fixed ladders shall be provided with at least 600 mm landings at every
6mt or less.
The width of ladder shall not be less than 300mm and rungs shall be spaced
not more than 300mm.
Stairway
For scaffolds exceeding 4mt height, stairway are safest means of access.
I t shall conform to the following:
Treads and risers shall be of uniform width and height in any one flight.
Minimum width of 1000mm.
No unbroken vertical rise of more than 4mt.
Maximum angle of ascent 50 degrees.
Stair railings on all open sides.
Hand rails on all enclosed sides.
Railings and toe boards on all landings.
Ramp
Ramp shall conform to the following:
Open sides of ramp shall be protected by railing and toe board, where ramp
is 1.5mt or more above ground or floor.
Where slope is more than 1 in 4, footholds shall be provided by stepping laths
of minimum size 50 x 30mm at interclass not exceeding 450mm.
Maximum permissible slope is 2 in 3.
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Metal Scaffolds
With the evolution of concept of designing multi -storied and long span
structures, metal scaffolds came into practice, mainly due to following
advantages.
Ease of assessing strength of scaffolds structure.
Reusable many more times than bamboo.
Possibility of human error while erection, is much less that in case of bamboo
scaffolding.
Aesthetically neat and good looking.
Metal scaffolds shall conform to IS:2750 - 1964, in addition to IS3696(Pt 1).
Scaffold tubes are usually 40mm N.B., mild still continuous weld conforming to
IS:1239 or IS1161, grade YST 210, of lengths varying between 4.5mt to 6mt.
These are manufactured and marketed by various agencies. As such, it is
essential to obtain guaruntee certificate from the manufacturer about safety and
stability of metal scaffolds under likely worst combination of loads.
Other General Safety Requirements for all types of Scaffolds
 Erection, alteration and removal shall be done under supervision of
experienced personnel.
Use of barrels, boxes, loose bricks etc., for supporting platform shall not be
permitted.
Every platform and means of access shall be kept free from obstruction.
Each supporting member shall be securely fastened and braced
Where planks are butt-joined, two parallel putlogs shall be used, not more
than 100mm apart, to give support to each plank.
Platform plank shall not project beyond its end support to a distance
exceeding four times the thickness of plank, unless it is effectively secured to
prevent tipping. Cantilever planks shall be avoided.
If Grease, mud, gravel, mortar etc., fall on platform or scaffolds, these shall
be removed immediately to avoid slipping.
Workers shall not be allowed to work on scaffolds during storms or high wind.
After heavy rain or storms scaffolds shall be inspected by site-in-charge
before reuse.
All scaffolds or platforms shall be fastened with adjacent structure, and if
independent, scaffolds shall be braced properly.
Scaffolding shall be erected on firm and level ground. In case of loose soil,
the soil should be compacted by watering and ramming, besides using
wooden base plate of minimum thickness 30mm for erecting standards.
All members of metal scaffolding shall be checked periodically to screen out
defective /rusted members. All joints should be properly lubricated for easy
tightening.
Clear access to scaffolds shall be maintained at all times. For prohibiting
entry of unauthorised persons in scaffolds area, barricades should be put up
and warning notices prominently displayed.
If scaffolds are used, where public movement is anticipated, entry of public
should be prohibited for the duration of the job.
Where lifts are provided to hoist premixed concrete, reinforcement etc., to
upper floors, barricades should be raised to prevent accidental entry of
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workers under the lift. Such lifts shall not be used for hoisting people, unless
those are designed specifically for that purpose.
Dismantling of scaffoldings shall be done in a pre-planned, sequential
manner in order to maintain stability throughout the process. If necessary,
additional tying, bracing may have to be done to prevent sudden collapse of
scaffolds structure.
Before initiating dismantling process, precautions should be taken to ensure
removal of all loose materials from the scaffolds.
Use of scaffolds, under dismantling process, must be prohibited.
Wearing safety helmets shall be made mandatory within 10mt from scaffolds.
Dismantling of Form -work
Action for dismantling form-work, used for supporting concrete casting, must be
done after expiry of requisite number of days after casting and proper curing.
Untimely dismantling of form-work may cause total collapseof structure.
Bottom shuttering of chajia or sun-shed should not be removed, till the attached
lintel is properly secured by brickwork, to avoid failure of lintal due to toppling /
torque.
In case of casting of multi-storied framed structure, casting of upper floor should
be avoided till expiry of minimum curing period of lower floor. But, if essential,
bottom shuttering of the lower floor shall be suitably strengthened by additional
props.
INDUSTRIAL SAFETY BELTS & HARNESSES
Primary functions of safety belt & harness are to minimise injury after a fall.
Despite providing proper scaffolds, railing etc, possibility of slipping and falling
can not be over-ruled. This equipment is the last check to prevent worker from
getting fatal injury.
Four types of safety belts & hareness are available in the market, depending on
nature of various jobs. Failure to choose right type of safety belt & harness may
led to endangering life of worker at the time of need. All safety belts and harness
shall conform to IS3521-1989.
Type Consists of Permissible fall Used for
I
Waist belt with safety
line
Not more than
0.6mt
Building / Structural
maintenance.
II
Waist belt with two
shoulder straps &
safety line
Not more than
1.8mt.
Construction, structural
erection.
III
Waist belt with two
hoisting straps & safety
line, with provision for
leg straps.
Not more than
0.6mt.
Working in confined
atmosphere and rescuing.
IV
Waist belt with pole
strap.
- Working on electric line pole.
Proper choice of anchoring point for anchoring the safety-line is essential. At
many instances, the workers have met with fatal accidents due to anchoring with
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weak supports. Sometimes anchoring points are found to be chosen by mistake
in such a way, that should a person fall, he would hit against a rigid structure due
to swinging action of the safety line. Hence anchoring point for safety-line needs
to be judiciously chosen. Where proper anchoring points are not likely to be
available, action should be taken in advance to provide for hooks and fixtures.
The shock absorbing capacity of the safety-line is critical for reducing impact of
fall. A stiff safety-line, would arrest a fall suddenly, resulting in an abnormal
impact load on body of the worker, causing injury. According to IS3521, safetyline
should be made of nylon or polyester or synthetic fibre. It shall not break
under minimum tensile load of 2000kg. The minimum diameter of test specimen
shall be 10mm. Performance test of the Safety belt & Harness shall be carried
out as per annexure - B of IS3521, by dropping an articulated anthropometric
dummy weighing 100+5 kg with an overall height of 1.6mt to 1.8mt, and waist not
more than 1000mm circumference.
INDUSTRIAL SAFETY NETS
Industrial Safety Nets are designed to catch workers and / or debris falling whilst
working on high buildings or structural fabrications.
The safety net should be installed as close to the work level as possible.
Sufficient clearance should be maintained between the safety net and the ground
or structure below, in order to accommodate full deflection of the net under
impact.
IS 11057-1984 specifies requirements for two types of safety nets.
Suitable for use at maximum duty height (*) upto 6mt
Suitable for use at maximum duty height (*)upto 1mt
(* The maximum vertical distance between working level and the level at which
safety net is to be placed in use.)
Salient features are as under:
Minimum nominal size shall be 4mtX 3mt.
Shall be made with square or diamond mesh and the length of mesh side
shall not be more than 100mm.
In cae of multi layer nets, all layers shall be joined together and fitted to a
common border cord or cords.
A continuous length of net, with no joints shall be used.
When in use (without any load,except dead weight of the net), the sag at
centre of the net shall be between one-fifth and one-fourth of the length of the
shorter side.
Performance shall be tested by actual drop test of a sand bag weighing
140kg, in accordance with appendix A of IS-11057-1984.(Safety nets are
available with an overlay net to catch small tools and debris. But, the
performance test shall be carried out only after removing such overlay net.)
The deflection at the centre of the net during above drop test, shall not
exceed 2mt or one-half of the length of the shortest side, whichever is more.
Manufacturer shall declare the duty height at which net conforms to IS11057
by fixing labels marked with indelible ink at two different positions on the net.
The labels should also contain following information.
_ Manufacturer’s name or trade mark
_ Nominal size of safety net.
_ Date of manufacture.
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_ Deflection at centre of the net during above drop test.
ROOFTOP LADDERS
Asbestos cement sheets are usually used as industrial roofing material. These
are very brittle. In some cases GI sheets are used, which when rusted, become
fragile. The collapse of fragile roofs, while walking on it, can cause fall from
rooftops. These roofing materials are often laid on slopes, causing additional
hazards of slips and falls from edges. For working on fragile and / or slopping
roof, the following safety measures shall be taken:
 Crawling boards or roof top ladders shall be used.
While working, the worker should always stay on those and remember not to
step on the roof surface, which may give way.
Before commencing any work on fragile roof, the site-in-charge shall verify
the availability of crawling board or roof top ladder and competence of
workers to use those equipment.
26.6 STORAGE TANKS / SPHERES / BULLETS
The safety of tanks depends more on the standards and quality of inspection
applied at all stages of construction than any other single feature. The contractor
shall ensure adherence to relevant code and all safe practices required during
construction of tanks including handling of plates from storage yard to fabrication
yard
26.6.1 FABRICATION
Before commencing the fabrication work, work area is to be made free from
combustible materials, used asbestos cloth and place proper fire extinguisher
near work site.
While gas cutting of structural items, there is a possibility of back fire to the
portable gas cutting set and hence cutting torch, rubber hoses pressure
gauges shall be checked thoroughly at regular intervals.
All personal protective equipment shall be worn by welder.
Loose nylon or polyester dresses shall not be used during work.
All gas cylinders to be kept, in upright position and avoid mishandling.
26.6.2 ERECTION
Proper supports to be provided on both sides of plate after erection by guy
ropes/wires/cranes to hold the plate in position and to avoid falling of plates
on ground.
Only proper structural supports shall be used for workmen standing purpose
and not boxes / drums etc. .
Holes in plate work to assist in erection are not permitted. Lugs nuts, clamps
etc. to assist in erection may be attached to tank shell plate by welding for
erection.
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The tank shell shall be safeguarded from damage due to wind by provision of
steel wire guy ropes or cables after erection of 3rd shell or 3 M height
whichever is less until completion of roof.
Support for steel scaffolding shall be checked. Each scaffolding shall be tied
up with other to avoid fall of welder from a height due to shifting/sliding of
scaffolding from its position.
To avoid accident at height “jacking up method” shall be adopted from safety
point of view.
Suitable capacity of crane and authorized driver shall be deployed for
operation.
26.6.3 WELDING AND GAS CUTTING
Adherence to relevant codes and employment of qualified and tested welder are
two basic requirements for welding and gas cutting process. Hazards such as
electricity, heat/flame, flammable gas etc. are present in this process. Hence
following precautions must be followed while carrying out these operations.
Hot work permit shall be obtained wherever applicable before
commencement of the work.
All fire precautions as stipulated in IS:3016 (code of practice for fire
precautions in welding and cutting operations) shall be followed while
welding/gas cutting.
Fire extinguishers, sand buckets, water and gunny bags shall be provided
when hot work is in progress. Gas cylinders used for gas cutting and welding
shall
- Be of approved make.
- Be stored upright, and is kept away from hot work and care shall be
taken to prevent heating of gas cylinders.
- Gas cylinder valves shall always be checked and shall be closed when
not in use.
- Be stored in a well-ventilated area.
- Be fitted with safety caps when not in use.
- Not be lifted by nozzle and rolled.
All gas and oxygen regulators shall be fitted with Flashback arrestors, being
non-return valves designed to prevent an explosive mix developing in
cylinder.
Checking for leaks shall be with help of soapy liquid applied to each joint and
under no circumstances shall a naked flame be applied to any part of the
cylinder.
When working at a height, do not place cylinders directly beneath the working
area, as molten metal may fall onto the hoses, causing leaks and possibly
igniting the gasses.
During electric arc welding process, very high ultra violet radiation is
generated. The welder and any person working in close proximity, in order to
prevent permanent damage to the eyes must wear suitable eye protection.
When not in use, power supply to the holder and electrode shall be turned off.
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Hose shall be in good condition, and properly clamped. Welding cable shall
have proper insulation with minimum number of joints.
All equipments shall be properly earthed, and cables properly insulated and
connected.
ELCB / RCCB shall be provided in every welding circuit. Earthing shall be
dedicated for each circuit. Diesel generating set shall have separate earthing.
Circuit shall always be made by cables of right quality and cross section only.
Diesel generating set shall be connected with welding transformer through
switch board fitted over a rigid support at height of 100 cm from ground with
appropriate ELCB / RCCB.
The welder or welding operator shall be insulated from both the work and
metal electrode and holder. The bare metal part of an electrode holder shall
never be permitted to touch the operator’s bare skin or wet clothing.
Consistent use of well insulated electrode holders and cables, dry clothing on
hands and body and insulation from the ground shall be helpful in preventing
contact with electricity.
Electrode should never be changed with bare hand or wet gloves or when
standing on wet floor / ground.
Frame of welding unit (portable/stationary) should be grounded using
correctly rated wire/strip and earth pit.
Resistance to earthing must be checked daily before start of work.
Receptacles of power cables for portable welding unit should be used so that
it is impossible to remove the plug without opening the power supply switch.
 If cable is worn, exposing bare conductors, it must be immediately replaced /
insulated.
Welding cables shall be kept dry and free of grease and oil to prevent
premature breakdown of the insulation.
Cables laid on the floor/ground shall be protected in such a way that they will
not interfere with safe passage or become damaged or entangled.
Welding cables shall be kept away from power supply cable or high tension
wires.
Welding cables shall not be coiled or looped around any structure.
While coupling several lengths of cables for use as a welding circuit,
insulated connectors on both the ground and electrode holder line shall be
used if occasional coupling and uncoupling is necessary.
Supervisor shall ensure that the portion in the circuit of liquid or gas
circulation e.g. the storage tank, pipelines, valves, pumps etc. where
welding/cutting work is to be carried out, is blanked or isolated and purged
with inert gas or washed thoroughly, so as to make absolutely certain that no
inflammable liquid/gas is present in an amount, which can catch fire under
action of heat, spark, flame, welding spatter or red hot objects. The area shall
be checked and ascertained that concentration of combustible gas in the air
is within permissible limit.
Goggles, if used, shall be for welding with right shade conforming to ANSI Z
87.1 or BIS.
The shade number of the glass to be used for various purpose/ process shall
be as under:
101
OPERATION SHADE NO. OF THE GLASS
Soldering 2
Torch brazing 3 or 4
Gas cutting (1” to 6”) 4 or 5
Gas cutting (over 6”) 5 or 6
Gas welding 5
Shielded metal arc welding 10
Other personal protective equipment shall be as under:
_ Protective cloth/apron long enough to cover wrists and forearms against
heat, sparks, molten metal and radiation. Leather or asbestos apron can
be used for this purpose.
_ Flame resistant gloves
_ Safety shoes
_ Helmet / shoulder cover for over head welding as necessary
_ Safety harness while working at heights
_ Ear protection (wool or rubber plugs) in case of noise pollution or
overhead welding.
_ In a confined place or where fumes/gas emissions cannot be below the
toxic level, respiratory protective equipment duly certified for the
exposure by reputed Government organization, like DGFASLI, shall be
used.
Space of more than 284 cum. per welder should be provided.
Clothing should be free from oil & grease. Collars and cuffs should be
buttoned and turned up inside. Pockets should be eliminated from the front
vests, shirts and apron
 After welding or cutting is completed a warning sign should be provided to
keep workers away from heated surfaces.
Electrode rod stubs should be kept in a proper waste container
Gas cylinders for each type of gas should be stored separately. They should
be kept away from any source of heat and shielded from direct sun light. If
stored, the store must be well ventilated. The cylinders in use should be
retained upright in a rack or trolley and not be left free standing.
While unloading /loading gas cylinder nozzle valve guard cap must be
properly fitted and cylinder shall be unloaded over rubber/soft mat.
Regulators, noses, torches and other Oxy-fuel gas equipment should be kept
free. from grease, oil and other combustibles.
Lubricants should never be used on Oxy-fuel gas equipment
Oxygen should never be substituted by compressed air
Oxygen pressure reducing regulator, hose or other pieces of apparatus
should never be used with any other gases.
Oxygen cylinder should never be used without first connecting a suitable
pressure-reducing regulator to the cylinder valve.
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Acetylene cylinder should be turned & kept in such a way that the valve outlet
will point away from oxygen cylinder
While opening acetylene cylinder valve, key or spindle should not be turned
more than one and one-half turns -
Gas cylinder should not be lifted by nozzle and rolled
All gas and .oxygen regulators shall be fitted with flash back arresters ,being
no return valve design to prevent an explosive mix developing in cylinder
Checking for leaks shall be by means of soapy liquid applied to each joint and
under no circum stance shall a naked flame be applied to any part of the
cylinder.
When working at height do not place cylinder directly beneath the working
area as molten metal may fall on the hoses causing leaks & possibly igniting
the gas
Acetylene cylinder key for opening valve must be kept on valve stem while
cylinder is in use so that it may be quickly turned off in case of emergency
Acetylene should never be used at pressures in excess of 15 PS.I. The use
of higher pressures is prohibited by all insurance authorities and by law in
many localities
The gas hoses should be in a good condition and easily distinguishable and
protected against heat, sharp objects, dirt, oil & grease.
LPG Cylinders, if used, should be stored kept in a well-ventilated place and
there should be no excavations, drains or basements nearby.
LPG cylinders should never be stored below ground level or closer than 3 M
to cylinders containing oxygen or materials which are toxic and corrosive.
Cylinders full or empty should never be stored upright with the valve
uppermost.
The valve of empty LPG cylinders should be kept closed, if they are left open,
air will diffuse into the cylinder and may form an explosive mixture.
For storage of large numbers of gas cylinders regulations of
NFPNA/OISD/CCOE should be observed.
If an outlet valve of acetylene cylinder becomes clogged with ice or frozen, it
should be thawed with warm water (not boiling), applied only to the valve.
A flame should never be used. This is because the fusible safety plugs on
acetylene cylinder melts at about boiling point of water.
Cylinders are not designed for temperatures in excess of 54°C and hence
storage/handling should be done keeping this in mind.
Never bring cylinders into tanks
Portable fire fighting facilities and first aid facilities should be made available
in ready condition
Adequate water should be made available at work spot for emergency
requirements
BIS Code IS: 3016-1982 on "code of practice for fire precautions in welding
and cutting operations" shall be referred for further safety measures.
27.0 PRECAUTIONS IN ELECTRICAL WORK
Electrical hazards are different from other types of hazard found in construction
work because the human senses provide no advance warning. It is the voltage
that determines the current through the body. Since reduced voltage reduces the
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severity of electric shock, attempt shall be made to work with reduced voltage of
110 V wherever possible.
Some of the basic safety steps to be ensured by contractor at construction sites
are given below:
1) Only authorized persons with license issued by State Electricity Boards or
any other Government regulatory body, shall carry out operation and
maintenance of electrical systems.
2) Work permit and isolation of the electrical system before taking up the work
must be ensured.
3) Proper protective equipments like rubber hand gloves, insulated apron etc.
shall be used. FLP fittings /enclosure as per IS: 2148 and certified by
CCOE, Nagpur should only be used in Zone-1&2 area. Capacitors should
be relieved of charges before working on them
4) Check for defective cables, loose joints in conduits, damaged fuse boxes,
loose pins, faulty sockets and defective earthwire. Cable joints must be
properly insulated and protected.
5) Do not overload electrical equipment. All circuits shall be provided with
dedicated ELCB / RCCB. There shall also be dedicated earthing for each
circuit.
6) Use right type of tools for the jobs.
7) After maintenance of flameproof fittings, ensure that the fittings meet
requirements of flameproof standards.
8) Power supply cable shall be laid at least 45 cm below ground level from
source to the work place.
9) Tag with marking should be provided on each cable for identification and
correct connections to terminals must be ensured
10) The route and depth of any underground cables should be determined and
power should be switched off if possible before execution of work for the
existing cable
11) Jointing of cable shall always be made using proper junction box and
flameproof junction box when in hazardous areas even in case of
temporary connections. Power cables should not be tied in knots; it should
be looped instead.
12) All equipments LT or HT that are likely to cause hazard shall be turned off
and segregated. All base terminals etc. shall be insulated, Rubber mats
shall be used for LT/HT switch room, where applicable.
13) All electrical equipments like wires, switch board etc., shall be protected
against rains or leaking water lines etc. In wet condition switches shall not
be operated until it is dried up properly. Switches starters shall be placed
well above ground level.
14) Proper earthing shall be provided for all electrical items and effectiveness of
earthing shall be checked every time before commencing work/switching on
the electrical system.
15) Electrical items shall be handled after isolation and care shall be taken to
identify and replace damaged electrical items. Guard wire shall be provided
for aboveground HT wires.
16) Ensure all ELCBs and RCCBs are of good quality and conform to correct
ratings.
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17) Always plug of right specification should be used for taking connection from
a socket.
18) Cables should be kept out of the way of other workers (or with proper
guard/warning) and are not in contact with water
19) Moving parts of all equipment should be properly guarded.
20) All electrical transmission and operational equipment must observe safety
clearances as stipulated in IE Rules.
21) Fail safe features should be available for interlocking mechanism.
22) Suitable overcurrent tripping device should be provided in the electrical
Circuit.
23) Earth leakage relay with high sensitivity should be provided in the electrical
system.
24) Earth pits should be tested periodically and certified by the licensed
electrician
25) Before working on an electrical line fuse should be physically removed and
the line is isolated and a suitable locking mechanism must be provided to
prevent accidental switching/fixing fuses by other persons. A notice board
displaying "Men at work" message should be placed. The section of circuit
under repair should be connected to earth.
26) Temporary switchboards at site must conform to the following:
structures are firm and strong
fully protected from rain and dust
properly grounded
all connections are made with right size lugs
suitably barricaded
rubber mat of correct rating is provided on floor
Danger band indicating system voltage should be displayed
27) No electrical equipment /cables/parts should be touched with wet
hand/cloths
28) Lightning arrestors should be provided .
29) Electrical maintenance workman working around a wet area near a fuse
box must use wooden platform with rubber mat, insulated tools and rubber
boots.
30) All electrical installation including incomer line, temporary distribution board,
electric motor and machine must be installed as per IE Rules with proper
earthing and must be inspected and certified by a licensed electrician at
periodic intervals.
31) IS: 5216-1982 -" Recommendations on safety procedures and practices in
Electric Works" shall be referred for further safety measures.
28.0 SAFETY IN RADIOGRAPHY WORKS
Planning and procedure for radiography initially shall be formulated by
contractors and submitted to proper authority. Procedure $hall be thoroughly
discussed by all related persons for familiarization. All radiation equipment and
radioactive materials shall be stored, handled, transported or disposed off, so
that, no person receives unnecessary dose of radiation. Shield ability of the
radioactive materials container shall be inspected every six months. Warning
signs and posters shall be displayed. Radiography shall be performed under the
105
direction of radioactive supervisors/officer responsible for this work. Supervisor
and source must possess valid BARC certificate indicating-
1. Type & strength of source
2. The serial number of radiography camera
3. Names of radiographer
4. Training/competency of person handling the source
All workers shall be experienced and knowledgeable of the work such as
radiation procedure, operation of radiation apparatus and effects of radiation on
the body.
The following spaces or areas shall be classified as restricted areas.
a) Storage place of radioactive materials
b) Any area where the radiation exists at levels such that large portion of the
body could receive a dose in excess of 30 milligram per week.
c) Emergency storage area for radiation apparatus or radioactive material
capsules.
Warning signs, labels and fence shall be provided for restricted area to prevent
trespassing.
The area covered within a radius of 5 Mts. from the radiation working spot or
location and subject to a dose of radiation in anyone hour in excess of 50
milligrams shall be called the radiation area and trespassing in that area shall be
strictly prohibited.
All workers entering the restricted area shall wear film badges sensitive to
radiation. All workers who could receive a dose of radiation in excess of 100
milligrams per day shall wear a pocket dosimeter and the dose of radiation
received shall be recorded everyday. The dose of radiation shall be checked by
the supervisor for each radiation exposure when the dose of radiation exceeds
100 milligrams. In such case, suitable alternative for shortening the radiation
time, reinforcing the shield plate etc. shall be arranged. During radiation work,
dose of radiation at the boundary shall be measured and recorded.
The radiography supervisor shall measure and record the surface dose rate of
restricted area every day as under:
a) Date of measurement
b) Measuring method
c) Description and capacity of apparatus
d) Measured condition
e) Results of measurement
f) Name of measurement
g) Any action taken
Radioactive materials shall be stored separately from other material or
equipment. The storage place shall be 10 cm or more above the ground and
locked to prevent unauthorized entry. Radioactive materials shall be stored in a
case made of lead of ample thickness with a lock on the exterior surface of the
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case. The description of materials, quantity and danger sign shall be distinctly
visible.
29.0 WORKING WITH MACHINERIES / MATERIAL HANDLING EQUIPMENT
29.1 General
Many accidents place while handling materials at site. It is 'highly hazardous
operation. Hence special attention by contractor is required in this respect.
Following precautions are essential:
Safe working space for all handling equipment shall be provided. Proper
material stockyard should be made and all material should be stacked
/arranged/kept in orderly manner with proper moving space for handling
machinery. Proper wooden sleepers should be provided below steel plates
and such other materials.
Mixers, winches, cranes, bending machines etc., shall be overhauled
regularly as per manufacture's advice/maintenance schedule.
Proper warning boards/signs shall be provided when machineries like cranes,
hoists are being operated.
Brakes, clutches of winches shall be checked on regular basis. Chains,
ropes, belts shall be inspected and repaired/changed as necessary.
All moving parts of the material handling equipment must be provided with
suitable guards.
Lifting ropes should be inspected for kinking, loose wires, high strands,
corrosion, nicking, lubrication, change in diameter /cross section
Slings and other lifting materials, which are not suitable for use should be
promptly withdrawn and destroyed
Lifting chains should be inspected for bent links, cracks in weld areas or any
other section of link, traverse nicks and gauges and corrosion pits.
Elongation of the lifting chain link due to over loading should be inspected
before using it.
Maximum allowable wear at any point of link of the lifting chain is given
below: -
CHAIN SIZE (mm) MAXIMUM ALLOWABLE WEAR(mm)
61
10 2
12 3
16 3.5
20 4
22 4.4
25 4.8
28 5.5
31 6.4
35 7
40 8
45 8.7
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For lifting hook, if the throat opening exceeds 15% of the normal opening, it
should be replaced. When inspecting the hook, measurement must be made
between the shank and narrowest point of the hook opening
 A chain used for lifting should not be spliced by inserting a bolt between two
links
Strain should not be put on a kinked chain
Hammer should not be used to force a hook over a chain link
A safety hook fitted with a latch to prevent displacement of loads should only
be used for material handling/lifting
IS: 7293-1974 (Code of Practice for Working with Construction Machinery)
shall be referred for further safety measures.
29.2 CRANES
All works involving the use of crane shall be properly planned in advance and the
following shall be ensured
The crane is capable of lifting the load. Safe load capacity should be clearly
marked on jibs, winches, pulleys, slings and ropes. All job cranes should
have an automatic safe load indicator which alerts the operator
The condition of the ground at the crane location is satisfactory to support the
crane and the load
The rotation of the cab and, therefore the boom is not restricted. Suitable
matting or plates are available to protect underground services and paving.
All slings shackles, hooks etc. are of correct rating and in good condition
Cranes and lifting equipments must be inspected and carry a valid test
certificate issued by an accredited testing agency.
Crane hooks are to be fitted with properly functioning safety clips to prevent
displacement of the sling from the hook during the lift.
Driver of the crane must be watchful and must ensure before driving the
vehicle either forward or reverse that no one is near the wheel of the vehicle
and no one is trying to climb the vehicle while moving. .
Crane operators and signalers must be trained and sufficiently experienced.
There should always be a signalman or a signaling system such as a
telephone, if the crane operator cannot see the load throughout the lift. Hand
signal shall be clear and distinct and shall follow recognized code or system.
Workers must use safety shoes and helmets. They are also required to wear
gloves and other PPE s for handling materials.
Raising, lowering and braking of jib should not be done abruptly in order to
prevent it from snapping.
No part of the crane or crane load should be closer than 4 Mts. to live
overhead power lines.
For movement of crane or other material handling equipment ,ramp gradient
should not exceed 1 in 10
No person should be allowed to stand or work under lifted load.
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29.3 MANUAL HANDLING
Assistance should be obtained if the load is too heavy or awkward for manual
handling. Clear walkway to the destination and safe stack should be ensured
before handling the load manually. Following procedure should be followed while
lifting a load manually:
Stand close to the load on a firm footing and with feet about 30 cm apart
Bend the knees and keep your back as straight as you can
Take a firm grip on a load ..
Breathe in and throw the shoulders backwards
Straighten the legs & continue to keep the back as straight as you can
 Make sure that your view is not obstructed by the load
Keep the load close to the body
Lift slowly and smoothly
When carrying the load ,avoid twisting spine to turn, move your feet instead
One person shall not pull more than 63 kg.
The weight unit for lifting by a worker is 18 kg and hence should be fixed as
upper limit of load to be lifted by worker
If two or more workers are lifting, one should give instructions to ensure that
the team works together
Type of clothing is very important in manual handling of material. Clothing
should be such that it allows easy movement of arms and will not catch in
machinery or on a load.
30 VEHICLE SAFETY
All vehicles used for carrying workers and construction materials must
undergo preventive maintenance and daily checks.
Contractor shall maintain a register for this purpose for each vehicle.
All documents related to the vehicle shall be kept in vehicle for checking. -
Driver with proper valid license shall only be allowed to drive the vehicle.
Routes shall be leveled, marked and planned in such a way so as to avoid
potential hazards such as overhead power lines and steep sloping ground.
Speed limit shall be specified.
While reversing the vehicle, help of another worker should be enlisted and his
instructions should be complied at all times during reversing and sound signal
should be provided before reversing
An unattended vehicle should have the engine switched off.
Foot injuries to drivers and their assistance during loading and unloading are
common and they should wear safety boots and shoes.
Wherever possible one-way system shall be followed.
Head clearance must be ensured on the route of the vehicle and no vehicle
shall be allowed to deviate from its route.
Overloading, carrying unauthorized passengers etc. shall not be allowed.
Load on vehicle should be evenly distributed, properly secured and normally
should not project beyond the plan of vehicle. If some degree of projection is
unavoidable, it should be clearly shown by the attachment of red flags.
Load should be properly secured
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The body of a tipper lorry should always be lowered before driving the vehicle
off.
Signs/signals/caution boards etc. should be provided on the routes.
31 SAFE OPERATION OF PLANT, TOOLS AND EQUIPMENT
The following four basic principles shall be applied for the safe use of hand and
power tools.
1. To choose right tool for the job
2. To use only tools in good condition
3. To use tools correctly, and only for the purpose they are intended
4. To maintain and store tools properly.
Electrical tools shall be checked to ensure that the supply voltage is as per
requirement.
Electrical tools shall always be properly earthed.
 High speed rotating equipments such as grinders shall be fitted with
protective guards.
Static load on shoulder or arm due to continuous holding of a tool at a raised
position or gripping of a heavy tool should be avoided
Awkward wrist angles to be avoided
Uncomfortable posture and pressure on the palm or joints of the hand should
be avoided.
Repair or discard the tool, if tool heads mushroom, tool jaws open out and
cutting tools loose their edge
Tools handle should have a firm grip
Tools should be properly cleaned and stored
Air connection to pneumatic tools should be clamped and secured properly.
Electrical cable/pneumatic tube should be protected against damage
Socket, terminal boxes, fuses etc. must be of high quality and properly
covered and protected
Correct fuse should be used for the electrical tools.
Power tools shall never be left operating unattended.
Spark arrestor shall be fitted to all equipment exhausts where risk of
presence of combustible gases exists.
Periodical inspection shall be done.
32 WORKING OVER WATER
Falling into water and drowning and getting carried away by water current is an
ever-present danger when working over or adjacent to large water bodies. The
following precautions should always be followed:
Working platform should be made secured and there shall be no tripping
hazards such as tools, wires, timbers, bricks etc. Surface should not be
slippery.
Access ladders, guard rail and toe board for the working platform should be
firmly held.
Safety helmet should always be used.
110
A life jacket should be used
A safety harness or net shall be used.
Lifebuoys fitted with lifelines should be kept ready in hand for immediate use.
Availability of safety boat (motor driven with self-starter for tidal/fast flowing
river) should be ensured.
Availability of alarm system should be ensured
33 PIPELINE CONSTRUCTION SAFE PRACTICES
I. Handling and storage of pipes
a) Bare Pipes
* Unloading, loading, stockpiling and transportation of bare pipes should be
done using suitable means and in a manner to avoid denting, flattering or
other damages to pipes
* Pipes should not be allowed to drop but should be lifted or lowered from
one level to another by suitable equipment
* Lifting hooks when used, should be equipped with a plate curved to fit the
curvature of the pipe
* Pipe when stockpiled, should be placed on a suitable skid to keep it clear
of the ground.
* The stacks must be properly secured against sliding and should consist of
pipes of the same diameter and wall thickness
* Personal Protective Equipment like safety shoe and glove should be used
by worker while handling pipes.
b) Coated Pipes
* Coated pipe shall be handled by means of slings and belts of proper
width made of non-metallic/ non-adhesive materials
* Belts/slings when used should be cleaned to remove hard materials such
as stone, gravel etc.
* Coated pipes should not be bumped against any other pipe or any other
objects
* Rolling, skidding or dragging of coated pipes should be strictly avoided
* Coated pipes at all times should be stacked completely clear from the
ground so that the bottom row of pipes remains free from any ground
contact. Pipelines should be stacked at a slope so that during rain, water
does not collect inside the pipe.
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* The coated pipes may be stacked by placing them on ridges of sand and
covered with a plastic film.
* Stacks should consist of limited number of layers so that the pressure
exercised by the pipe's own weight does not cause damages to the
coating
* The weld lead of pipes should be positioned in such a manner so as not
to touch adjacent pipes
* Coated pipes stacked in open storage yard should be suitably covered on
top to decrease direct exposure to sunlight
* The ends of the pipes during handling and stacking should always be
protected with end protectors
II. Swabbing and Night capping
To ensure that all dirt and objects likely to cause obstruction in the interior of the
pipe are removed, each length of pipe should be thoroughly scrabbled prior to
alignment and welding. At the end of each day's work a steel plate or nightcap
should be adequately secured over open ends of incomplete section of the
pipeline to prevent ingress of extraneous objects and ground or floodwater. .
III. Inspection of field welds
In case of cross-country pipeline and where specifically specified, all weld joints
should be radiographed to ensure the soundness of welding joints to avoid failure
of joints, which may create serious pollution or environmental problem.
IV Coating Inspection in the field
Where pipeline coating is carried out in the field, all bare and primed pipe should
be kept free from dust and grease, oil etc. Before the pipeline is lowered into the
trench the coating should be thoroughly inspected both visually and by using
holiday detector. Any visible damage should be repaired and the pipeline shall be
retested.
V. Lowering and Backfilling
Equipment used for lowering the pipeline from the skids and positioning it finally
in the trench should be sufficiently padded at points of contact with the pipe to
prevent damage to the protective coating
* Slings used for lowering the pipe should be made of canvas or equally
non-abrasive material and of a width not less than the diameter of the
pipe.
* The trench should be clear of loose rocks, lumps or other objects that
might prevent the coated pipe from bearing evenly on the trench bottom.
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* When digging soil from beneath the pipe in order to remove slings, care
should be taken to avoid damage to the protective coating. The coating
should subsequently be inspected and any damage shall be repaired.
* In waterlogged areas it may be necessary to provide additional weighting
or screw anchors to prevent floatation of pipeline.
* No lowering should be done after sunset without proper lighting
arrangement
* Minimum 3 side booms should be used and mounting of counter weights
should be ensured on side booms for lowering the pipes.
VI. Road, Rail and Water Crossing
* Where work being done either adjacent to or any public or private road;
warning signs and night time warning lights should be provided and
maintained.
* Crossing will frequently necessitate laying the pipeline at greater depth
than normal and may therefore call for special measure to support the
trench or boring pit.
* Where crossings are made by open cut, the work should be programmed
so as to minimise the amount of time that the normal traffic or flow is
interrupted. Where necessary temporary conduits or pumping system
should be provided to maintain the flow in water courses
VII. Trenching
* Barricading should be made while trenching in heavy traffic area.
* Sign boards should be provided while trenching in heavy traffic area
* Trench cross over shall be provided at every 30 Mts. of its length while
trenching
* Lighting should be provided for night working
* Shoring should be provided for trench support
* Underground service connections should be identified and marked
prominently
* Excavation tools should be properly insulated to avoid electric shocks
* Evacuation of workers should be ensured before blasting
* Entry of workers in site, where blasting is planned to be done, should be
allowed after inspection and clearance from qualified Blaster
Requirements of safe procedure as stipulated in BIS Code IS:4081-1986
for blasting and drilling must be observed during blasting operation.
VIII. Pipeline Marks
Distinctive markers should be created at all crossings to indicate the alignment of
the pipeline and should give information about ownership, diameter, the nature of
content, the normal direction of flow and the location of the crossing. A telephone
number for use in emergencies shall also be displayed.
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34.0 STORAGE OF HAZARDOUS MATERIALS
Harmfulness of materials shall be identified and proper care shall be taken
against fire/health hazards e.g. against asbestos fibre/rope, sand/shot blasting,
paints, handling leaded container and tank, furfural liquid etc. Waste materials
and consumables like woods, papers, and plastic pieces etc. shall be cleared on
regular basis. Petroleum products/solvents used for cleaning etc. shall be kept
away from working site specially when hot work is in progress. No smoking
board/signs etc. shall be used in sites where such materials are stocked. Paints
shall be stored in separated areas. The quantity of paint stored in actual working
areas shall be as minimum as practicable. The ingestion of paint shall always be
avoided. Food and drink shall not be brought, stored, prepared or consumed in
areas where paints are stored, handled or used. Smoking in such areas shall be
prohibited. The inhalation of paints, dusts or fumes shall always be avoided by
the use of local ventilation or extraction. Where fumes or dusts are unavoidable,
then suitable approved respirators or facemasks shall be worn. All personnel who
handle and use paints shall wear appropriate protective clothing (such as,
gloves, eye protection and overalls). Splashes of paint on skin shall be treated
promptly by copious washing with water or an approved cleaning agent. (Solvent
shall not be used for personal cleaning).
35 CLASSIFICATION & WORKING IN HAZARDOUS ZONES
Hazardous (flammable atmosphere) zones are classified as zone-O, zone-1 and
zone- 2. All other areas are unclassified but not necessarily non-hazardous. In
these areas, safety precautions must be observed in order to eliminate risk of
explosion. Zone-O is defined as the vapour space in and directly around product
storage tanks. Zone-1 is defined as an area where vapours, may be expected at
all times. For zone 2, flammable vapours may be expected to be presently when
a failure to equipment or plant occur. Unclassified areas cannot be assumed to
be always non-hazardous, therefore must be checked prior to issue of work
permits, Following precautions shall be taken while working in hazardous areas.
35.1 NON-SPARKING EQUIPMENT
Sparks can be produced from electrical tools/devices, and where two surfaces
collide. In order to avoid risk of sparking, only tools approved for use in
hazardous zone-1 shall be used. The condition of all equipments used within
hazardous zones shall be checked by BPCL Engineer. Where chipping or
scraping is necessary in a hazardous area, several precautions shall be taken
such as; the surface being chipped or scraped shall be kept moist with water at
all times ; Air driven jackhammers may be used where atmosphere has been
certified to be safe and the impacting surfaces must be submerged in water.
35.2 CHECKING OF WORKERS
Workers are to be checked for matchboxes, lighters and other spark producing
items. If workers are found to be carrying any such item, the same shall be taken
into custody by security at the entry point.
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35.3 SAFETY CHECKS
In all cases where work is to be carried out within hazardous zones, BPCL
Engineer shall check the area using an explosimeter for the presence of
flammable vapours. The explosimeter shall be verified before each use, for its
smooth functioning. Should there be any indication of flammable vapours, steps
shall be taken to reduce the vapour content of the surrounding atmosphere. If
found safe after re-checking by explosimeter, the work permit shall be issued.
35.4 FIRE SCREEN WALL
Fire screen shall be provided to segregate area where hot works, such as
welding & cutting, is planned to be done from surrounding. To construct fire
screen, the following shall be complied with:
Members shall be made of appropriate size MS pipes, MS structurals, strong
enough to withstand the wind, live and dead loads. The bottom of columns
shall be properly grouted.
Good quality G.I. Sheets free from damage and holes shall be used as
screening wall. G.I. Sheets shall be properly tied up with the structure.
 The height of fire screen wall shall be decided based on the level at which hot
work is supposed to be carried out. For example, in case of above ground
tanks fabrication by jacking up method, a fire screen of 6 M height is sufficient
where as in the other case it is required to have a height equal to height of
structure to be fabricated.
36. WORK PERMIT SYSTEM
If work is to be performed in a hazardous area, a duly authorized written work
permit shall be obtained by the contractor from BPCL or any official duly
authorized by BPCL for this purpose. This is a document authorizing contractor
to carry out the work concerned, warning him of the possible hazards and
spelling out precautions needed for the job to be done safely. The contractor
shall be fully aware of the details of the work permit system and shall obtain the
same signed by authorized person before starting the job. Based on the nature,
the work shall be undertaken either under Cold Work Permit or Hot work / Entry
to confined space permit or Electrical isolation and energisation permit.
Permits and certificates are to be issued by BPCL Engineer or any official duly
authorized by BPCLfor this purpose with overall responsibility for the work area.
All work permits shall carry serially printed numbers. The printing of all work
permits shall be done by the contractor in adequate quantity at his own cost.
36.1 COLD WORK PERMIT:
Work falling under the category of cold work such as opening process machinery,
blinding & deblinding, tightening of flanges, hot bolting, painting etc. shall be
performed through Cold Work Permit.
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This Permit shall be in minimum two copies. The original should be in yellow
colour and the copy should have the word "Copy" printed in large yellow letters.
Original shall be issued to the contractor, retaining the duplicate in the book.
(Ref. Annexure-I)
36.2 HOT WORK / ENTRY TO CONFINED SPACE PERMIT:
All hot work such as welding, grinding. gas cutting, burning, shot blasting.
soldering, chipping, excavation, open fire, use of certain non-explosion proof
equipment etc. shall be carried out through Hot Work Permit. Entry and operation
of petrol or diesel driven vehicles or equipment without spark arrester in
hazardous area also falls in the category of hot work, and shall be performed
under the hot work permit.
The confined space entry permit is required for the protection of personnel
entering a confined space such as Vessels, boilers, storage tanks, large diameter
piping etc against hazards such as oxygen deficiency, toxic and flammable
materials, falling objects, power driven equipment etc. Excavation more than 1.2
meter deep, entry on floating roof tank when the roof is more than 3 meter down
from the top, space located below ground level such as pits, drain, channels etc.
also fall under the confined space.
For excavation work regardless of the depth, permission from various sections
shall be obtained with precautions to be taken for the underground facilities viz;
sewers, telephone lines, cables, pipelines etc.
This work permit shall be in minimum three copies. The original should be in pink
colour and copies should have the word "COPY" printed in large pink letters.
Original shall be issued to the contractor, duplicate to the Safety Section and
triplicate retained in the book. (Ref. Annexure-II)
36.3 ELECTRICAL ISOLATION AND ENERGISATION PERMIT
Before issuing any work permit, it is essential that the equipment / facility to be
worked on is electrically safe and electrical power is isolated to the extent
necessary for the safe conduct of the authorized work.. Permit for electrical
isolation and energisation shall be in triplicate and in two sections with tear off
facility. Section-A shall be used for electrical isolation and Section-B for
energisation. The original should be in light blue color and copies should have
the word "COPY" printed in large letters in light blue colour. Original along with a
copy shall be issued to the electrical section for electrical isolation / energisation.
Electrical section authorized person on isolation / energisalion of the equipment /
circuit shall return the original to the issuer keeping copy for record. (Ref.
Annexure-III)
36.4 SCAFFOLDING FITNESS CERTIFICATE
For all temporary scaffolds erected by contractor, fitness certificate, in format
given in Annexure IV, shall be issued by BPCL site in charge after due checking
to his satisfaction .
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36.5 TEMPORARY ELECTRICAL CONNECTION FITNESS CERTIFICATE
For all temporary electrical connections taken by contractor including diesel
generating sets, fitness certificate, in format given in Annexure V, shall be issued
by BPCL site in charge after due checking to his satisfaction.
37. ACCIDENT REPORTING AND CLASSIFICATION
37.1 ACCIDENT REPORTING
All employees must be encouraged to report any near miss incident that has or
could have caused injury, illness, damage to property, or interruption in work.
The reporting of such incident helps in analyzing what went wrong and enables
steps to be taken to prevent recurrence. The accident reporting forms the basis
for objective investigation of the accident and will bring out essential and
contributory factors leading to It. The necessary decisions then can be taken to
prevent recurrence in future.
37.2 CLASSIFICATION OF ACCIDENTS
Accidents are classified as follows:
a) Near Miss
It is a 'narrow escape' where accident, major loss or injury did not occur.
Such incidents must be reported locally and the working conditions leading to
it must be investigated.
b) Fatality
A death resulting from work injury is covered under this category irrespective
of the intervening time between injury and death.
c) Permanent total disability
Personal injury which incapacitate a person completely and results in
termination of employment.
d) Permanent partial Disability
Any injury which results in complete loss or permanent loss of use of any part
of body or any permanent impairment of the function of the body.
e) Lost Work-Day Case
Any injury excepting permanent partial disability which renders the injured
person unable to perform any regular job on any day after the day of
receiving the injury.
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f) Restricted work case
After the injury, the injured person can not perform his normal duties or
regular job.
g) Lost work days
The number of calendar days on which the injured person was temporarily
unable to work.
h) Restricted Work days
The total number of calendar days from the start of Restricted work, by the
injured persons, till he returns to his regular job.
i) Medical treatment cases
The injury requiring medical treatment under order from a physician but does
not involve Lost work Days, or restricted workdays.
37.3 REPORTING
Contractor shall notify BPCL as under:
Lost time injuries / Fatality / Injury which may cause total or partial disability to
injured etc -immediately.
Fire and Miscellaneous Events- immediately.
First Aid injuries-Within a day.
38 SAFETY TRAINING
Training is a pro-active measure. The contractor shall engage only those workers
who are proficient in their respective jobs. It is responsibility of contractor to
impart job knowledge to all workers and supervisors before engaging them for
any work. It is also binding to the contractor to depute persons for safety training,
if arranged by BPCL.
39 DOCUMENTATION
Following documents shall be maintained by contractor at site:
_ Safety & Environment Policy
_ Safety committee minutes of meeting
_ Critical machinery/equipment fitness certificate.
_ Stock register of Personnel Protective Equipment.
_ Maintenance registers for major machineries/equipment.
118
_ Accident / incident investigation reports.
_ Various work permits.
_ Earthing test certificates.
_ Materials test certificates.
_ P.F., Contract Labour, ESI registration.
_ All records & registers as required under Contract Labour (Regulation &
Abolition Act) 1970 and Building & Other Construction Workers Act 1996.
40 ENVIRONMENT PROTECTION
Contractor should ensure that the work carried out by him does not change the
quality of air, water & soil at the work site & surrounding areas. Disposal of
surplus earth, rubbish, scrap etc. shall be done in Eco-friendly manner. The
contractor shall ensure that the greenery is protected to the extent possible while
executing the work.
41 ENVIRONMENTAL IMPACT MITIGATION MEASURES
The best way of impact mitigation is to prevent the event occurring. All efforts
should be made to locate the developmental activities in a area free of
agricultural lands, cyclones, earthquakes, ecologically sensitive, erosion, forests,
flooding, human settlements, land slides, natural scenic beauty, water logging. In
case this is not feasible, the next step is to look at the raw
materials/technologies/processes alternatives which produce least impact i.e.
adopting or using processes or technologies which are efficient and produce
recyclable wastes/minimum waste/wastes that can be easily disposed, without
affecting the environment. However if the developmental activity produce the
adverse impact, action has to be taken to mitigate the same. Following are the
suggested methods, which shall be taken in to consideration by the contractor to
choose right technology for executing the work:
41.1 AIR
Attenuation of pollution on pathway or protection of receptor through green
belts.
Particulate removal devices such as : cyclones, setting chambers, scrubbers,
electrostatic precipitators, and bag houses.
Gas removal devices using absorption (liquid as a media), adsorption
(molecular sieve), and catalytic converters.
Uses of protected, controlled environment, such as oxygen masks, Houston
Astrodome, etc.
Control of stationary source emission (including evaporation incineration,
absorption, condensation and material substitution)
Use of masks
Dilution of odourant (dilution can change the nature as well as strength of an
odour)
Odour counteraction or neutralize (certain pairs of odours in appropriate
concentration may neutralize each other)
119
Odour masking or blanketing (certain weaker malodours may be suppressed
by a considerably stronger good odour)
41.2 NOISE
The mitigation measure may include damping, absorption, dissipation and
deflection methods. Common technique involve constructing sound
enclosures, applying mufflers, mounting noise sources on isolators, and/or
using materials with damping properties.
Performance specifications for noise represent a way to insure the procured
item is controlled.
Ear protective devices should be used. When an individual is exposed to
steady noise levels above 85-dB (A), in spite of the efforts made to reduce
noise level at the source, hearing conservation measures should be initiated.
41.3 WATER
Conjunctive use of ground/surface water, to prevent flooding/water
logging/depletion of water resources. Included are land use pattern, land
filling, lagoon/reservoir/garland canal construction and rainwater harvesting
and pumping rate.
Minimize flow variation from the mean flow.
Segregation of different types of wastes.
Storing of oil wastes in lagoons should be minimized in order to avoid
possible contamination of the ground water system.
Surface runoff from oil handling areas should be treated for oil separation
before discharge into the environment. If oil wastes are combined with
sanitary sewage, oil separation will be necessary at the waste water
treatment facility.
All effluents containing acid/alkali/organic/toxic wastes should be processed
by treatment methods. The treatment methods may include biological or
chemical processes. The oil water separator of appropriate size based on
catchment area shall be provided.
 The impact due to suspended solids may be minimized by controlling
discharge of wastes that contain suspended solids; this includes sanitary
sewage and industrial wastes. Also, all activity that increases erosion or
contributes nutrients to water (thus stimulating alga growth) should be
minimized.
Waste-containing radioactivity should be treated separately by means of
dewatering procedures and solids or brine should be disposed of with special
care.
41.4 LAND
The environmental impact of soil erosion can best be mitigated by removing
vegetative cover only from the specific site on which construction is to take
place and by disturbing the vegetation in adjacent areas as little as possible.
Land clearing activities should be kept to the absolute minimum.
120
Disturbing the existing vegetation and natural contour of the land as little as
possible can mitigate increases in surface runoff. Vegetation along
watercourses should not be cleared indiscriminately. Neither should potholes
or swamps be drained unless absolutely necessary for successful completion
of the activity.
Construction activities that result in the soil being laid bare could be
scheduled in such a way that some type of vegetative cover appropriate to
the site could be established prior to the onset of intense rain or windstorms.
If grass is to be seeded, mulch of straw will help to protect the soil from less
extreme erosive forces until vegetative and root development begins.
Natural drainage patterns can often be maintained by preparing sodden
waterways or installing culverts.
Steep slopes can be terraced, thereby effectively reducing the length of
slope.
Check dams built near construction sites can reduce the quantity of eroded
soil particles reaching free-flowing streams or lakes.
Use of “floating” foundations and height restrictions in earthquake zones and
increased foundation height, wall strength and roof support in areas
periodically subject to cyclones can reduce the hazards.
All forms of temporary structures should be avoided from the flood plain and
all permanent structures should be raised to a height above the level which
flood waters can be expected to reach once very 100 years (100-year flood).
Installation of underground drainage structures helps to reduce sediment
loads.
Engineering plans can be drawn to reduce the area of earth cuts on fills
below what might otherwise be acceptable, provide physical support for
exposed soil or rock faces, concentrate or distribute-as appropriate the
weight loading of foundations to areas or state better able to support that
weight.
Use small charges for mining/blasting.
Restricting the number, frequency and area of movement of heavy
machinery.
Compatibility between adjacent land uses can best be assured by providing a
green belt between the proposed activity and nearby properties where any
significant degree of incompatibility is likely to result.
41.5 ECOLOGY
 Intruding as little as possible on their habitat can best mitigate the impact of
activities on animals. If such animals use the area where the activity will take
place, the activity should be concentrated to the maximum extent possible in
those parts of the area that they least often frequent.
During the planning phase of an activity, an attempt should be made to avoid
extending into the home range wild animals. If this is not feasible, the activity
should be completed, as quickly as possible, and regular and sustained use
of the area over time should be minimized.
Regular or sustained intrusions of men or equipment into nesting areas of
birds should be avoided to the maximum possible extent, especially while are
being incubated by the adults and until the young have left the nest. The
121
sanitation cuttings of non-commercial individual trees should destroy no
known nests.
Restricting the input of polluting substances into watercourse, estuaries and
the open sea can mitigate impacts upon fish and shellfish populations.
Additionally, when a part of the activity involves water level control, changes
in such levels should be programmed to be extent, it is possible to do so in a
way that will minimally disturb nesting and feeding habitat.
122
APPENDIX-I
COLD WORK PERMIT
Sl.No.______________
Work clearance from_ ________hrs of date_________ To _________hrs of date ________(Valid
for the shift unless renewed)
Issued to (Department / Section / Contractor) ______
______________________________________________________
Exact Location of work (Area / Unit / Equipment no.
etc)_____________________________________________________________
Description of work
_____________________________________________________________________________
_____________________________________________________________________________
THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT
(Tick mark in the appropriate box. Checklist items marked with asterisk ( * ) shall be complied by
receiver)
Sr
no.
item Don
e
Not
Reqd.
Sr
no.
Item Done Not
Reqd
.
1 Equipment / Work Area
inspected
6 Equipment water flushed
2 Surrounding area checked,
cleaned and covered
7 Equipment properly
steamed / purged
3 Equipment
blinded/disconnected / closed /
isolated / wedge opened
8 Proper ventilation and
lighting provided
4 Equipment properly drained
and depressurized
9*
Area cordoned off & caution
boards / tags provided.
5 Equipment electrically isolated
and tagged vide
Permit no. --------------------------
-
10 Gas test: HCs / Toxic etc.
HCs = %
LEL
Toxic gas = ppm
Remarks:
1. The activity has the following expected residual hazards (Tick the relevant items): Lack
of Oxygen / H2S, Toxic Gases / Combustible gases / Pyrophoric Iron / Corrosive Chemicals /
Steam – Condensate / Others _____________
2. Following additional PPE to be used in addition to standards PPE (Helmet, Safety Shoes,
Hand gloves, Boiler suit): Face Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask /
Lifeline / Safety Belt / Airline / Earmuff etc.
3. Additional precaution if any:
_____________________________________________________________________________
Issuer Name & Designation Issuer Signature Receiver Name & Designation Receiver Signature
123
Closing of the work permit:
Receiver : Certified that the subject work has been
completed / stopped and area cleared
Issuer: Verified that the job has been completed and
area cleared and is safe from any hazard.
Date &
Time
Name &
Designation
Signature Date &
Time
Name &
Designation
Signature
Clearance renewal
Time
Date
From To
Additional precautions
if any, Otherwise
mention “NIL”
Issuer's Name,
Designation &
Signature
Receiver's Name,
Designation and
Signature
124
General Instructions:
1. The work permit shall be filled up carefully and accurately in clear handwriting
ensuring that complete information is provided in all the sections / subsections.
Sketches should be provided wherever possible to avoid miscommunication.
2. Appropriate safe guards and required personnel protective equipment (PPEs)
shall be determined by a careful analysis of the potential hazards and the
operations to be performed prior to starting the work.
3. Requirement of standby personnel from Process / Maintenance / Contractor /
Fire / Safety etc if any shall be mentioned in the additional requirement.
4. In case of fire alarm / siren, all work must immediately be stopped.
5. For renewal of work clearance, the issuer shall ensure that the conditions are
satisfactory for the work to continue. If the conditions have changed, it may be
necessary to issue a new permit or amend the existing permit.
6. This clearance on the same permit can be renewed / extended upto a maximum
of seven calendar days.
7. This permit must be available at work site at all times.
8. On completion of the work, the permit shall be closed.
The industry may add other relevant instruction based on their operating and
maintenance practices.
125
APPENDIX -II
WORK PERMIT
for
HOT WORK / ENTRY TO CONFINED SPACE
Sl.No._
________
Work clearance from __________hrs of date__________To________hrs of date __________(Valid
for the shift unless renewed)
Issued to (Department / Section / Contractor)
______________________________________________________
Exact Location of work (Area / Unit / Equipment no.
etc)___________________________________________________
Description of work
____________________________________________________________________________
_____________________________________________________________________________
THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT
(Tick mark in the appropriate box. Checklist items marked with asterisk (*) shall be complied by
receiver)
Sr
no
Item Done Not
Reqd
.
Sr
no
.
Item Done Not
Reqd
A General points B For Hot work / Entry to
confined Space
1 Equipment / Work Area inspected 1 Proper ventilation and Lighting providing
2 Surrounding area checked, cleaned and
covered
2 Proper means of exit / escape provided
3 Sewers, manholes, CBD etc and hot
surfaces nearby covered
3 Standby personnel provided from
Process / Maint / Contractor / Fire /
Safety dept.
4 Considered hazard from other operations
and concerned persons alerted.
4 Checked for oil and Gas trapped behind
the lining in Equipment
5 Equipment blinded/disconnected / closed /
isolated / wedge opened
5* Shield provided against spark
6 Equipment properly drained and
depressurized
6* Portable equipment / nozzles properly
grounded
7 Equipment properly steamed / purged 7* Standby persons provided for entry to
confined space
8 Equipment water flushed
9 Iron sulfide removed / kept wet C For Vehicle Entry
10 Equipment electrically isolated and tagged
vide permit no.
1* Spark Arrestor on the mobile equipment /
vehicle provided.
11 Gas test : HCs = %LEL
Toxic gas = ppm, O2 =
%
12* Running water hose / Fire extinguisher
provided. Fire water system available.
D For Excavation works
13* Area cordoned off and Precautionary tags
/ Boards provided.
1 Clearance obtained for excavation / road
cutting / Dyke cutting from concerned
depart.
126
REMARKS:
1. The activity has the following expected residual hazards (Tick the relevant items): Lack of
Oxygen / H2S, Toxic Gases / Combustible gases / Pyrophoric Iron / Corrosive Chemicals /
Steam – Condensate / Others
2. Following PPEs to be used in addition to standards PPEs (Helmet, Safety Shoes, Hand
gloves, Boiler suit): Face Shield / Apron / Goggles / Dust Respirator / Fresh Air Mask /
Lifeline / Safety Belt / Airline / Earmuff etc.
3. Additional precautions if
any:.____________________________________________________________
__________________________________________________________________
_____________________________________________________________________
Issuer Name & Designation Issuer Signature Receiver Name and
Designation
Receiver Signature
Clearance renewal
Time
Date
From To
Gas Test Values
for HC's, Toxic,
O2 etc
Additional
precautions if any,
Otherwise mention
“NIL”
Issuer's Name,
Designation &
Signature
Receiver
Name,
Designation
and Signature
127
Closing of the work permit:
Receiver: Certified that the subject work has been
completed / stopped and area cleaned.
Issuer: Verified that the job has been completed
and area cleaned and is safe from any hazard.
Date &
Time
Name &
Designation
Signature Date &
Time
Name &
Designation
Signature
General Instructions:
1. The work permit shall be filled up carefully and accurately in clear handwriting ensuring that
complete information is provided in all sections / subsections and none of column is left blank.
Sketches should be provided wherever possible to avoid miscommunication.
2. Appropriate safe guards and required personnel protective equipment shall be determined by a
careful analysis of the potential hazards and the operations to be performed prior to starting the
work.
3. In case of fire alarm / siren, all work must immediately be stopped.
4. Only certified vehicle / engines and permitted type of electrical equipment and tools are allowed in
operating areas.
5. Welding machines should be located in non-hazardous and ventilated areas.
6. No hot work should be permitted unless the explosive meter reading is Zero.
7. When a person is entering confined space, the receiver must keep minimum two standbydesignated
persons at the manhole or entry point.
8. Before box up of any vessel manhole cover, ensure that no men / materials are inside the vessel.
9. For renewal of work clearance, the issuer shall ensure that the conditions are satisfactory for the
work to continue. If the conditions have changed, it may be necessary to issue a new permit or
amend the existing permit.
10. This clearance on the same permit can be renewed / extended upto a maximum of seven
calendar days.
11. This permit must be available at work site at all times.
12. On completion of the work, the permit must be closed and kept as record.
13. The industry may add other relevant instructions based on their operating and maintenance
practices.
128
APPENDIX -III
Electrical Isolation / Energisation Permit
Section-A: Isolation Permit.
Sl.No.______________
Request for Isolation: Date:
___________________Time:___________________
Department / Section / Area issuing the permit
_________________________________________________
Equipment number to be isolated:
________________________________________________
Name of the equipment / circuit to be isolated:
_______________________________________________
The above-mentioned equipment / circuit shall be de-energized and isolated from all live
conductors to carry out the maintenance work by ____________________________ section /
for operational requirement.
_____________________ ______________________ ________________
Issuer Name Designation Signature
Certificate of Isolation: Date:
____________________Time:__________________
Certified that Equipment / Circuit no. _____________________ of
_____________________________plant has been electrically isolated by switches / isolators /
links / fuses (tick as applicable) and the danger tag is put on the supply panel. Actions in respect
of electrical isolation have been recorded in the electrical shift logbook.
____________________ ___________________ _______________
Name of Authorized Person Designation Signature
129
Section-B: Energisation Permit.
Sl.No.______________
Request for Energisation: Date:
_____________________Time:__________________
Department / Section / Area issuing the
permit_________________________________________________
Equipment number to be energized:
_________________________________________________
Name of the equipment / circuit to be
energized:________________________________________________
Work on the above mention equipment / circuit has been completed and all the applicable permits
closed. This equipment / circuit may be energized.
_________________________ ___________________ _____________________
Issuer Name Designation Signature
Certificate of Energisation: Date:
___________________Time:_____________________
Certified that Equipment / circuit no._______________________ of
_____________________plant has been electrically energized and the danger tag removed from
the supply panel. This is also recorded in the electrical shift logbook.
__________________ _______________ _____________
Name of Authorized Person Designation Signature
130
APPENDIX -IV
Scaffolding fitness certificate
(Name of contractor )
Project___________________________
Exact location of scaffolding ____________________________________
Date of inspection _____________________
Type of scaffolding & height _________________________________
Purpose ____________________________________________________
We have personally checked the scaffolding and declare it as fit for use.
Signature of site in-charge __________________
Signature of contractor’s representative __________________
Date:
131
APPENDIX -V
Temporary electrical connection fitness certificate
(Name of contractor )
Project___________________________
Exact location of electrical temporary connection ______________________
Date of inspection _____________________
Purpose ____________________________________________________
We have personally checked the temporary electrical connection and workability of
ELCB/RCCB and declare it as fit for use.
Signature of site in-charge __________________
Signature of contractor’s representative __________________
Date:
132
GRIEVANCE REDRESSAL MECHANISM
PREAMBLE
Grievance Redressal Mechanism aims at speedy resolution of grievance of tenderes
and prospective tenderes by providing them with a platform to refer their grievances and
to seek appropriate remedy to the same.
1.0 Definitions
In this mechanism, unless repugnant to the meaning or context thereof, the following
expressions shall have the meaning given to them below :-
1.1 ‘Company’ shall mean Bharat Petroleum Corporation Ltd.
1.2 ‘Grievance’ shall mean a representation complaining of an interference in the
rights of a Tendering party or represetation complaining of an oppression on a
Tendering party by Bharat Petroleum Limited(BPCL) or its representatives,
resulting in denial of his rights as a Tendering party.
1.3 ‘Tendering party’ shall mean a party or parties as a group who has / have
participated in the tender process and submitted his / their tender in response to
an invitation to participate in the tender or a party / parties who is / are
prospective tenders qualified to participate in a tender based on notice issued by
the Company inviting tender.
1.4 ‘Tender Inviting Authority’ shall mean an employee or committee of BPCL
employees authorised to invite and / or to accept a particular tender.
1.5 ‘Grievance Redressal Officer’(GRO) shall mean respective Functional Director
to whom the originator of Tender reports.
2.0 Authorities to handle grievances
2.1 Their will be a two -tier mechanism to handle the grievance received from a
Tendering party.
2.2 The first level of Grievance Redressal Mechanism (GRM) shall comprise of a
Grievance Redressal Committee(GRC) consisting Tender inviting authorities as
the Co-ordinator,head of SBU/Entity orginating the Tender and the ED
(Finance).All the grievance shall be lodged with the Coordinator of the GRC with
a copy to the Tender Inviting Authority.
2.3 The second level of GRM shall be Standing Committee of the Board for Tenders
(SCBT) to whom appeal against the Orders of the GRO can be filled by the
Tendering party in case he is not satisfied with the decision of the GRC.
133
3.0 Contact details co-ordinator
Telephone No. Address:
Fax:
Our Ref: