SAFETY MANUAL

SAFETY MANUAL
2015
HPGCL
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 INDEX
SECTIONS PAGE
1 SAFETY POLICY 5-10
2 SAFETY REGULATIONS & GENERAL SAFETY RULES 11-19
3 CAUSES AND REPORTING OF ACCIDENTS 21-26
4 SAFETY COMMITTEES 37-30
5 GUIDELINES FOR CONDUCTING SAFETY AUDIT 31-39
6 SAFETY / GUIDELINES FOR CONTRACTORS 41-46
7 SAFETY / GUIDE LINES FOR MECHANICAL WORKS 47-56
8 SAFETY / GUIDE LINES FOR HANDLING CHEMICALS 57-63
9 SAFETY/ GUIDE LINES FOR ELECTICAL WORKS 65-71
10 SAFETY GUIDE LINES FOR FIRE 73-78
11 OCCUPATIONAL HEALTH & SAFETY 79-87
12 POTENTIAL THERMAL PLANT HAZARDS 89-113
13 PERSONAL PROTECTIVE EQUIPMENT 115-123
14 CHECK LIST FOR CONSTRUCTION & OPERATION OF PLANT 125-144
15 WORK PERMITS 145-151
16 PERFORMAS 153-164

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 CHAPTER 1

SAFETY POLICY

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 SAFETY POLICY
1.0 HPGCL recognizes and accepts its responsibility for establishing and maintaining a safe
working environment for all its employees. This responsibility arises from:
 Corporation's moral responsibility to its employees, to provide the best
practicable conditions of work from the point of view of health and safety.
 The obligation to consult with its staff and their representatives to implement
policies and procedures developed as a result of discussions.
 Statutory responsibility in respect of health, safety and welfare of employees
emanating from relevant legislations such as The Factories Act, The Indian
Electricity Act, The Explosive act, The Boiler Act etc.
1.1 Quality, Environment, Health & Safety Policy
HPGCL is an ISO 9001-2008, ISO 14001-2004 and OHSAS 18001-2007 accredited
organization.
HPGCL is committed to generate sufficient, uninterrupted environment friendly power
for millions consumers of the State of Haryana with optimum efficiency under safe
working conditions.
To achieve this goal, HPGCL shall:
 Set & achieve regular targets of Plant efficiency.
 Comply with all applicable legal and other requirement related to Quality,
Environment and Occupational Health & Safety (OH&S) issues.
 Prevent pollution & accidents due to our various Plant operations.
 Make continuous improvements in the effectiveness of Quality, Environment and
OH&S management systems.
 Reduce the environmental impact from various emissions & discharges from Plant
operations, by optimum utilization of resources.
 Improve the Health & Safety of our employees & associates while performing
various tasks related to generation of power.
1.2 Corporation’s responsibility
The HPGCL shall take all such steps which are reasonably practicable to ensure best
possible conditions of work and with this end in view, to do the following:
 To allocate sufficient resources to provide and maintain safe and healthy
conditions of work.
 To take steps to ensure that all known safety factors are taken into account in the
design, construction, operation and maintenance of Plants, machinery and
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 equipment.
 To ensure that adequate safety instructions are given to all employees.
 To provide wherever necessary protective equipment, safety appliances and
clothing and to ensure their proper use.
 To inform employees about materials, equipment or processes used in their work
which are known to be potentially hazardous to health and safety.
 To keep all operations and methods of work under regular review for making
necessary changes from the point of view of safety in the light of experience and
up to date knowledge.
 To provide appropriate facilities for first aid and prompt treatment of injuries and
illness at work.
 To provide appropriate instruction, training, retraining and supervision in health
and safety and first aid and ensure that adequate publicity is given to these matters.
 To ensure proper implementation of prevention and an appropriate fire fighting
service, together with training facilities for personnel involved in this service.
 To ensure that professional advice is made available wherever potentially
hazardous situations exist or might arise.
 To organize collection, analysis and presentation of data on accident, sickness and
incident involving personal injury or injury to health with a view to taking
corrective, remedial and preventive action.
 To promote through the established machinery, joint consultation in health and
safety matters to ensure effective participation by all employees.
 To publish/notify regulations, instructions and notices in the common language of
employees.
 To prepare separate safety rules for each type of occupation/process involved in a
project.
 To ensure regular safety inspection by a competent person at suitable intervals of
all buildings, equipments, work places and operations.
 To co-ordinate the activities of the company and of its contractors working on the
Company's premises for the implementation and maintenance of safe systems of
work, to comply with their legal obligations with regard to the health, safety and
welfare of their employees.
1.3 THE RESPONSIBILITY OF THE EMPLOYEE
The establishment and maintenance of best possible conditions of work is, no doubt, the
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 responsibility of Management, it is also necessary that each employee follows prescribed
safe methods of work. He should take reasonable care for the health and safety of himself,
of his fellow employees and of other persons who may be affected by his actions at work.
With this in mind, employees should be health and safety conscious and:
REPORT Potential hazards
OBSERVE Safety rules, procedures and codes of practice.
USE With all reasonable care the tools, equipment, safety
equipment and protective clothing provided by the
Company; these items should be kept in good condition.
PARTICIPATE In safety training courses when called upon to do so.
MAKE USE Of safety suggestions schemes.
TAKE An active and personal interest in promoting health and
safety at work.

1.4 RESPONSIBILITY FOR IMPLEMENTATION

 The ultimate responsibility for ensuring the implementation of the policy on health
and safety at work rests on the HPGCL Management the Corporate Personnel
Division at the corporate level and the concerned Chief Engineers at the
Project/Station level. The Officer In-charge of safety will be functionally
responsible to the Corporate headquarter for ensuring that the policy is
promulgated, interpreted and carried out in the manner expected.
 Immediate responsibility for safety at work is that of the Engineer In-charges of
each department/section who are primarily responsible to prevent accidents
involving members of their staff and other persons. It is their responsibility to
issue clear and explicit working instructions, compliance with which will ensure
safe working and to require the effective use of approved equipment.
 Accepted rules, procedures and Codes of Practice which are formulated with
proper regard to health and safety consideration must be strictly observed by all
concerned. Contracting Agencies executing works should be made responsible
through various measures including appropriate provisions in the contract for
discharging their safety obligations.
 In designated areas of particular hazard the appropriate Executives are required to
authorise, in writing the commencement of any work and, before doing so,
personally to satisfy themselves that all necessary safety precautions have been
carried out, such Executive incharge must themselves be authorised, in writing as
competent to perform these duties.
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 Safety Officers are appointed to advise Management on questions of safety at
work including advice on the application in particular local situations of the
system of work, implementation of Company's Rules and Relevant Codes of
Practices in consultation with Area In-charges. They will be consulted in the
interpretation of rules and codes being formulated by the Corporate Management
and shall advise Management in the investigation and analysis of accidents and
circulation of appropriate statistics.
 Major Site Incidents: - The Chief Engineer at each Project/Station is required to
ensure that plans are devised for action in the event of fire, major site incident or
necessity for evacuating procedure. These plans must be communicated to all staff
and rehearsed from time to time.
 Fire-fighting training and the formation of fire-fighting team on a voluntary basis
will be encouraged by the Project/Station management.

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 CHAPTER-2

SAFETY
REGULATIONS
&
GENERAL SAFETY
RULES

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2.0 SAFETY REGULATIONS
Various regulations governing safety of Plants are broadly as under:-
1. Safety and Health Provision under Factories Act – 1948
 Sections 11 to 20 of the Act contain certain provisions intended to ensure that the
conditions under which work is carried on in factories do not affect the health of
the workers injuriously.
 Sections 21 to 40A, 40B and 41 of the Act lay down rules for the purpose of
securing the safety of workers.
 Section 45 for first-aid boxes as and when required.
2. Safety and Health Measures under other Construction Workers (Regulation
of Employment and Conditions of Services) Act 1996.
 Sec. 6 Appointment of registering officers.
 Sec.28-Fixing hours for normal working day, etc.
 Sec. 29-Wages for overtime work.
 Sec. 30-Maintenance of registers and records.
 Sec. 31-Prohibition of employment of certain persons in certain building or other
construction work.
 Sec. 32-Drinking water.
 Sec. 33-Latrines and urinals.
 Sec. 36-First-aid.
 Sec. 44-Responsibility of employers.
 Sec. 48-Penalty for failure to give notice of the commencement of the building or
other construction work.
 Sec. 49-Penalty for obstructions.
3. Safety provisions under Indian Electricity Rules-2003
 Sec.53 (1) Provisions relating to safety and electricity supply.
 Sec.161 (1), Sec.161 (2) Notice of accidents and inquiries.
 Sec.53 Provisions relating to safety and electricity supply.
 Sec 73(c) Functions and duties of Authority: specify the safety requirements for
construction, operation and maintenance of electrical plants and electric lines.
4. Central Electricity Authority
 Rule 4(l) of the (Safety Requirements for Construction, Operation and
Maintenance of Electrical Plants and Electrical Lines) Regulations, 2011.

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 5. Haryana Factories Rules or The Punjab Factory Rules, 1952 As Applicable In The
State Of Haryana
 Section 7-A (3) and 41-B(2) for Health & Safety Policy.
 Rule 55 : Safety Precautions.
 Rule 70 : Ambulance Room.
 Rule 71 to 77 : Canteens.
 Rule 78 : Shelters, etc.
 Rule 102 : Special provision dangerous operations.
 Part-II (9) : Handling and storage of chemicals.
 Part-II (11) : Personal protective equipment.
 Part-II (15) : Testing, examination and repair of plant & equipment.
 Part-II (18) : Entry into or work in confined spaces.
 Part-II (20) : Permit to work system.
 Part-II (3) : Protective equipment.
 Rule 69, 69-A, 69 B and 70 for maintaining of FIRST –Aid Box.
2.1 GENERAL SAFETY RULES
2.1.1 Duties of supervisors in Promoting Safety Regulations
(Supervisor’s responsibility is only indicative and not limited to the following activities).
1. Each supervisor shall exercise close watch over those employees who report or are
assigned to report their duties under his control. He shall ensure that the persons
working under him are competent to perform their work safely by adopting safety
rules and procedures.
2. Supervisors must take immediate corrective action/follow up whenever unsafe
conditions/practices are noticed and must report to the management for issuing
periodical/notification.
3. Supervisor shall explain in detail the particular hazard where the employee is
working besides the precautions to be taken for ensuring safety of the personnel &
the material in the vicinity.
4. Supervisors shall develop safety awareness in the minds of all employees.
5. Supervisors shall ensure that the safety regulation are understood, that all hazards
are eliminated wherever possible and all means of egress/Outlet exist, stairways
and similar means of escape are clear, workable and thoroughly known to all his
men.

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 6. He must set a good example in knowing and observing all Safety rules and
precautions.
7. Supervisors shall investigate and report the root causes of all accidents that take
place in their areas of responsibility on such forms as may be prescribed by the
company and immediately take/suggest such action so that similar accidents do not
reoccur/happen again.
8. Supervisors are required to make contacts with persons working in isolated places.
9. Regular and systematic inspection shall ensure that all tools, equipments,
machineries and premises are in safe and operative conditions.
10. Supervisors must take corrective action whenever rules are not observed because a
single violation may become a source of major accident and may put the safety of
an individual or a group in jeopardy/danger/trouble.
2.1.2 General Safety Rules For All Employees
1. Smoking is not allowed in any part of Fuel Oil Handling/Storage area.
2. All persons will follow work instructions displayed at different sites.
3. Every employee should consider it as a part of his duty to take an active part in all
safety related works and follow safety rules.
4. Every employee should insist on the observance of safety rules by fellow
employee.
5. Every employee of the Thermal Plant must know the location and procedure for
using fire fighting equipment.
6. Never enter work area without helmet.
7. Before starting any job it is to be ensured that the necessary permit/clearance has
been obtained.
8. When any dangerous/unsafe condition is observed, it should be immediately
reported to supervisor, Fire and Safety Division.
9. Employees should ensure that the job area is cleaned as soon as the job is
completed. Good housekeeping will eliminate many unnecessary hazards causing
accidents.
10. Always use walkways instead of short cuts. While using roadway, keep to right
side so as to see the approaching vehicle.
11. All stairways, platforms and walkways must be kept clean at all times.

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12. Walking and moving in work place is to be done carefully. Slipping, tripping or
falling should be avoided. Major work should not be attempted while standing on
pipelines or fittings.
13. Running during normal operation is to be avoided.
14. Make-shifts of any kind are strictly prohibited.
15. Walking on pipelines is prohibited.
16. No attempt should be made to operate or set in motion any machine or equipment,
which are not assigned.
17. Suggestion for any additional guard or improvements to existing guards for
additional safety is always welcome.
18. Compressed air must not be used except for process/system requirements.
19. Never look directly in to the arc produced while welding without proper eye
protection.
20. Falling objects have caused many injuries. Handle material with care.
21. Keep clear of suspended loads at all times.
22. Horseplay/Fun is strictly forbidden/prohibited. Apply your thoughts to safety and
thorough workmanship.
23. Defective equipment of any kind should not be used.
24. Keep the access to firefighting equipment free of obstructions, as these are
required to be used in emergencies.
25. Any injury, no matter however slight, must be reported to supervisor immediately
and treatment obtained. Even a small accident can become a potential source of
permanent disability.
26. Polyester or nylon clothing should not be worn while on duty as they create
hazards of static charges.
27. Clothes saturated with oil are to be changed immediately and the affected parts of
body are to be thoroughly washed with water. In case of an acid/caustic splash,
wash promptly with copious quantity of water and report immediately to medical
centre for further treatment/advice.
28. No clothing or other inflammable material should be dried out on steam lines or
any other hot equipment.
29. If any gas leak occurs, supervisor and Fire Station are to be informed immediately
and the area is to be cordoned off/barricaded.

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30. Operators must always stand on the upwind side when taking samples or draining
lines or equipment.
31. No maintenance or other type or work should be started in the Thermal Plant
without obtaining a clearance certificate from the operating department/control
room.
32. When a person is working inside any vessel/confined space, one person must be
stationed at the opening of the vessel as a watcher. Persons working in the
confined places should use safety belt with a life line. The free end of a life line
should be held by the man standing outside the vessel. Breathing apparatus should
be worn, if necessary.
33. Protruding nails should be pulled out or bent over.
34. Walking on or over any mechanical or rollers conveyor is strictly prohibited.
35. Goggles or shields must be used when working on emery wheel, chipping, sand
blasting or under other circumstances where there are possible eye hazards.
36. When working around moving machinery, the wearing of loose clothing such as
dhotis, lunges etc. is strictly prohibited.
37. Employees should not walk on the rail tracks.
38. Passing under railway wagons as a short cut is very dangerous and is strictly
prohibited.
39. Sample bottles should not be used for any purpose other than making samples.
40. Motorcycling through/into any operating areas is prohibited.
41. Gas cylinders should never be dropped, especially from trucks or platforms.
Always use a special carrier for hoisting the gas cylinders.
42. All traffic signs and regulations must be complied with at all times.
43. Protective valve caps must always be placed on all gas cylinders (Oxygen,
Acetylene, Ammonia, Carbon Dioxide, LPG, Chlorine etc.) except when in use.
44. All belts, coupling and moving parts of a machine must be securely guarded at all
times (as covered under the Factories Act)
45. Never remove or adjust the guard while the machinery is in motion. The machine
must be rendered inoperative by removal of fuses or such other methods before the
guard is removed or some repairs/adjustments are carried out. Guards must,
however, be put back in position before the machinery is operated.
46. It is strictly prohibited to use gasoline or any other highly inflammable liquid or
corrosive chemicals such as caustic soda or acid for cleaning purposes.
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47. Ladders, which are defective in any respect such as broken rung/steps etc., must
not be used.
48. In placing portable ladders, be sure to pitch them at a safe angle so that they cannot
fall backward or slip at the bottom.
49. When ascending or descending, it is important that worker faces the ladder and
obtain a firm grip with both hands.
50. Ladders when placed must either be fixed at the top or a man must be stationed to
hold the foot of the ladder.
51. Ladders must rise 3 to 4 ft. above the place of landing.
52. Ladder must be carefully lowered and not be dropped on the floor or any other
object/structure.
53. When climbing on ladders or structures, carry tools or material in such a way as to
provide free use of hands.
54. Never go on a false ceiling, it may break any moment with one’s weight while
working on asbestos covered roofs, crawling boards or cat ladders must be used.
55. The right way of lifting is to be practiced to avoid sprain/strain. One should bend
the knees, keep the body erect and feet close to the object and use leg/arm muscle
and avoid forward bending while lifting the material.
56. When electrically driven pumps, compressors etc. are shut down for repairs, the
electrical circuit must be isolated before repairs commence.
57. For maintenance work inside vessels or tanks, which are gas free, a low voltage
Transformer must be used on the electric light extension cord. The voltage must
not exceed 24 Volts.
58. Light globes and bulbs must be replaced only by the electrical department
personnel.
59. All storage containers such as tanks, drums etc. containing corrosive chemicals
must be clearly marked indicating the nature of the contents.
60. Inserting of bolt or nail in a chain to shorten it should not be practiced. The bolt or
nail may slip or break and cause an accident.
61. Persons other than from instrument Section should not tamper with or attempt the
repair of instruments.
62. Tools or materials should not be left here and there, where they may accidentally
drop on persons below.

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63. Gloves must be worn while grinding material on an emery wheel. Gloves are not
provided to keep hands clean but to protect against abrasions, splinters,
corrosiveness and extreme temperatures. Gloves should not be used while
operating machinery without ensuring that these are safe to use.
64. The engines of all vehicles and mobile stationery equipment such as welding
machines, air compressors, cranes, bull-dozers etc. must be stopped when being
filled with petrol or any other fuel.
65. Acetylene, Oxygen and LPG cylinders must not be taken inside any closed vessel
under any circumstances, neither any acetylene torch connected with the cylinders
or Generators be left inside any vessel. Torches must always be kept outside the
vessel.

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 CHAPTER-3

REPORTING
OF ACCIDENT
AND DANGEROUS
OCCURRENCE

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3.0 Reporting of Accident and Dangerous Occurrence.
All accidents and dangerous occurrences will be reported immediately to the Executive
Engineer/Safety officer who will implement an established procedure to ensure that an
investigation takes places and recommendations are made to prevent recurrence.
3.1 Principal Causes of Accidents
The basic causes of accidents can be classified under four main categories:
3.1.1 Supervisory Responsibilities:
1. No instruction given/incomplete instruction.
It is the responsibility of the supervisor to give clear and complete instruction to
the employees working under him.
2. Standard rules/instructions not enforced.
Supervisor should ensure that standard rules/instructions are being followed.
3. Personal safety devices not provided/used.
It is the responsibility of the supervisor to provide necessary PPE to the employees
working under him and ensure that they use the same.
4. Correct or safe tools/equipment not provided.
Supervisor should ensure the availability of correct tools.
5. Inadequate inspection of equipment of jobs.
Machinery tools and equipment should be regularly inspected. Defect, if any,
should be rectified immediately.
6. Improper method of working.
Supervisor should ensure that the method of working being followed is proper and
safe.
7. Poor job planning.
Poor planning of job may lead to unsafe situation. Supervisor should explain jobs
properly to his workmen.
8. Too much rush.
Supervisor should not be in hurry. It may lead to an accident.
3.1.2 Personal Action or Characteristics of Employee:
1. Haste or short cut.
Proper roads/path way is to be used. Short cuts may result in slips and falls.
2. Protective devices not used.
Every employee is expected to use all safe-guards, safety appliances or devices
provided for his protection.
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 3. Improper tools and devices.
Always use proper tools for the job.
4. Horse play or fooling.
Horse play is not allowed inside the Thermal Plant premises. It is a contributing
factor for accident.
5. Instruction or rules disregarded.
For smooth working and safe operations, proper rules and instruction are essential.
Many accidents happen because the employees sometime deviate from the
established rules and procedures.
6. Absent-mindedness.
Every employee should pay proper attention on the job he is doing. Absent
mindedness/day dreaming may lead to accident/injury.
7. Inexperience/lack of knowledge.
Every employee should be trained properly and should know his job thoroughly
before being put on regular duty.
8. Improper methods of doing work.
A safe workman knows the correct method of performing his job.
9. Loose clothing.
Loose clothing must not be worn. This is the cause of many accidents particularly
around moving machinery.
10. Working without authority.
No maintenance job is to be carried out without a valid permit/clearance.
3.1.3 Unsafe Equipment or Materials:
1. Infectively guarded/unguarded equipment.
Proper and adequate guard is to be ensured to the equipment particularly moving
equipment.
2. Defective/unsafe equipment.
Equipment should always be maintained in healthy condition. Defective/unsafe
equipments are to be rectified/replaced on priority.
3. Improper type of poorly designed equipment.
4. Improper equipment is not to be used as it is a potential safety hazard.
5. Defective material/defective tool.
Tools should always be maintained in perfect working conditions. Defective tool
may lead to an accident.
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 3.1.4 Unsafe Conditions:
1. Poor light.
Adequate light is must to work safely.
2. Poor ventilation.
The working area should be well ventilated.
3. Congestion.
Adequate space should be provided between the equipment.
Working area should not be congested.
4. Improper pilling, storing, stacking.
Materials are to be stored at their designated locations and to be stacked properly.
5. Exit or emergency escapes inadequate or not provided.
Sufficient emergency escape routes are to be provided.
6. Slippery floor/other places open drainage.
7. Floors are to cleaned/washed regular.
8. Trenches/ Drains should be covered properly.
9. Unsafe weather condition.
3.2 Procedure For Reporting of Accidents / Dangerous Occurrences
Objectives
In order to make prompt report of accidents, dangerous occurrences & fire accidents to
comply with requirements /obligations under different statutes/Laws; and to inform the
concerned authorities within the organization for keeping complete information of
accidents for record and analysis, which will be of help in taking remedial measures for
recurrence of such accidents.
3.2.1 Procedure for Reporting Near Miss Accidents
3.2.1.1 All near miss accidents are to be reported to Head of Safety by the Head of the
Department immediately or within 24 hrs.
3.2.1.2 Head of Safety should investigate all near miss accidents and circulate the enquiry
report along with remedial measures at the Project / Station.
3.2.2 Procedure in Case of Accidents Causing Injuries/ Fatalities
3.2.2.1 The executive of the concerned Section where the accident has occurred shall
immediately refer the injured to Hospital / Dispensary / First – aid unit with a
preliminary report. In addition he shall inform about the accident to Head of the
Department, Head of Safety by any fastest mode of communication with full
description of accident and details of the injured persons.
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 3.2.2.2 In case of injury to Contractor’s employee, the contractor shall immediately
inform the accident / dangerous occurrences to Engineer In-charge and Head of
Safety by any fastest mode of communication with full description of accident and
details of the injured persons and will arrange to the injured to Hospital. The
Engineer In-charge shall submit the information of accident.
3.2.2.3 In case injured has come / is taken directly to hospital / dispensary / first-aid unit,
the Medical Officer will inform about the incident to Head of the Department with
a copy to Head of Safety. In case of serious accident, he shall also immediately
inform the concerned as above over telephone.
3.2.2.4 Subsequently the concerned department / section In-charge will prepare a detailed
report of accident within 4 hrs of the accident.
3.2.2.5 The Head of Safety will intimate the accident to concerned Statutory Authorities
as per the provisions of relevant Act / Rules. However, the State Rules concerned
should be referred to for additional provisions, if any.
3.2.3 Procedure in Case of Dangerous Occurrences
As prescribed under the relevant rules made by the State Government with reference to
the provision of Section 88-A of the Factories Act, schedule of some common
dangerous occurrences
3.2.3.1 In case of dangerous occurrences, the same will be informed by Section In charge
to Head of Safety, Head of Department.
3.2.3.2 The Safety Officer will intimate such dangerous occurrences to Statutory
Authorities as prescribed by the State Government.

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CHAPTER-4

SAFETY
COMMITTEES

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4.0 Safety Committees
4.1 Provision for Constitution of Safety Committee:
Rule No. 41 st of Factories Act
Model Rules under Factories (Amendment) Act, 1987.
Under the above rules, the following provisions are made for Safety Committee:
1. In every factory
a. Wherein 250 or more workers are ordinary employed or
b. Which carried on any process or operation declared to be dangerous under Section
87 of the Act; or
c. Which carried on 'hazardous process' a defined under Section 2(cb) of the Act;
there shall be a Safety Committee.
2. The representatives of the management on Safety Committee shall include:
a. A senior official, who by his position in the organization can contribute effectively
to the functioning of the Committee, shall be the Chairman;
b. A Safety Officer and a Factory Medical Officer, wherever applicable and the
Safety Officer in such a case shall be the Secretary of the Committee;
c. A Representative each from the operation, maintenance and purchase departments.
3. The Workers' Representatives on this Committee shall be elected by the workers.
4. The tenure of the Committee shall be one year.
5. Safety Committee shall meet as often as necessary, but at least once in every quarter. The
minutes of the meeting shall be recorded and produced to the Inspector on demand.
6. Safety Committee shall have the right to:-
a. Ask for necessary information concerning health and safety of the workers.
b. Seek any relevant information concerning health and safety of the workers.
4.2 Function and duties of the Safety committee shall include:-
a. Assisting and co-operating with the management in achieving data aims and
objectives outlined in the 'Safety Manual' of the occupier;
b. Dealing with all matters concerning health, safety and environment and to arrive at
practicable solutions to problems encountered;
c. Creating safety awareness amongst all workers;
d. Undertaking educational, training and promotional activities;
e. Deliberating on reports of safety environmental and occupational health surveys,
emergency plans, safety audits, risk assessment and implementation of the
recommendations made in the reports;
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 f. Carrying out health and safety surveys and identify causes of accidents;
g. Looking into any complaint made on the likelihood of an imminent danger to the
safety and health of the workers and suggest corrective measures; and
h. Reviewing the implementation of the recommendations made by it.
4.3 Safety Sub Committee
Where owing to the size of the factory, or any other reason, the functions referred to in
Sub Rule (7) cannot be effectively carried out by the Safety Committee; it may establish
sub-committees as may be required to assist it.

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CHAPTER 5

SUGGESTED
CHECK-LIST
FOR
SAFETY AUDIT

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5.0 Suggested Check-List for Safety Audit
Following activities/areas should be checked during the course of Safety Audit.
5.1 Operation and Maintenance Activity:
a. Coal handling unit.
b. Boiler area.
c. Turbine area.
d. Switch yard area.
e. Control room.
f. Hydrogen Generation Plant.
g. Chlorination Plant.
h. Other auxiliaries.
In all above activities at least following aspects should be specifically seen:-
a. Requirements of Factories Act:
All provisions of the Act/Rules sets implementation should be reported.
b. Requirements of Electricity Act and Rules:
All provisions of the Act/Rules sets implementation level should be reported.
c. House Keeping.
d. Approaches.
e. Illumination.
f. Ladders.
g. Supply of personal protective equipments to employees.
h. Conditions of fire fighting installations.
i. Preparedness for disaster like fire, explosion, chlorine leakage, etc.
j. Compliance of IBR.
k. Any other information, if felt necessary.
5.2 Construction and Erection Activity:
a. Structural Erection.
b. Boiler Erection.
c. Turbine Erection.
d. Chimney Erection.
e. Civil Construction.
f. Other areas not covered above.
In all above activities following areas/system should be specifically seen and it should be
a part of report.
33
 a. Approaches.
b. Scaffolds.
c. Ladders.
d. Lifting equipments and tackles condition and test certificates.
e. Earthing of electrical equipments.
f. Condition of electrical wires/cables.
g. Support for electrical wires/cables.
h. Employment of competent and authorized electrician for doing electrical
repair/addition/alteration.
i. House keeping.
j. Guarding of dangerous machines.
k. Practices adopted during lifting of equipments.
l. Material handling.
m. Supply of personal protective equipments to construction workers.
n. Appointment/nomination of safety officers by the Principal Contractor.
o. Any other information, felt necessary.
5.3 For plants as well as projects supply and use of personal protective equipments:
a. Quantum of various personal protective equipments purchased by the Project.
b. Quantum of personal protective equipments issued to the employees.
c. Quantum of personal protective equipments stored in the store for regular or
emergency requirements.
d. Average percentage of employees using the given personal protective equipments.
5.4 Constitution and Working of Safety Committee
a. Number of Meetings held.
b. Implementation of recommendations.
5.5 Safety Training -
a. Number of training programmes.
b. Number of participants.
5.6 Use of Audio Visual Aids for Creation of Safety Consciousness
5.7 Safety Organisation
5.8 Any Other Activities, Found Necessary
Information may be submitted for following also. While assessing for safety award, this
information shall be the basis of assessment (to be implemented in second phase)

34
A. Reporting of Accidents:
a. Is the accident reporting system effective?
b. Are all accidents reported to Safety Department?
c. Is reporting figure of Hospital and safety Department same?
d. Has the Hospital maintained a separate record of accidents?
e. What are total numbers of accidents (Fatal/non-fatal) in the Project for the last
years?
B. Efforts for enhancing Safety Awareness
a. Training Programmes - Quote details including number of training programmes,
duration of programmes, subject of training and level of participants.
b. Safety Committee - Detailed constitution including name of members, main
suggestions, implementation of main suggestions & Dates of meetings.
c. Safety Suggestions
Number of safety suggestions received. Details of suggestions, number of
suggestions awarded and implemented.
d. Emergency preparedness.
Enclose emergency plan. Inquire, if it is submitted to State Government and is
approved by them.
e. Celebration of National Safety/Fire Days
Specific activities carried out during the day/week. Collect reading material etc. as
distributed.
f. Investigation of Accidents:
Inquire, if all accidents are investigated. Collect copy of reports and enclose. Find
out, if recommendations and implemented.
g. Prosecutions:
Number of prosecutions filed by State Government against the Plant. Enclose
copies thereof.
Check List for Safety Audit:
I Safety:
1. Accidents
a. Fatal & non fatal Accidents occurred in the station /Project.
b. Enquiry Committee recommendations for the above accidents occurred in
station/project

35
 c. Implementation status of Enquiry committee recommendation point wise‐‐‐List to
be enclosed
d. Details of Penalty imposed on Agencies for above Fatal Accidents occurred in
station /Project.
2. Safety Training to Employees:
a. Total number of employees in station/Project and number of employees
underwent Safety Training.
b. Name of Program ,Date of Program ,no of employees attended ‐‐‐List to be
enclosed
3. Employees participation:
Safety committee meeting dates, No of Recommendations in the meeting,
Implementation of committee recommendations.

4. Safety Promotional Activities

a. Safety week celebration
b. Safety month celebration
c. Other Safety campaigns
5. Safety literature, Manuals, Rules Job instruction cards released.
6. Compliance to safety statutory requirements as per OHSAS 18001.
7. Cross functional safety Task force for stations
a. Constitution of safety task force by Project Head
b. Functioning of cross functional Task force and no of observations made.
c. Implementation status of above observations –List to be enclosed
8. PPE issue to Employees
a. Issue of Helmet, Safety shoe and Dust mask etc. to employees.
b. Availability of fall arrestors in station/Project.
9. Housekeeping.
10. Machine Guarding and Double earthing
11. Inspection and testing of following by competent person.
a. Goods elevator.
b. Passenger Elevator.
c. EOT crane & Hoists.
d. Pulleys.
e. Wire ropes/slings.
36
 f. Total nos. of above and nos. inspected/tested category wise ‐List to be enclosed
12. O&M safety Rules and Permit to work system:
a. Functioning of Permit to work system .
b. PTW Audit conducted and its recommendations .
c. Implementation of above recommendations –List to be enclosed
d. Refresher Training on PTW conducted at station.
13. OHSAS 18001 certification status, date of Surveillance Audit done, Observations.
14. Occupational work place monitoring –coal dust, noise, recording and reporting.
15. Occupational Health check-up, no. of employees working in Hazardous areas ,check-up
done.
16. Emergency Preparedness;
a. Preparation of Disaster management Plan & latest revision made.
b. No of mock drills conducted in line with DMP and mock drill observations.
c. Implementation of mock drill observations –List to be enclosed.
d. No of Training program on DMP and no of persons covered.
17. Safety in Fuel Handling Area.
18. Safety in Water Treatment Plant area.
a. Inspection of Acid/Alkali Tanks done.
b. Availability of Chlorine detection and absorption system in
Chlorination Plants
c. No. of periodical checking /inspection done at Chlorination plant & Observations
made.
19. Contractor Safety systems
a. Deployment of Qualified Safety Officer by Agencies.
b. Safety observations made by Agency safety officer and Review.
c. Testing of winches, Elevators, Pulleys, wire rope, slings and Tackles being used
by the agencies with records of testing done and identification marks for testing
done on the Tools.
d. Testing of portable electrical hand tools of Agencies and records.
e. Provision of Earth Leakage Circuit Breakers (ELCBs) on Power Supply boards
of agency.
f. Issue of helmet, Shoe to workers and Relevant records maintained by agency .
g. Availability of fall arrestor ,Safety net with Agency.

37
 h. Safety Training provided to Agency worker and records
i. Health check up of Agency worker engaged for hazardous area & Height works
20. Statutory compliance
Inspection points communicated by Factory Inspector through his letters during his visits
to HPGCL station.

21. Previous Audit Points

a No of Recommendations of previous year Internal Safety Audit done, No of
points implemented & List of pending points
b No of Recommendations of previous year External Safety Audit done, No of
points implemented & List of pending points.
c No of Recommendations of previous PTW Audit done, No of points
implemented & List of pending points.
22. Compliance status of conference/workshop held:
a Previous Safety officers conference recommendations
b Electrical workshop Recommendations
c Occupational Health & safety workshop Recommendations
23. Detail of safety awards won by Station/Project.

II. Fire Detection & Protection System

1. Fire Station – Fire Tenders & Pumps, availability of chemicals, working conditions of
Fire Tenders & Pumps, periodicity of inspection.
2. Fuel Oil Storage Tanks – Hydrant valves, water pressure, water spray system, foam
pouring system, detection system, pressure and chemicals conditions, periodical
checking etc.
3. Transformers – Emulsifier system, nozzles, water pressure, functioning of the system,
periodicity of inspections.
4. Coal Conveyors – healthy condition of the Water Sprinkler System, Checking of
nozzles & valves, periodicity of inspections, Linear Heat Sensing system.
5. Boiler Burner Front – Water sprinkler system, working conditions
6. Cable vaults, control rooms, cable galleries – water spray system, smoke detectors,
water sprinklers and other Fire suppression system like CO2 flooding system etc.
7. Water Pumps for Hydrants & Sprinklers Systems
8. Fire extinguishers – placement, working conditions, inspection and testing facilities etc.

38
 9. Fire Detection & Fire Fighting System in the plant excluding the above areas
10. Fire Safety Committees existence, periodicity of meetings, review of previous meetings,
major recommendations, if any.
11. Details and status of auto fire extinguishing system in the Plant control room, other
vulnerable areas etc.
12. Status of Fire Emergency / control room, location, types and No. of PPE available
including self-contained breathing apparatus, Fire suites, other emergency equipments
etc.
13. Overall preparedness of the Projects / Stations with respective to Fire Hazards.
14. Any Other areas as required.
III Safety Promotion:
1. Through wall or other supporting hoardings, banners etc. safety requirement shall be
popularized for different activities;
2. Films shall be shown by safety department to all Contract Labours depicting hazards and
required control measures;
3. Each worker shall be provided one full day training at least once every 6 months.
4. Compliance of all HPGCL Safety Rules and Legal provisions shall be ensured in
accordance with GCC provisions. And violators shall be penalized as mentioned therein.
IV Issue of Permit To Work:
Following permits shall be monitored by Engineer In Charge of the same discipline along
with Safety Department
1. Permit for working at height.
2. Permit for working in excavated area / confined area.
3. Permit for working near water, where possibilities of drowning exist.
V Other Provisions:
1. Colour Coding of Helmet shall be made to differentiate between main contractor and
subcontractor.
2. Penalty shall be imposed on workers if violates Safety provisions.
3. PTW for construction work shall be issued from Safety Department after job safety
requirements are submitted by concerned Engineer in Charge.
4. Display of safety violation through projector on the same day at the key locations shall be
made.
5. Colour coding for working agencies for easy identification.

39
40
 CHAPTER-6

SAFETY GUIDLINES
FOR
CONTRACTORS

41
42
6. Safety Guidelines for Contractors
6.1 The Contractor shall ensure proper safety of all the workmen, materials, Plant and
equipments belonging to him or to HPGCL or to others working at site. The Contractor
shall also be responsible for provision of all safety notices and safety equipment required
both by the relevant legislations and the Engineer-in-charge as he may deem necessary.
6.2 The Contractor will notify in advance to the Engineer incharge of his intension to bring
any container at site filled with liquid or gaseous fuel or explosive or petroleum substance
or such chemicals which may involve hazards. The Engineer-in-charge shall have the right
to prescribe the conditions under which such container is to be stored, handled and used
during the performance of the works and the contractor shall strictly adhere to and comply
with such instructions. The Engineer-in-charge shall have the right at his sole discretion to
inspect the material in the container which is required to be used and if in his opinion, its
use is not safe , he may forbid its use. No claim due to such prohibition shall be
entertained by HPGCL and HPGCL shall not entertain any claim of the Contractor
towards additional safety provisions/ conditions to be provided for/constructed as per the
Engineer's instructions.
6.3 Further, any such decision of the Engineer shall not, in any way, absolve the Contractor of
his responsibilities and in case, use of such a container or entry thereof into the site area is
forbid by the Engineer, the Contractor shall use alternative methods with the approval of
the Engineer without any cost implication to HPGCL or extension of work schedule.
6.4 Where it is necessary to provide and/or store petroleum products or petroleum mixtures
and explosives, the Contractor shall be responsible for carrying out such provision and/or
for storage in accordance with the rules and regulations laid down in Petroleum Act 1914,
Explosives Act 1984 and Petroleum and Carbide of Calcium Manual published by the
Chief Inspector of Explosives of India. All such storage shall have prior approval of the
Engineer. In case, any approval is necessary from the Chief Inspector (Explosives) or any
statutory authority, the Contractor shall be responsible for obtaining the same.
6.5 All equipments used in construction and erection by Contractor shall meet Indian/
International Standards and where such standards do not exist, the Contractor shall ensure
these to be absolutely safe. All equipments shall be strictly operated and maintained by the
Contractor in accordance with manufacturer's operation Manual and safety instructions
and as per Guidelines / Rules of HPGCL in this regard.
6.6 Contractor shall ensure Periodical Examinations and all tests for all lifting/hosting
equipment & tackles shall be carried out in accordance with the relevant provisions of
43
 Factories Act 1948, Indian Electricity Act 1910 & amendments thereof and associated
Laws/Rules in force from time to time. A register of such examinations and tests shall be
properly maintained by the contractor and will be promptly produced as and when desired
by Engineer or by the person authorized by him.
6.7 The Contractor shall provide suitable safety equipment of prescribed standard to all the
employees and workman according to the need, as may be directed by Engineer who will
also have right to examine these safety equipments to determine their suitability,
reliability, acceptability and adaptability.
6.8 Where explosives are to be used, the same shall be used under the direct control and
supervision of an expert, experienced, qualified and competent person strictly in
accordance with the code of practices/Rules framed under Indian Explosives Act
pertaining to handling, storage and use of explosives.
6.9 The Contractor shall provide safe working conditions to all workmen and employees at the
Site including safe means of access, railings, ladders, scaffoldings etc. The scaffoldings
shall be erected under the control and supervision of an experienced and competent
person. For erection, good and standard quality of material shall only be used by the
Contactor.
6.10 The Contactor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to HPGCL or other contractors under any circumstances,
whatsoever, unless specifically permitted in writing by HPGCL to handle such fuses,
wiring or electrical equipment.
6.11 Before the Contractor connects any electrical appliance to any plug or socket belonging to
the other Contractor or HPGCL, he shall:
a. Satisfy the Engineer that the appliances are in good working condition.
b. Inform the Engineer of the maximum current rating, voltage and phases of the
appliances.
c. Obtain permission of the Engineer detailing the sockets to which the appliances
may be connected.
6.12 The Engineer will not grant permission to connect until he is satisfied that:
a. The appliance is in good condition and is fitted with a suitable plug.
b. The appliances are fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.
6.13 No electric cable in use by the Contractor/Owner will be disturbed without prior
permission. No weight of any kind will be imposed on any cable and no ladder or similar
44
 equipment will rest against or attached to it.
6.14 No repair work shall be carried out on any live equipment. The equipment must be
declared safe by the Engineer and a permit to work shall be issued by the Engineer. If
Contractor is working on electric lines/equipments whether live or dead, suitable type and
sufficient quantity of tools will have to be provided by Contractor to electricians/
workmen/officers.
6.15 The Contractors shall employ adequate number of qualified, full time Electricians/
Electrical Supervisors to maintain his temporary electrical installation.
6.16 The Contractor employing more than 100 workmen whether temporary, casual,
probationer, regular or permanent or on contract, shall employ at least one full time officer
exclusively as safety officer to supervise safety aspects of the equipments and workmen
who will co-ordinate with the Project Safety Officer. In case of work being carried out
through sub-contractors, the sub-contractor’s workmen/ employees will also be considered
as the Contractor's employees/workmen for above purpose. The name and address of such
Safety Officer of Contractor will be promptly informed in writing to Engineer-in-charge
with a copy to Safety Officer before start of the work or immediately after any change of
the incumbent is made during currency of the contract.
6.17 In case any accident occurs during construction/erection of the associated activities
undertaken by the Contractor, thereby, causing any minor or major or fatal injury to his
employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to
promptly inform the same to HPGCL’s Engineer-in-charge in prescribed form and also to
all the authorities envisaged under the applicable laws.
6.18 The Engineer-in-charge/Executive Engineer (Safety) shall have the right at his sole
discretion to stop the work, if in his opinion the work is being carried out in such a way
that it may cause accidents/ loss to the safety of the persons and/or property and/or
equipments. In such cases, the Contractor shall be informed in writing about the nature of
hazards and possible injury/accident and he shall comply to remove shortcomings
promptly. The Contractor after stopping the specific work can appeal if felt necessary,
against the order of stoppage of work to the Chief Engineer of the project of such stoppage
of work and decision of Chief Engineer in this respect shall be conclusive and binding on
the Contractor.
6.19 The Contractor shall not be entitled for any damages/compensation for stoppage of work
due to safety reasons as provided in above mentioned Para 6.18 and the period of such
stoppage of work will not be taken as an extension of time for completion of work and will
45
 not be the ground for waiver of levy of liquidated damages.
6.20 The Contractor shall follow and comply all HPGCL’s Safety Rules, relevant provisions of
applicable laws pertaining to the safety of workmen, employees, Plant and equipment as
may be prescribed from time to time without any demur, protest, contest or reservation. In
case of any unconformity between statutory requirement and HPGCL Safety Rules
referred above, the later shall be binding on the contractor.
6.21 If the contractor fails in providing safe working environment as per HPGCL Safety Rules
or continues the work even after being instructed to stop work by the Engineer as provided
in above mentioned para 6.18, the Contractor shall promptly pay to HPGCL, on demand
by the Owner, compensation at the rate of Rs.5,000/- per day or part thereof till the
instructions are complied with and so certified by the Engineer. However, in case of
accident taking place causing injury to any individual, the provisions contained in above
mentioned para shall also apply in addition to compensation mentioned in this para.
6.22 If the Contractor does not take all safety precautions and/or fails to comply with the Safety
Rules as prescribed by HPGCL or under the applicable laws for the Safety of the
equipment and Plant and for the safety of personnel and the Contractor does not prevent
hazardous conditions which cause injury to his own employees or employees of other
contractors or HPGCL employees or any other person who are at site or adjacent thereto,
then action as per the provision of contract/safety rules shall be taken against the
contractor.
6.23 Permanent disablement shall have same meaning as indicated in Workmen's
Compensation Act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of the
Workmen's Compensation Act and Rules framed there under or any other applicable laws
as applicable from time to time. In case, HPGCL is made to pay such Compensation then
the Contractor is liable to reimburse HPGCL such amount.

46
 CHAPTER 7

SAFETY
GUIDELINES
FOR
MECHANICAL
WORKS

47
48
7.0 Safety Guidelines for Mechanical Works
Employees engaged in machining and mechanical work must be familiar with and observe
relevant sections of this manual that apply to all employees. The following refer more
specifically to employees performing this type of work.
1. Always wear goggles while operating lathes, drill presses or shapers.
2. Never wear neckties, dangling sleeves or other loose clothing while operating or
working close to moving machinery.
3. When using a drill/press, the work should be securely clamped to the table, jig or
chuck.
4. Always use a brush to remove cuttings from a machine. Never use your hands.
5. Whenever compressed air is used for cleaning, the same should not be done
without the consent of Engineer in-charge.
6. Do not stand in line with high speed wheels. Do not use emery wheels that are out
of round. For side grinding, use only the special wheels provided for this work.
7. Before using a grinding wheel, be sure that the guards are in place and that the
tools rest is properly spaced. The guard shall be adjusted so that clearance between
the grinding surface and the guard is proper. Do not adjust while the wheel is
moving.
8. Never use files without handles.
9. Before making repairs to any pump, valve or any other piece of mechanical
equipment, be sure that the pressure has been released, fluid are drained and lines
are drained or properly isolated.
10. Before starting work on operating equipment, obtain permission from the shift in
charge and see that the equipment is properly isolated.
11. Before starting work on a chemical or hot oil equipment, keep proper protective
equipment on hand and available for use.
12. Oil spillage should be cleaned up promptly, and waste rags put in metal containers
provided for that purpose.
13. Clothing that has become saturated with any chemical or oil should be changed at
once. If any portion of the body is affected, it should be washed thoroughly with
water. A report must be made to your supervisor.
14. Always keep passageways clear and free of oil and litter.

49
 15. When performing work on internal parts of an engine, be sure that the engine has
been properly tagged or locked out of service and a work permit obtained before
operating a drill or doing other work likely to cause sparks.
16. Inspect the ceiling hoist thoroughly before lifting heavy loads. Never overload
chain hoists or walk under suspended loads. The capacity should be properly
marked on the hoist.
17. Always have adequate ventilation when doing metalizing work.
7.1 Moving Equipments
Before starting any equipment with moving parts:
1. Be sure that all safety guards are properly in place.
2. Be certain that all personnel are clear of moving parts.
3. Check start-up procedure.
7.1.1 Before shutting down any equipment with moving parts and turning over to
maintenance:
1. Check shut down procedure
2. Shut down the equipment.
3. Be sure that prime mover is secured safely from the power source and check the
following:
i. Electrical equipment must be shut off at the switchbox and locked until the work is
completed.
ii. Steam or fuel valves should be closed and locked or blinded until the work is done.
iii. If the work is to be done on the prime mover, the fuel or steam must be blinded or
double-blocked.

7.1.2 Fencing of Motors etc.

Engineer-in-charge / Supervisor shall ensure at a construction site of a building or other
construction works that:
1. All motors, cogwheels, chains, and friction gearing, flywheels, shafting, dangerous
and moving parts of machinery (whether or not driven by mechanical power) and
steam pipes are securely fenced or lagged.
2. The fencing of dangerous parts of machinery is not removed while such machinery
is in motion or in use;
3. No part of any machinery which is in motion and which is not securely fenced is
examined, lubricated, adjusted or repaired except by a person skilled for such

50
 examination, lubrication, adjustment or repairs;
4. Machine parts are cleaned when such machines is stopped;
5. When a machine is stopped for servicing or repairs, adequate measures are taken to
ensure that such machine does not re-start inadvertently.
7.1.3 Lifting And Carrying Of Excessive Weight:
Engineer In-charge/Supervisor shall ensure at the construction site of a building or other
constructions work that:
No building worker lifts by hand or carries overhead or over his back or shoulders any
material, article, tool or appliances exceeding in weight the maximum limits set out in
the following table:
Person Maximum Weight Load
Adult – man 56 kg
Adult - woman 30 kg
Adolescent – male 30 kg
Adolescent - female 20 kg
Unless aided by any other building worker or a Mechanical device
7.1.4 Slipping, Tripping, Cutting, Drowning and Falling Hazards:
1. All passageways, platforms and other places of construction work at the building or other
construction work shall be kept by the employer free from accumulations of dust, debris or
similar material and from other obstructions that may cause tripping.
2. Sharp projections, protruding nails or similar projections that may cause injury to a
building worker at the building or other construction site shall be removed or otherwise
made safe by taking suitably measures.
3. Don’t allow any building worker at the building or at other construction work to use the
passageway, or a scaffold, platform or any other elevated working surface which is in a
slippery and dangerous condition and shall ensure that water, grease, oil or other similar
substances which may cause the surface slippery, be removed or sanded, saw dusted or
covered with suitable material to make it safe from slipping hazard at a building or other
construction work.
4. Wherever building workers at a building or at construction work are exposed to the hazard
of falling into water, they shall be provided with adequate equipment for saving
themselves from drowning and rescuing from such hazard and if HPGCL authority
considers necessary, well-equipped boat or launch manned with trained personnel shall be
provided at the site of such work.
51
 5. Every open side or opening into or through which a building worker, vehicle or lifting
appliance or other equipments may fall at a building or other construction work , shall be
covered or guarded suitably to prevent such fall except where free access is necessary by
reasons of the nature of the work.
6. Wherever building workers at a building or other construction work are exposed to the
hazard of falling from height while employed on such work, they shall be provided with
adequate equipment or means such as safety net etc. for saving them from such hazards.
Such equipment or means shall be in accordance with the national standards.
7. Whenever there is a possibility of falling of any material, equipment or building worker at
a construction site relating to a building or other construction work, adequate and suitable
safety net shall be provided in accordance with the national standards.
7.2 Cranes and Other Lifting Machines and Tackles
7.2.1 Introduction

Lifting machines includes cranes, crabs, winches, tackles, pulley blocks, gin wheels,
transporter or runway chain ropes, lifting tackles i.e. chain slings, rope slings, rings,
hoods, shackles and swivels etc.
7.2.2 General Instructions
1. The maximum safe working load in kg, should be marked on each hoisting apparatus at a
conspicuous place.
2. The hoisting apparatus should not, except for actual testing purposes, be loaded beyond
the maximum safe working load.
3. It is the responsibility of the operating personnel and his supervisor to ensure that any
equipment is not overloaded.
4. In case of mobile cranes, the safe loads at various angles of the boom and jib should
clearly be indicated on such crane and indicators should be affixed showing the angles of
the boom or jib in various positions.
5. Loads should be raised and lowered smoothly, avoiding, sudden starts and stops or jerks.

6. It is the duty of the operating personnel and the supervisor-in-charge to ensure that no
person remains in a position of danger in the course of lifting operation.
7. Riding on loads being lifted or lifting of personnel up or lowering them on crane ropes is
strictly forbidden.
8. When lifting the load which necessitates signals to the operator from the ground or
intermediate floors, one man should be detailed for this duty by the person supervising the
52
 job and made known to the operator so that he should take the instructions from the
deputed person only.
9. Hands or feet should not be removed from the controls while a load is suspended.
10. If there is a power failure during the operation of an electric crane, the control should be
thrown to the off position. The area under the suspended load should be cordoned.
11. Loads should not be carried over the head of other employees.
12. Before lifting and unloading overhead crane, the hooks and slings should be raised to a
height above all fixed and moving objects below, such as pedestrians or vehicles etc.
13. When the operator of a crane takes over charge, it is his first duty to check the controls of
the crane and see that the crane tracks are clear. He should satisfy himself that:
a. All guards, such as guards over gears, couplings, rotating shafts etc. are in place.
b. The limit switches and other electrical and mechanical devices are in proper working
condition. He should also run the block up or down to see that the wire rope is
winding on the drum properly. While doing this, he can scan the rope to see if it has
any kinks or exposed broken strands.
14. Before the main switch is closed/on, the operator should check to see that all controls are
in “OFF” position.
15. Any defect in the crane including unusual noise or faulty operation such as sparking
motors, bridge jumping or binding, slow response from controls etc. should be reported to
the Engineer-in-charge for immediate rectification before attempting to lift a load.
16. The crane operator is responsible for the safe operation of the crane and he should follow
the following principles:
a. Avoid placing an additional strain on the crane or swinging the load. The operator
should be certain that the hook is directly over the load to be lifted.
b. Loads or equipment should not be moved by sliding or dragging them on the floor or
ground.
c. The bridge or trolley should not be started before the load is lifted from the ground to
the desired height.
d. The block should never be lowered to a point where less than two full wraps of the
cable are on the drum.
e. When a long sling is attached to a load, consideration should be given to the height
of the lift, so as to prevent the block from tripping the limit switch.
f. The limit switch is a safety device. It is not designed as a control and must not be
used to stop the hoist.
53
 g. When picking up a heavy load, it is advisable to lift the load slightly and test the
brake.
h. When two cranes are operating independently on the same rails, they should
maintain a safe distance between them. When two cranes are used to lift the same
load, the work should be carefully supervised by a responsible engineer.
i. The hoisting cable must not be slung round a load to be used as a sling. If a crane is
equipped with chain, loads should never be lifted while chain is kinked.
j. The operator should not allow the crane to bump against rail stops.
k. When boom cranes are used, the boom should be lowered to a horizontal position
when it is not in operation.
l. If a warning bell, gong, whistle or siren is available, use it to warn everyone that you
are starting to move a load.
m. It is the responsibility of the operator to ensure that the jobs do not fall on overhead
electric lines or structures etc. Under no circumstances an attempt should be made to
raise electrical wires by anyone other than the electrical personnel.
n. When any person is working on or near the wheel track of an overhead crane,
effective measures should be taken to ensure that the crane does not approach within
6 meters of the place where he is working.
o. A minimum distance of 2 meters must always be maintained between the boom or
load and all power lines or feeders. In case , it is not possible to maintain safe
clearance for any particular job, the Engineer-in-charge of such jobs should consult
in advance of the operation of the crane with the Electrical authorities so that the
power lines may be de-energized to avoid accidents.
7.3 Hoisting Tackles
1. All hoisting tackles should conform to the standard specifications.
2. Rings, hooks, shackles, swivels and links for hoisting and sling chains should be made of
the same material as the chains to which they are fastened. When the latter are of wrought
iron of ordinary steel, special care should be considered individually.
3. The factor of safety for all hoisting tackles should be as per OEM recommendation.
4. All repairs of chains should be done by experienced men or by chain manufactures. Make-
shift repairs are dangerous. Do not use bolts or nails to fasten two links together.
7.4 Wire Ropes
1. Wire ropes for hoisting, lowering or hauling loads should conform to the standard
specifications.
54
2. The factor of safety for wire ropes should not be less than six.
3. Eye splices and loops for the attachment of hooks, rings and other parts to wire ropes
should be provided with suitable thimbles.
4. Size, material and the maximum safe working load should be marked on all cranes/lifting
machines by means of metal tags or any another suitable way.
5. Depending upon the physical condition of Wire ropes due to which their strength is
affected eg. broken wires (strands), corrosion, kinds etc. same should be immediately
removed from service.
6. Ends of wire ropes should be seized to prevent the strands from becoming loose.
7. In order to keep wire rope pliable and prevent from rust, the ropes should be treated at
regular intervals with a suitable lubricant free from acid or alkali or as recommended by
the OEM.
8. Wire ropes should be stored in a cool place, which is free from moisture, excessive heat
and corrosive fumes.
7.5 Fiber Ropes
1. Fiber ropes for hoisting, lowering, or hauling loads should be of high grade Manila hemp
or other hemp of equal quality and the factor of safety of such ropes should not be less
than ten.
2. Manila rope is stronger, easier to handle and will not kink as badly as sisal or their fiber
ropes.
3. When ropes of fiber other than high grade manila rope are used for hoisting purposes,
proper allowances should be made for the proportionate tensile strength. All fiber ropes
should bear a metal tag indicating the maximum permissible load, date of placing in
service and the name of the supplier.
4. Eye splices on fiber ropes should be made round with suitable thimbles.
5. When two ropes have to be joined-it should be spliced instead of being knotted. Splices
are safer and stronger than knots for permanent connections. The use of knots reduces the
strength of a rope by as much as 50% while a short or long splice reduces it only by 5% to
10%.
6. Rope should not be dragged along the ground, or rough surfaces. Always use padding on
sharp edges and corners to avoid cutting of the rope.
7. Fiber ropes should not be used for hoisting purposes or stored in locations where they will
be exposed to contact with acid, alkali or other fumes or other destructive chemicals.

55
 8. Always dry the ropes after wetting. A dry unheated room with good ventilation is the best
place of storage. Place ropes in loose coils off the floor on wooden pegs. Manila ropes will
rot very quickly if it is kept wet and is not properly dried.
9. Wet ropes should not be piled against steam pipes to dry. This will dry out the natural
moisture and destroy the life of the fiber.
10. Always inspect ropes at frequent intervals while in use and also before placing it in
storage if it has been subjected to any wear of destruction by the action of corrosive
chemicals and their fumes.
7.6 Hooks and Rings
1. Hooks and Rings used with chains should be of material at least as good as that of chain.
Forged steel is preferable in every case and especially for lifting heavy loads.
2. A ring must be strong enough to carry a load equal to the sum of safe loads of the attached
chains.
3. When a hook has been bent by overloading it should be used where there is a danger of
catching on an obstruction. The maximum safe working load should be stamped on each
hook for hoisting apparatus.
7.7 Slings
1. Slings for hoisting purpose should be of sufficient strength to carry the loads to which they
will be subjected.
2. The maximum safe working load should be legibly marked in a suitable manner and the
slings should be conforming to standards applicable to chains, wire ropes etc.
3. When placing hoist slings around sharp edges or with projections etc., pads should be
inserted between the load and the slings in such places.
4. Where double or multiple slings are used for hoisting purposes, the upper end of the slings
should be connected by means of suitable shackle or ring and should not be placed
separately in the lifting hook.
5. Hoisting slings that show evidences of cuts, excessive wear or other damages, should be
discarded and destroyed.

56
 CHAPTER-8

SAFETY
GUIDELINES
FOR HANDLING
CHEMICALS

57
58
Safety Guidelines for Handling of Chemicals
8.0 General
Precautions to be taken in handling the various chemicals used in the Power Houses are as
under.
1. Treat all chemicals as toxic.
2. Avoid contact of the chemicals with eyes, bare skin or clothing.
3. Avoid breathing chemicals, dust or vapour.
4. Before starting any job involving use of chemicals:
a. Read the instructions on the container.
b. If there is an indication on the label that the chemical may be toxic, be sure that
you know the specific precautions to be followed in its use. Ask your supervisor if
you are uncertain.
c. Plan the job to avoid direct physical contact with any chemical or its dust or
vapour.
5. All the chemicals used in Plant are not listed. Employees are expected to become familiar
with the details of hazardous materials used in their unit or section so that safe handling
becomes an integral part of the job.
6. The hydrocarbons we process are all flammable in various degrees depending on their
temperature and concentration of their vapours in air. Most of them dissolve fat from the
skin. This leads to dryness, cracking and possible dermatitis.
7. Hydrogen gas is hazardous due to its high inflammability and colorless flame due to
which it is difficult to detect.
8. The presence of harmful materials in a place of work does not constitute a hazardous
condition provided that these materials are handled keeping in view the potential hazard
involved.
8.1 Sulphuric Acid
8.1.1 Nature
Sulphuric Acid is a viscous, oily, corrosive liquid with a strong affinity for water, which it
removes from organic materials. It chars and destroys Plant, animal or body tissues. In
concentrated form , it acts on the skin destroying the epidermis penetrating some distance
into the skin and sub-cut-tissues, causing necrosis. Inhalation of acid can cause
inflammation of the upper respiratory tract leading to bronchitis and damages to lung
tissues. Serious eye injury and permanent coronal damage may result even with small
amount of acid in the eyes.

59
8.1.2 Precautions in Handling
1. Whenever handling sulphuric Acid or when taking up maintenance of lines, vessels or
drums etc. which contain or have contained Sulphuric acid, use personal protective
Equipment (PPE) such as tight fitting chemical goggles / face shield / hood, rubber apron /
jacket, rubber hand gloves, rubber boots etc.
2. Unprotected lights and fires should be kept away from sulphuric acid lines or storage
tanks as hydrogen may be evolved from the action of the acid on certain metals.
3. In preparation of equipment for mechanical work, care shall be taken to ensure complete
removal of all sulphuric acid from lines, pumps etc. by steaming and flushing prior to
handing over for the maintenance work.
4. Avoid all contacts of inhalation of fumes by using a gas mask with a canister to protect
against exposure to acid gases.
5. Adequate fresh water supply should be available for emergency washing.
6. Closed vessels should be vented periodically to release hydrogen, if formed.
8.2 Ammonia
8.2.1 Nature
Ammonia is a colorless gas with penetrating pungent suffocating odour. It liquefies under
pressure and is soluble in water. When liquid ammonia or ammonia solution is exposed to
the air , suffocating fumes are given off which are harmful to the eyes and respiratory
organs. Ammonia attacks the skin rapidly and is poisonous if swallowed in solution. It
burns when mixed with air in concentration of 16% to 25% by volume. Contact with
liquid ammonia can cause frost bite. When contacted in eye, can produce temporary
blindness to severe blindness.
8.2.2 Precautions in Handling
1. Rubber gloves, boots and goggles must be worn when working on equipment containing
ammonia.
2. Respiratory safety equipment should be used when schedule to work on leaks or when
other conditions warrant. Gas masks with canister are useful for concentration upto about
3%.
3. All persons who work on ammonia should be familiar with emergency procedures in case
of serious leaks.
8.3 Caustic Soda
1. Caustic soda in the anhydrous form is white to slightly colored pallets. In solution, it is
clear to slightly turbid liquid.
60
 2. It causes severe skin burns often resulting in dead ulceration.
3. Eye contact can result in severe damage. Rapid inhalation results in damage to upper
respiratory tract and also lung tissues. Ingestion can cause severe damage to inner
membranes. Penetration into vital area may be fatal.
8.3.1 Precautions in Handling
1. Use goggles, face shields, rubber aprons, jackets, rubber hand gloves and rubber boots as
protective equipment whenever handling Caustic Soda. Be careful about spilled caustic
soda while opening its drums making solutions or sampling.
2. Use all the above equipment while going near any leak to stop it.
3. Avoid inhalation of caustic vapours and splashing of caustic soda.
4. Whenever caustic solution is spilled, wash it immediately. Never leave the spillage of this
material unattended.
5. Use all the safely equipment (face shields, goggles, rubber aprons / jackets, rubber hand
gloves, rubber boots etc) while sampling or doing any other job near or on the caustic
handling facility, even if the job is quite small/minor.
6. Always keep a water hose ready nearby.
7. Avoid pipetting by mouth.
8.3.2 Emergency Treatment
1. If any part of the body has been contaminated by Caustic Soda. Wash it off quickly with
water.
2. If clothing is contaminated, remove it while under the shower and wash the body
thoroughly.
3. If eyes are involved, wash them with abundant quantity of water.
4. Report to nearby hospital for medical attention.
8.4 Chlorine
8.4.1 Nature
Gaseous chlorine is of a yellow green color and has a density two and a half times that of
air, so it tends to flow downwards and collect in low spots. Moist chlorine is extremely
reactive and attacks metals. It is extremely irritating to the mucous membrane of the eyes
and respiratory tract. If taken to lung, it will destroy the tissues and cause severe lung
edema. It is so intensively irritating that the concentrations above three to five ppm by
volume in air are readily detectable by a normal person. The threshold limit value of
chlorine accepted at present is 3 mg/m3 of air (1ppm).

61
8.4.2 Precautions in Handling
1. Chlorine leaks must be immediately attended. Leaky valves must be repaired by tightening
the packing nut.
2. Containers should be stored with enough room between them so that leak is completely
accessible in case of an emergency.
3. Employees who handle chlorine must use respiratory safety equipment.
4. Following procedure should be followed when a leak is detected in a chlorine container:-
a. Warn all people to move upwind of the leak and stay out of the contaminated area.
b. Notify your supervisor of the leak at once.
c. Remove anyone who has been overcome by chlorine. Be sure that the first aid is
rendered at once.
d. When plugging a leak, wear impervious clothing and suitable respiratory safety
equipment.
e. If leak cannot be stopped, disconnect the container and move it away from the
Plant and personnel to a place where it can empty itself without creating a further
hazard.
5. Cylinders should neither be lifted by means of the metal cap nor by a magnet.
6. Unloading platform should preferably be at truck level. One ton container should be
handled with suitable cradle with chain slings in combination with a hoist or crane having
at least two metric tons capacity.
7. If liquid chlorine or chlorinated water has contaminated skin or clothing, the emergency
shower should be used immediately. Skin should be washed with large quantities of water
and soap. No attempt should be made to neutralize chlorine with chemicals.
8. Always provide chlorine emergency kit and a neutralization pit near chlorine cylinder
handling area.
8.5 Hydrochloric Acid:
8.5.1 Nature:
It is colorless gas with pungent/suffocating odor. It is soluble in water. It is non
combustible in nature. Contact with common metals produces hydrogen which may form
explosive mixture in air, when heated toxic & corrosive hydrogen chloride gas is released.
Inhalation of vapours causes imitation of upper respiratory tract, coughing, burning of
throat and choking. Inhalation of higher concentrations can be dangerous. Ingestion can

62
 cause severe irritation, bumming of throat etc. Skin contact can cause bums. Contact with
eyes can cause severe bums and damage.
8.5.2 Precautions:
Protect container against physical damage. Store in cool well ventilated place away from
oxidizing materials. Use face shields, PVC hand gloves and PVC suits to avoid skin and
eye contact. In case of eye / skin contact, flush eyes/skin immediately with plenty of water
for 30 min. or more and remove contaminated clothing.
8.6 Hydrogen:
8.6.1 Nature:
Hydrogen is colorless / odorless gas lighter than air. It is highly flammable & explosive in
nature. Container may explode violently. It reacts vigorously with oxidizing materials. It is
relatively nontoxic but can cause asphyxiation by misplacing air. Contact of liquid
hydrogen with skin can cause frost bite.
8.6.2 Precautions:
Protect the container against physical damage. Outside storage is preferred. Isolate from
oxidizing gases especially chlorine. Store in well ventilated place and it should be away
from possible source of ignition & combustible materials. Allow to burn unless shut off
can be effected. Fight fires from safe distance. In case of contact of liquid hydrogen with
skin & eyes, remove contaminated clothing; flush affected area with plenty of water.

63
64
CHAPTER-9

SAFETY
GUIDELINES
FOR
ELECTRICAL
WORK

65
66
SAFETY GUIDELINES FOR ELECTRICAL WORK
9.1 General
Electricity, if not properly used, may be the cause of both fire and personal injury.
However, if used in accordance with well established methods, electricity presents one of
the safest and most convenient means of illumination, power and heating. Electricity may
become a fire hazard through arcing, sparking or over- heating. It presents casual hazards
through burns , shocks or fall. Therefore, to minimize and avoid electric hazards, electrical
safety rules and rules of electrical installations must be followed strictly.
9.2 Recommendations
1. Electrical department is responsible for installation, alteration, maintenance and up-keep
of all equipment for generation, distribution and utilization of electric power. Only
qualified members of the department must undertake work on electrical equipment,
wiring, alteration of any circuit etc.
2. All wiring installations must comply with the standard electrical code. The following
hazards are likely to develop from the wiring itself:
a. Corrosion of metal covering or enclosure of conductors.
b. Conductors overloaded.
c. Joints not properly soldered, taped or otherwise made safe.
d. Covers of outlet or junction boxes removed.
e. Deterioration of mechanical strength or insulation of conductor.
f. Corrosion & loosening of supports.
3. All circuits must be protected by fuses of the correct rating or other over-current protective
devices.
4. Conductors of open wiring systems must be separated/electrically insulated from their
supports, in contact with pipes, woodwork, other conducting or combustible material.
5. Be sure that all the switches have been put off and proper isolation has been carried out by
removing the fuses; taking out breaker trolleys or opening the disconnector /isolator as the
case may be before starting work on any wiring or equipment or overhead lines. Where
power is supplied from more than one source, be sure that the supply is cut off from all
sources and check that the right switches are cut-off.
6. High tension lines or equipment must be made dead by an Electrical Engineer only or a
person deputed by him and preceding rule (4) should be followed. Before starting any
work, lines or equipment must be short circuited all the 3 phases and earthed by using
Earth electrodes/Earth stick and a clearance certificate must be issued.
67
7. Use of temporary wiring should be avoided as far as possible. It should either be made
permanent or dismantled within certain period after installation. If it may remain in
position with the permission and approval of Electrical Engineer who should thoroughly
check it at intervals.
8. The electrical department must inspect at regular intervals all portable and temporarily
installed electrical equipment and check for earthing when a connection is made.
9. In hazardous areas, only flame-proof electrical equipment, protection must be used. In all
dangerous areas, use of extension cords or portable temporary electrical equipment etc.
must be avoided as far as possible.
10. Whenever water is used for washing floor or any equipment, protection of electrical
equipment must be assured from splashing of water on them. In locations where
considerable moisture may be present, specially designed water-tight fittings should be
used.
11. Before demolition work is started on any building or process Plant, the wiring, especially
the lighting wire must be disconnected from the power supply. The responsibility for
disconnecting power supply as above rests with the Engineer-in-charge of demolition
work. Electrical department should ensure the disconnection.
12. For the operation of electrical machine, operators are allowed to handle the operating
controls only. They must on no account open up or tamper with any other electrical part of
the machine. If any defect develops, this must be reported to the Electrical Department.
13. Electrical Department will carry out regular inspection and tightening up of all current
carrying and earthing connections on motors and other Plant equipment that might
possibly be subjected to vibrations and keep a record in the log book.
14. While extinguishing fire in electrical equipment, the power supply must be switched off
first and if the fire still continues, use fire extinguishers having electrically non-conducting
extinguishing materials like DCP or CO2. It is not advisable to use soda acid, foam type
extinguishers on fires in electrical equipment. Only DCP or CO2 extinguishers should be
used.
15. Employees should regard all electrical wires as live and dangerous and are warned against
permitting any object being handled to come in contact with electrical lines. Any wire
found hanging from a pole or any other electrical equipment should be reported
immediately to the Electrical Engineer.
16. It is necessary to tag out electrical switches and starters of equipment, so that inadvertent
starting of electrical equipment is avoided.
68
 17. Before starting work on a Power Transformer, make sure that it is isolated completely i.e.
both from HV and LV side and the residual charge/stored energy is discharged.
18. All employees should wear proper personal protective equipment on all jobs where
required. Electrician gloves, rubber mats etc. must be inspected for punctures or other
defects/damages before their use each time.
19. While doing work on overhead lines, which may cause danger for the pedestrians passing
beneath, a sign to be placed prominently “Danger- Men working overhead”.
20. Do not attempt to free somebody who comes in contact with live conductors with bare
hands. Try to disconnect/switch off the power supply, if not possible, put on rubber gloves
or thick fold of dry clothing before attempting to release the victim. If live wires are
directly upon the victims a dry stick should be used for removing the wires. Artificial
respiration to be given If the victim ceases to breath as a result of electric shock as soon as
he is freed from the electrical contact.
21. Working areas in the Fuel oil Tank should be adequately illuminated so that work can be
done conveniently at night.
22. All temporary electrical connections should be got done to conform to statutory
regulations & a certificate obtained by the authorities. As far as possible, the cable to be
safely buried to ensure free access to equipments & machinery movement.
23. Earthing of machines and equipment shall be ensured and no open/ bare connections
allowed.
24. Danger signals & safety tags in the live areas shall be demonstrated properly.
25. For temporary electrical connection to construction area, main switch board should be at
least 1mtr above the ground level.
9.3 Construction, Installation, Protection Operation and Maintenance of Electric
Supply Lines and Apparatus
1. All electric supply lines and apparatus shall be of sufficient ratings for power, installation
and estimated fault current and of sufficient mechanical strength, for the duty which they
may be required to perform under the environmental conditions of installation, and shall
be constructed, installed, protected, worked and maintained in such a manner as to ensure
safety of human beings, animals, and property.
2. The relevant code of practice of the Bureau of Indian Standards including National
Electrical Code if any may be followed to carry out the purposes of this rule and in the
event of any inconsistency, the provision of these rules shall prevail.

69
 3. The material and apparatus used shall conform to the relevant specifications of the Bureau
of Indian Standards where such specifications have already been laid down.
9.4. Service Line and apparatus in various working areas.
1. The Electrical Department shall ensure that all electric supply lines, wires, fittings and
apparatus belonging to him or under his control for which electric supply is to be given are
in a safe condition.
2. Service-lines by the Electrical Department shall ensure to secure the system under all
ordinary conditions against electrical, mechanical, chemical or other injury to the
installation.
3. The Electrical Department shall also ensure that the installation under his control is
maintained in a safe condition.
9.5 Accessibility of Bare Conductors
Where bare conductors are used in a building, the Electrical department shall
1. Ensure that they are inaccessible.
2. Provide in readily accessible position switches for rendering them dead whenever
necessary; and
3. Take such other safety measures as are considered necessary.
9.6 Danger Notices
The owner of every medium, high and extra-high voltage installation shall affix
permanently in a conspicuous position a danger notice in Hindi or English and the local
language of the district, with a sign of skull, bones and voltage level as per the relevant
ISS No. 2551 on:
1. Every Motor, Generator, Transformer and other Electrical Plant and equipment together
with apparatus used for controlling or regulating the same;
2. All supports of high and extra-high voltage overhead line which can be easily climbed-
upon without the help of ladder or special appliances.
Explanation Rails, tubular poles, wooden supports, reinforced cement concrete poles
without steps. I-sections and channels shall be deemed as supports which cannot be easily
climbed upon for the purposes of this clause.
3. Luminous tube requiring high voltage supply, X-ray and similar high-frequency
installations:
Provided that where it is possible to affix such notices on any Generator, motor,
Transformer or other apparatus, they shall be affixed as near as possible thereto or the
word 'danger' & the voltage of the apparatus concerned shall be permanently painted on it
70
 Provided further that where the Generator, motor, Transformer or other apparatus is within
an enclosure one notice affixed to the said enclosure shall be sufficient for the purposes of
this rule.
9.7 Instructions for Restoration of Persons Suffering from Electric Shock
1. Instructions, in English or Hindi and the local language of the district and where Hindi is
the local language, in English and Hindi for the restoration of persons suffering from
electric shock, shall be affixed by the owner in a conspicuous place in every generating
station, enclosed sub-stations, enclosed switch-stations and in every factory as defined in
clause (m) of section 2 of the Factories Act, 1948 (63 of 1948) in which electricity is used
and in such other premises where electricity is used.
2. Copies of the instructions shall be supplied on demand by an officer or officers appointed
by the Central or the State Government in on this behalf at a price to be fixed by the
Central or the State Government.
3. The owner of every generating station, enclosed sub-station, enclosed switch-station and
every factory or other premises to which this rule applies, shall ensure that all authorised
persons employed by him are acquainted with and are competent to apply the instructions
referred to in sub-rule (1).
4. In every manned high voltage or extra-high generating station, sub-station or switch
station, an artificial respirator shall be provided in good working condition.

71
72
 CHAPTER 10

SAFETY
GUIDELINES
RELATED TO FIRE

73
74
Safety Guidelines Related to Fire
10.1 Introduction:
In view of the fire incident in the power houses, fire protection facilities have to be
provided & fire department has to be always well prepared & ready to tackle
effectively any fire occurrence. Hazardous situation in the Plant premises cannot be
ruled out as materials like wood, plastic, paper, oil, lubricants, electric cables etc. are
used.
This fire order provides compiled information on details of fire protection facilities
and fire prevention guidelines. It is expected that everyone will study and adopt the
procedures and precautions and be well conversant with all responsibility during any
emergency situation.
10.2 Fire Extinguishers:
10.2.1 Portable fire extinguishers are provided at conspicuous and accessible locations on
each floor so that these can be utilised to control the fire when it is in an incipient
stage and easiest to control.
10.2.2 The fire extinguishers provided are of Water Type gas fire extinguishers, Carbon
dioxide fire extinguishers, DCP fire extinguishers, AFFF fire extinguishers etc.
1. Water type gas extinguishers contain liquid carbon dioxide cartridge surrounded
by water. When top knob of extinguisher is hit, the gas cartridge breaks and CO2 gas
forces water to come out through the outlet nozzle in the form of a jet which
extinguishes fire primarily by its cooling action. These water type gas extinguishers
are good for fighting fires due to plastic, foam, wood, paper etc. These extinguishers
should not be used on electrical equipment since water conducts electricity and makes
the user vulnerable to electrical shocks.
Directions and precautions for use:
a. Take the extinguisher from the box and bring it near to the fire.
b. Hold up right and remove the safety clip from the knob.
c. Strike the knob with the palm of the hand.
d. Direct the jet to the base of the flame by means of hose pipe.
2. CO2 Type Extinguishers contain liquid carbon-dioxide in the cylinder body which
comes out on opening the valve in the form of gas. CO2 gas extinguishers extinguish
fire by reducing the oxygen content of surrounding air to appoint where combustion
can’t sustain itself. It is mainly used for fighting fires on electrical or electronic
equipment.
75
 Directions and precautions for use:
a. Carry the extinguisher to the place of fire.
b. Remove the safety pin and unscrew the valve of the extinguisher.
c. Direct the jet at the base of the fire starting at one edge and sweeping across the
burning material.
d. When use in open air, Operator should stand upwind direction and apply the gas
in a downward direction.
e. Direct the gas as close as possible to the fire.
f. The gas at the time of discharge makes considerable noise. The user should,
therefore, be well conversant with its operation and prevent the jet from being
misdirected during first few vital seconds.
3. DCP Fire Extinguisher can be used on any electrical fire.
Direction and precaution for use:
a. Pull out safety pin from valve
b. Aim discharge nozzle at the base of Fire
c. Pressure control lever of the Extinguisher
4. AFFF Fire Extinguishers can be used for Extinguishing Class ‘B’ fire involving
flammable liquids like petroleum products, HFO, LDO etc. Foam acts as a
extinguishing medium by providing blanketing effect.
Direction and precaution for use:
a. Pull out safety pin from valve.
b. Aim discharge nozzle at the base of Fire
c. Pressure control lever of the Extinguisher.
d. Direct the jet to the base of the flame.
10.3 Fire Exits/Escape Routes
1. Fire exits are provided on each floor. In the event of a fire, occupants should vacate
the building by using either the main staircase or the spiral staircase in fire Exits.
2. The key of the fire Exits are kept in the glass boxes provided at the entrance of the
fire Exit. To open the fire Exit, one has to break the glass and take out the key of the
fire Exit.
3. All employees should in their own interest, know the fire Exits of various floors.
4. Ensure that fire Exits do not have any obstruction.
10.4 Fire Prevention Measures:
1. An enhanced awareness of fire protection equipment and facilities is the first step
76
 towards fire prevention.
2. Do not smoke in the office as smoking is banned in HPGCL Offices. If any one does
in his own interest, we must object and also report.
3. Do not keep electrical appliances "ON" unnecessarily. Switch off fans, tube lights,
A/C etc. while leaving the office.
4. Smoke coming out of electrical appliances or smell of burning electrical wiring must
be reported to Administrative/Safety Department immediately and supply should be
switched off.
10.5 Classification of Fires
Fires are classified in four groups based on the type of material under fire.
1. Class "A" fires involve solid materials of organic nature like wood, paper, textiles,
etc. A cooling media like water is essential for extinguishing such fires.
2. Class "B" fires involve flammable liquids like petroleum products, solvents, paints
etc. Blanketing effect with foam or heavy gas like CO2 is essential for extinguishing
these fires.
3. Class "C" fires involve gases or liquefied gases under pressure. It is necessary to
isolate the burning gas at a fast rate with an inert gas, powder or vaporizing liquid for
extinguishment. CO2 or DCP should be used for extinguish such fires.
4. Class "D" fires occur in combustible metals like magnesium, sodium etc. and
specialized techniques and extinguishing agents are needed to control such fires.
Special dry powder should be used in such cases.
10.6 What to do in Case of Fire:
1. Attempt to extinguish fire using appropriate fire extinguisher.
2. Switch-off power supply in case the fire involved electrical equipment.
3. Inform fire department immediately on telephone numbers displayed at various
locations like control room and critical sites fire station security on their Telephone
numbers.
4. Use CO2 or DCP type extinguisher only on electrical fires.
5. In case fire is spreading beyond control then employees should rush to the nearest Fire
Exit and leave the floor. Fire brigade staff will take care of fire fighting thereafter.
6. While evacuating the floor, employees should have a quick look for any suspicious or
unusual object lying on the floor/passage.
7. Help handicapped colleagues, if any, on your floor or any others who may need help.

77
10.7 What Not to do in Case of Fire:
1. Do not panic.
2. Do not stop to collect personal belongings.
3. Do not use lifts and make use of staircases only.
4. Never leave the fire Exit door open unnecessarily in the event of fire as smoke may
enter the fire Exit staircase thereby making the evacuation of other employees
difficult.
5. Water based fire extinguishers should NEVER be used on electrical fires since water
conducts electricity thereby making human beings vulnerable to electrical shocks.
10.8 Role of Fire Staff During a Fire :
1. After receiving information the fire personnel should rush to the spot and attempt to
extinguish the fire with the suitable fire extinguishers.
2. Inform the Fire Section Control Room about fire incident giving all details like
building No., Floor Department or exact location of the site etc.
3. Assist in fire-fighting operation and evacuation/rescue of employees.
4. Ensure that drive way is clear of vehicles for movement of fire brigade vehicles.
5. Stop entry of outsiders/visitors.
6. A record of Fire calls/incidents will be maintained by Fire Department.
7. Every fire incident is to be investigated and preventive measures are to be informed
to the concerned.
10.9 Implementation:
1. Corporate Safety Group shall organise meetings at least once a quarter and conduct
periodical fire inspections.
2. Training will be provided by Fire Safety Group to employees including those
employed on security duties.

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 CHAPTER-11

OCCUPATIONAL
HEALTH
&
SAFETY

79
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OCCUPATIONAL HEALTH & SAFETY
11.1 Hygiene
Almost all work environments present some kind of hazards. These include burn from hot
objects/materials and action by toxic and corrosive chemicals. Contact with the later can
produce effects ranging from damage to living tissues, dermatitis etc. In order to prevent
oneself from getting affected by these agents, one should follow good hygiene. The
general preventive measures to be followed are:

1. Wash Frequently Using Proper Cleansers: Use plenty of fresh clean water and soap or
other approved cleaner. Do not use petrol, or solvents to clean skin.

2. Change cloth often: Do not keep work-soiled clothes on for long. Keep fresh laundered
clothes handy and change into them frequently

3. Remove irritants: Do not allow irritating matter to remain on skin, wash it right away.

4. Take showers: Take a thorough shower bath, before leaving any contaminated area after
work. Shower immediately in case of accidental splash of chemicals on skin.

5. Separate soiled clothing: Work clothes should not be mixed with the family wash,
especially if they are used in hazardous chemical handling areas. Heavily contaminated
clothing should not be taken to home. Generally wash them at the work place.

6. Treat abrasions promptly: Cuts, scraps, puncture etc. provide ready pathways for toxic
materials to enter the blood stream. Wash them immediately and thoroughly, and apply
antiseptic and bandage.

7. Apply barrier creams: Protective creams or “barrier creams: though not as effective as
protective clothing, should be used where wearing protective clothing is not possible, and
also as a supplement to protective clothing. The skin surface should be washed thoroughly
before applying barrier creams. Wash off with recommended cleansers and reapply
frequently.

11.2 First Aid

Although every injured person must be sent to the hospital/First Aid Center without delay,
there are always certain first aid measures that may be administered to prepare the patient,
and perhaps even save his life, before the doctor’s services can be obtained some of the
common injuries and the most important first aid measures are as follows:

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1 Shock
Practically every injury of any consequence is accompanied by shock, and every injured
person should be treated to prevent or reduce the severity of it. The treatment is
a. Lay the patient down
b. Keep him warm
2 Minor Wounds
a. Do not touch the wound with anything.

b. Proceed to the hospital immediately.

c. For wounds with spurting/Jet flow of blood, stop or retard the bleeding by placing a
clean bandage, a handkerchief or the like over the wound and applying moderate
pressure with fingers on the bandage. In case bleeding still persists, apply a
tourniquet, around the arm or leg between the arm, leg wound and the heart and twist
tightly enough to stop the circulation of blood to the injured part. The tourniquet
must be loosened at intervals for not more than twenty minutes to allow re-
circulation of blood or death to limb may result.

i. Lay the patient down and keep him warm.

ii. Transport by ambulance to medical.
3 Fractures – Definite or Possible
a. Don’t bend or twist a limb to determine whether the bone is broken.
b. Keep patient lying down and keep him warm.
c. For fracture on the back & neck or distorted fractures of the arm or leg, don’t move
the patient, except in cases where the life of the injured is in danger in which case,
remove the injured gently. Call the doctor.
d. For fracture or any other part of body – place the patient gently on stretcher and
transport by ambulance to hospital.

4 Burns

a. Remove the cause of the burning.

b. Apply cold water to the burn area and wrap in water gel blanket/bandage and lay
him on a stretcher.

c. Transport to hospital by ambulance.

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5 Asphyxiation by Drowning, Electrocution, Gas etc.

When a person stops breathing as a result of drowning, electric shock suffocation or other
causes, artificial respiration or resuscitation/Revival must be given.

The aim of resuscitation/Revival is to prevent damage to the brain and other vital organs,
which may occur due to lack of oxygen, prompt ventilation of the lungs, and if necessary,
external cardiac compression can re-establish the oxygen requirements. The three main
steps to be taken are:

a. Ensure an open airway.

b. Ventilate the lungs.

c. Stimulate heart

6 Mouth to Mouth Respiration Method

a. Lay the patient flat on his back – raise shoulders.

b. Tilt the head backward, maintain clear airway (clean the mouth throat for any
obstruction)

c. Open your mouth wide – take a deep breath.

d. Pinch his nostrils with your fingers.

e. Seal your lips around his mouth.

f. Blow into his lungs until they are filled.

g. Then remove your mouth, watch chest movement.

h. Repeat 13 times per minute, if his color does not improve, check the cardiac pulse
(neck) if there is no response and the pupils are widely dilated color becomes or
remains blue gray, the heart has clinically stopped beating. Start immediately
external cardiac compression.

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7. External Cardiac Compression
Stake the chest over the heart smartly, this mechanical stimulus may start the heart
beating, if still no response, start External Cardiac Compression while continuing to
ventilate lungs in the ratio of one inflation of the lungs to six or eight compression of the
sternum ( Breast Bone )
METHOD
a. Position yourself at side of patient.
b. Place the heal of your hand on the lower half of the breast bone keeping the fingers
raised
c. Cover this hand with your other hand
d. With straight arms, rock forward and down on the lower half of the heart bone.
e. Repeat the pressure once per second. (This pressure in all cases should be firm and
controlled violent action is dangerous)
f. Check by noting size of the pupils, feeling the cardiac pulse and patient’s color.
Heart resuscitation/Revival may have to be continued until patient reaches hospital.
g. The patient must be watched, and if natural breathing stops, artificial respiration
should be resumed at once.

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 h. In carrying out resuscitation/Revival it may be necessary to change the operator.
This change must be made without losing the rhythm of respiration.

11.3 Occupational Health Program

Occupational Diseases:
Occupational disease is defined as a condition that results from exposure in a workplace to
a physical, chemical or biological agent to the extent that the normal physiological
mechanisms are affected and the health of worker is impaired.
Occupational diseases normally develop over a period of time because of work place
conditions. Such conditions might include exposure to chemicals, dust, industrial noise
etc. In a power plant occupational diseases primarily occur in dust prone, high noise and
chemicals related workplaces.
Objectives of Occupational Health program:
Objectives of Occupational Health Program at Power Plant aim to preserve and promote
the health of employees. This program aspires to give better quality of life and promotes
well-being of employees which in turn will enhance productivity. Occupational Health
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 Program covers all aspects of health – Preventive, Promotive, Curative and
Rehabilitative.
The main objectives are:-
1. To take requisite necessary steps by concerned departments to prevent occurrence of
occupational diseases by using PPEs.
2. To promote and monitor general well being of employees by conducting medical
examination comprising medical tests like Audiometery, Pulmonary Lung Function Test,
Chest X-ray, Vision Testing, Liver Function Test, Kidney Function Test
3. For early detection and timely curing of occupational diseases medical examination to be
conducted on annual basis.
4. To advise proper medical treatment to employees found affected with occupational
diseases like hearing loss due to industrial noise, respiratory symptoms due to inhalation
of dust particles etc.
5. To relocate/rehabilitate severely affected employees by suitably shifting their workplaces.
Occupational Health diseases are categorized in three parts are mentioned below
A. Part A
1. Infectious and parasitic disease contracted on an occupation where there is a particular
risk of contamination.
2. Diseases caused by work in compressed air.
3. Diseases caused by lead or its toxic compounds.
4. Poisoning by nitrous fumes.
5. Diseases by organo phosphorus compounds.
B. Part B
1. Diseases caused by phosphorus or its toxic compounds.
2. Diseases caused by mercury or its toxic compounds.
3. Diseases caused by benzene or its toxic homologues.
4. Diseases caused by nitro and amino toxic denvative of benzene or its homologues
5. Diseases caused by chromium or its toxic compounds
6. Diseases caused by arsenic, or its toxic compounds
7. Diseases caused by radioactive sub-stances and ionising radiations
8. Primary cancer of the skin caused by tar, pitch, bitumen, mineral oil, anthracene, or the
compounds, products or residues of these substances
9. Diseases caused by the toxic halogen denvative of hydrocarbons (of the aliphatic and
aromatic series)
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 10. Diseases caused carbon disulphide
11. Occupational cataract due to infrared radiations.
12. Diseases caused by manganese or its toxic compounds
13. Skin diseases caused by physical, chemical or biological agents not included in other
items.
14. Hearing impairment caused by noise
15. Poisoning by dinitrophenol or a homo-logue or by substituted dinitrophenol or by the
salts of such substances.
16. Diseases caused by beryllium or its toxic compounds
17. Diseases caused by cadmium or its toxic compounds
18. Occupational asthma caused by recognized sensitizing agents inherent to the work
process.
19. Diseases caused by fluorine or its toxic compounds
C. Part C
1. Pneumoconioses caused by sclerogenic mineral dust (silicoses, anthraoosilicosis,
asbestosis) and silicotuberculosis provided that silicosis is an essential factor in
causing the incapacity or death.
2. Bagassosis
3. Bronchopulmonary diseases caused by cotton, flax hemp and sisal dust (Byssionsis).
4. Extrinsic allergic alveelifts caused by the inhalation of organic dusts.
5. Brononopulmonary diseases caused by hard metals

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88
 CHAPTER-12

POTENTIAL
THERMAL POWER
PLANT HAZARDS

89
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POTENTIAL THERMAL POWER PLANT HAZARDS
12.1 General
1. During the course of operation and maintenance of the Plant, care should be taken that the
procedures adopted are commensurate with laid down safety rules and codes. Overlooking
of any aspect of Plant and personnel could result in injury to personnel and in extreme
case, loss of life. During the procurement, installation and erection of the equipment, it
should be ensured that all in built safeguards applicable as per the relevant codes of
practice have been incorporated. It is important that all safety devices and means for
meeting emergencies are kept in good working order so that their immediate availability is
assured.
2. Safety codes must be strictly enforced. Accidents caused by apparently minor items
such as spillage on the floor of slippery materials like oil and greases, snapping of wire
slings & shearing of bolts in lifts in excess of capacity or due to broken/damaged strands,
loose clothing in the vicinity of rotating objects, such as jobs on lathes or unguarded
pulleys & chain drives, failing of temporary structures due to inadequacy or over loading
of members, electrical accidents etc. are largely avoidable provided due care is taken to
observe safety codes including good housekeeping, issue of proper written work permits,
careful checks of lifting devices, provision of guards on rotating machines. Where Plant
personnel may have to work in the vicinity, tagging of equipment on which men are
working, properly isolating all electrical circuits on which work is in progress and
interlocks to avoid inadvertent switching ‘on’ of circuits, are only but a few instances to
illustrate how accidents take place & how they may be avoided. Good house-keeping
practices in the power house not only contribute towards clean appearance of the building
and equipment but also ensure safe operation and longer life of equipment.
3. All power driven machinery are operational hazards if proper fencing and guards have not
been provided. It is not safe to assume that the designer has incorporated all safeguard
required for safe operation of the equipment. It is advisable to study & incorporate
adequate safeguards of equipment with V-belt drives and pulleys, conveyor head and tail
pulleys etc and make modification to suit local operating conditions. A look out is to be
kept for careless operators, who owing to misguided views of convenient operation,
deliberately by-pass the safety devices provided.
4. Safety goggles must be worn while using portable or stationary grinders to avoid foreign
matter causing injury to the eye. Welding operation in the workshop should be carried out
with temporary screens placed around the area to avoid exposure to ultra-violet rays of the
91
 people working in the neighborhood. While on field repairs, the workers should be careful
not to expose themselves and fail to protect their eyes from welding flashes. The planks
used in preparing scaffolding should be adequately secured on both sides to prevent
people against catapulting accidents. Manhole covers should always be replaced or a
temporary fence built around the opening to avoid accidents. An enclosure should be built
around acid and alkali tanks. Material and passenger lifts should be checked thoroughly
and frequently to ensure safe operation.
5. Effective means of fire protection have been provided in all the vital areas of the power
station. It is mandatory to maintain all the equipment for fire warning and protection in
prime condition so that their immediate availability can be assured at all times. The
necessary safety instructions shall be inculcated into the O&M personnel by providing
them adequate training.
12.2 Causes Of Accidental Fires
1. Calamitous fires can be caused by undetected leakage of turbine oil from the HP oil
system or oil leakage from turbine bearing seeping onto hot lagging on adjacent steam
pipes and turbine casings or spillage of oil on failure of a joint in the high pressure oil
system onto hot surface. Serious fire risk may arise from the leakage in Generator cooling
hydrogen circuit. Welding, smoking and other activities causing open flame in the area
should be prohibited.
2. Hazards also exist in heated fuel oil system, belt conveyors, cable in confined tunnels,
equipment under heavy fault conditions and containing oil, such as Transformer and oil
circuit breakers, fuel and light oil storage tank area, hydrogen generation Plant etc. It must
be ensured that fire hydrants, CO2 or foam type fire extinguishers have been provided in
all areas where potential fire hazards can be envisaged.
12.3 Fire Protection Measures
The protection system as available in the power Plant can be divided into two main groups
as stated below:
12.3.1 Fire Hydrant System
This system covers all the hydrants located in the Plant area. The fire fighting medium is
pressurized clear water. The pumps are interlocked to start whenever the line pressure
drops below a certain value (on the opening of any hydrants in the system). Jockey pumps
are provided to maintain the line pressure at the desired value to take care of small drips.
Periodic drill must be conducted to see that the equipment is in prime running condition
and available in the event of need. Fire hoses along with associated nozzles must always
92
 be available in close proximity of the hydrants. Pump ‘Start’ interlocks should be tested
under simulated conditions from time to time.
12.3.2 Emulsifier System
1. This protection has been provided to quench heavy duty oil filled Transformers i.e.
Generator Transformers, unit Auxiliary Transformers, Station Transformer and Turbine
Lube Oil Tank/Pipe work. This system automatically comes into operation through the
failure of quartzoid bulb of the sprinklers provided in lines pressurized by compressed air
for which a separate compressor has been provided. These bulbs, which are made of
quartz, contain a highly expansible liquid, break when the liquid in the bulb expands due
to excessive heat produced by fire.
2. This result in the drop of air pressure in the line, which in turn will open a differential air
deluge valve provided in the main emulsifier header of the affected Transformer, which
results in high pressure water sprinkling on the Transformer from all sides.
3. Daily checks shall be conducted to see whether the water and air line pressure are being
maintained. Emulsifier system for each Transformer shall preferably be tested under
simulated conditions on long outages of the units, when Transformer is in de-energized
state.
12.3.3 Fire Precautions
1. Smoking
a. Lighting cigarette ends carelessly thrown out of window, on the floor or into waste
paper baskets caused numerous fires. Discard them in ash-trays after extinguishing.
b. Don’t smoke in plant premises.
2. Cooking
a. LPG stoves should be lighted the correct way. The burner should be turned on after
holding a lighted match stick or a gas lighter close to the burner.
b. Cylinder valve should be shut off at the end of the day.
c. Tube connecting the cylinder and stove should be free from cracks and cuts. Change
the same regularly.
d. While using kerosene stove, never over-pump or attempt to refill it when it is
burning.
e. Store the LPG cylinder in a well-ventilated place.
f. Instruction card for handling LPG leak emergency should be kept in a really
accessible location for reference.

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3. Electrical Fires
a. Do not put too many plugs in one socket. This can generate heat through overloading
and burning away the insulation.
b. Inserting bare wire ends in a socket without a plug will cause arcing and generate
heat. Always use a proper plug.
c. Protect the circuit and equipment against excess current by a correctly rated use.
d. Leave the repairs and installation to an electrician.
e. ISI mark for electric switches, stoves, immersion heaters and irons is mandatory.
Check for this mark and as far as possible, use other electrical equipment also
bearing ISI mark.
f. Always switch off the appliance after use, especially the heaters, irons, etc.
g. Switch off mains on vacation.
h. When you notice a spark or fire in switch board, switch off the mains immediately.
i. Get the wiring checked for signs of wear & tear and for insulation resistance. If it is
less than 1 mega ohm, it needs replacement.
j. Do not run flexible cords/wires under mats, carpets or through doorways where they
may get crushed.
k. Plumbers, electricians, welders and other repairers may connect their portable
electric tools and welding equipment to the power outlets. Check that the rating of
the appliance does not exceed rating of the socket.
l. Use 3 pin plug and heavily insulated cords for all movable electrical equipment.
4. Flammable Materials
a. Do not dispose off match sticks into rubbish bins before they are completely
extinguished.
b. Follow the instructions of the manufacturer for storage and handling of
chemical/cleaning agents that are reactive/flammable.
c. Some aerosol dispensers which use propane/butane propellants present potential fire
and explosion risk. Similarly their lacquer which has volatile ethanol as an
ingredient may form explosive mist when dispersed in air. Ignition sources should
not be present when these are used.
d. Store the aerosol cans away from heat source.
e. Do not attempt to puncture the aerosol cans or throw them into fire. They will
explode.
f. Similar care be taken with paints, varnishes, turpentine and other cleaning solvents.
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 5. During Fire Emergency
a. If your clothes catch fire, pour water if it is available. If not, stop where you are,
drop to ground and roll. Do not run as it will only fan the flame.
b. In case of a fire, alert others to evacuate and call fire brigade.
c. If the fire cannot be fought, leave the room, shut the door and evacuate. Do not wait
to collect possessions.
d. Fire tends to spread upwards. Try to escape to lower floors and then to outside.
e. Do not use lifts in a fire emergency. Use stairs, preferably the fire escape if
available.
f. Do not hide behind furniture or in toilets or run up to the terrace. If the room is
getting smoke filled, use a wet cloth to cover nose and crawl out since the floor level
takes longer time to get smoke filled.
12.4 Potential Hazards
1. Fire Hazards in Coal-Yard
Dead storage of coal in a power Plant should be of crushed coal, thoroughly compacted by
use of mechanical equipment in separate stacks not higher than about 3 Meters. Few
vapour ventilating tubes must be provided in the stack to release accumulated volatile
matter. At frequent intervals inside temperature of the stack should be taken and recorded
to obtain advance information if conditions of spontaneous combustion appear to be
developing. Especially the coal should be thoroughly drenched (as opposed to just
wetting) otherwise in the later stage it will assist in the development of a large scale fire.
2. Mobile Cranes
Precaution must be taken to ensure that the booms/jibs are not overloaded and beams are
properly fixed before lifting heavy materials. A reference to load radius v/s lifting capacity
diagram mounted in the crane must be made especially in case of heavy lifts. Care must be
taken to maintain adequate clearance when operating near high voltage lines. Damage to
ropes must be observed & timely replacements made as necessary.
3. EOT Cranes
a. Good condition of wire ropes and their proper greasing must be ensured at all times.
Brakes must be tested and set especially before planning heavy lifts. Adequate
lighting must be ensured in the area of operation.
b. It is preferable to conduct all lifting operations through a single line of command to
prevent issue of contradictory instruction resulting in mishaps.

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4. Electrical Safety
1. In general, electrical safety is achieved through intrinsic in built safety
considerations in the equipment design, and strict implementation of the appropriate
operation and maintenance codes including competent supervision must be ensured.
Electrical accidents are not wholly due to electrical faults. Some situations cannot be
always predicted. The real hazard to personnel arises during maintenance or
inspection or routine test, when owing to ‘human element’, failure and omissions
risk liability is increased.
2. Proper use of all safeguard such as rubber gloves, rubber soled shoes, properly
insulated tools and obtaining of a timely ’Line clear’ from the concerned operation
staff etc. do much to reduce the risks. Prior information shall be given to the
operating personnel well in advance as to which equipment is to be taken up for
maintenance. Appropriates warning display signs on the respective control switches
must be ensured so that the affected feeder is not inadvertently charged by an
operator. Safety belts must be worn by the men working on the switchyard
structures.
5. Dangerous Fumes and Lack of Oxygen in Confined Space
1. This is applicable to any chamber, tank, pit, flue or similar confined space in which
dangerous fumes are liable to be present to such an extent that it constitutes a hazard
to any person entering inside for maintenance purpose. Trial tests must be conducted
and the space adequately purged. Continuous pressurized stream of air should be
supplied for the convenience of men working inside.
2. Work in boiler furnace and flue gas path should not be started until it is ascertained
that the furnace has sufficiently cooled down and adequately ventilated to permit
safe entry. Special precautions are necessary in dealing with piled up ash in various
passes and pent house. This may appear to be dead at the first sight but on raking the
ash may be glowing. All accumulation of ash piles should be removed & cooling of
the area must be ensured before permitting entry of the personnel in the area.
Scaffolding must be adequately supported and safeguards must be provided against
men falling off.
3. When the men are working in the drum, all piped connections connected to common
pressurized headers or tanks must be either blanked or both valves shut tightly and
tagged and preferably locked in position to prevent accident.
6. Accumulation of Inflammable Dust
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 1. Dust suppression/collection & safe disposal methods at the wagon tipplers, crusher
house, transfer towers, bunker bay etc. have been provided. Their proper functioning
must be ensured for the safety of the Plant & personnel. There is a potential danger
of explosion and fires in pulversing Plants arising from surge back of hot furnace
gases in to the mill. Observation of precautions like closing of hot air gate valves,
mill discharge valves and raw coal gate whenever the mill is under shut down for
maintenance do much to minimize the danger to personnel, who may be working on
or around the mill. Defined means of fire fighting should always be in readiness to
combat internal pulveriser fires. Leaks in pulveriser discharge, coal intake piping
and pulveriser body joints shall be effectively plugged.
2. While safeguard have been provided to minimize the chances of the outbreak of
fires, the operator should always be on the alert in case these safeguards fail.
7. Boiler Furnace Explosions
1. Continued pumping of unlighted oil in a hot furnace, leakage of oil line valves
resulting in continuous drips in the furnace, rich pulverized coal-air mixture without
adequate combustion air or accumulation of un-burnt pulverized coal in various
passes constitute a potential hazard of furnace explosion.
2. The furnace should be properly purged before lighting up. Keeping this in view
furnace Supervisory Safeguards System has been built in the scheme to avoid
dependence on the operators and to ensure safe operation of the Plant. Flame
monitoring is an essential feature of the system.
3. In spite of all safeguard provided there is no substitute for intelligent and careful
working in and around the Plant for better availability of Plant and to avoid human
misery as a result of accidents.
8. Compressed Air
There are many uses of air in a Thermal Plant. Compressed air is widely used as an
instrument and Plant air in process units and for cleaning purposes as well as powering
mechanical tools in workshops.
a. Compressed air should never be used to clean up dust, filling and clothing.
b. Compressed air should not be used to clean clothes or parts of body of any person.
c. Horse play with compressed air should never be indulged.
d. Whenever compressed air is used to clean any pressure vessel or other equipment,
air pressure should not exceed 2.0kg/cm2(gauge). Also correct type of hoses and
couplings should be used.
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9. Hydrogen
1. Increased use of hydrogen in processing during recent years has added a special
problem to Plant safety. Burning hydrogen generates tremendous heat and cannot be
detected by naked eye.
2. The invisibility of hydrogen flames is a property that has led workmen to walk right
in to the flame. The flame is totally carbonless. It also burn very rapidly with typical
combination-89% hydrogen and 11% oxygen. When ignited at atmospheric pressure,
this mixture has a flame speed of more than 3.3 K.M / second.
3. There is no chance of hydrogen accumulating at ground level, especially in the open.
It has a vapour density of 0.07kg/m3 much lighter than air and will rise immediately.
4. Hydrogen being a very light gas diffuses very easily and remains in atmosphere.
Therefore, special care should be taken to check hydrogen under pressure, especially
in Hydrogen generation units.
5. Because of the wide range of explosive limit of hydrogen (minimum 4.1% and max.
74.2%) extreme precautions are necessary when hydrogen is introduced or
withdrawn from a system.
10 Steam
1. Steam is very essential utility used in the Thermal Plant. If used properly &
following the right procedures, steam is not a hazard. However, it may be very
dangerous to use steam with insufficient knowledge of its limitation and dangers.
2. Steam can cause serious burns if any part of body comes in contact with it. Steam
connection to vessels can, therefore, be very serious hazards to maintenance
personnel. Therefore, all steam lines to process vessels must be disconnected,
blinded off or closed with double block valve and bleeder and the valve wheel must
be locked before workmen enter the vessel.
3. Another important feature is the isolation and the de-pressurization of steam lines for
maintenance work. There have been many cases where persons have sustained
serious burns, even total ones. Any work on steam line should be authorized by
competent personnel. Steam can condense to 1/1600 of its original volume. The
reduction in volume can cause high vacuum. Hence it is necessary to keep the vent
open.
4. Care should be exercised while placing steam lines into service. Steam should be
opened slowly to warm up the line slowly and expand thermally. Sudden heating by
opening a full head of steam may cause hunting & rupture of the lines. Steam lines
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 should have drain points at all low points and at the farthest point downstream, to
remove condensate and air from the line when being put into service.
5. For using a steam hose, make sure that the hose is secured properly to the steam-line.
Open the steam valve gradually and hold the free end of the hose with hand so that it
does not play around on its own. Use asbestos hand-gloves while operating the steam
hoses/lancers.
11 Coal and Coal Dust:
A. Spontaneous ignition Hazard:
When coal is stored in a small layer or a large stack, the phenomenon of oxidation is
certain to take place. Thus there is a tendency of self heating, which will be assisted by the
presence of foreign matter such as straw etc. This tendency is effected by both area and
type of the coal. The greater the area of the coal exposed surface compared with its bulk,
greater is the tendency to self heating in a stack, self heating generally begins in the fine
coal and dust. Coal should be stacked under water or in some other way designed to keep
out air, or sufficient ventilation should be provided, Coal should not be stacked in large
conical heaps. New coal should not be laid down upon old heaps. It should be stacked in
quadrangle shape with 10 feet wide roadway all round it to facilitate access.
B. Controlling of fires.
a. Surface of coal should not be watered, as this accelerates oxidations. Insufficient
quantity of water may result in explosion of water gas, while the steam generated
will create a draught that will increase the rate of oxidation of the interior of the
stack. Small quantity of water at high pressure may be used to keep the surface cool.
b. Hot area should be isolated from rest of the stock by Bulldozers etc
c. In an early stage of heating a stack, it may be cooled by inserting a crow bar into the
Top of the heap and moving it round so as to produce a funnel shaped hole. Holes
are made to prevent the outbreak of a fire.
C. Coal dust:
1. Characteristics of Coal dust and Explosion Hazards:
When a mass of solid flammable material is heated, it burns away slowly layer by layer
owing to the limited surface area exposed to the oxygen of the air. The energy produced is
liberated gradually and harmlessly because it is dissipated as quickly as it is released. The
result is quite different if the same mass of material is ground to a fine powder and
intimately mixed with air in the form of a dust cloud. In these conditions the surface area
exposed to the air is very great and, if ignition now occurs, the whole of the material will
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 burn at once. The energy which in the case of the mass was liberated gradually and
harmlessly is now released suddenly with the evolution of large quantities of heat and
reaction products.
2. Explosive Concentrations:
The lower explosive limits for most flammable dusts, such as coal is assumed to be 0.0550
ounces per cubic foot. The explosive limits are not well defined. The explosive range is
not solely a function of dust material. The limits vary with the size and shape of the dust
cloud.
3. Causes and Condition of Explosion:
a. The concentration of dust and air should be within explosive limits.
b. A source of heat at or above the ignition temperature is present. Generally explosion
occurs in grinding and pulverising mills, in dust extraction Plants and cyclones. They
are very frequently caused by the accidental inclusion of foreign particles of steel or
stone in grinding or pulverising process, resulting in heat or sparks, though these
sparks occur frequently but often in a favorable explosive atmosphere. In dust
extraction ducts and cyclones, the cause has frequently been somewhere within the
enclosed machinery either by friction or by break down of electric motors or wiring.
4. Characteristics of coal dust:
a. Ignition temperature 6100C.
b. Minimum spark energy required for ignition 600 milli Joules.
c. Minimum explosive concentration 55 oz/ 1000 cu. ft.
d. Maximum explosion pressure 85 psi.
5. Precautions:
a. Fires and explosions in atmospheres of coal dust can be avoided by maintaining
humid conditions.
b. A dust explosion will occur only if coal is in the explosive range and at the same
time a suitable source of ignition is present. Preventive measures should be aimed at
avoiding the presence of either or preferably both, these factors in the system.
12 Belt Conveyors
Power driven belt conveyors are provided for transport of coal in Thermal Plants. The
personnel working in the sections having belt conveyors must take extreme care not to get
entangled in the belts. The rule prohibiting the wearing of loose clothing, loose turbans,
shawls or Mufflers must be strictly observed.

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 a. Persons must not cross over the moving conveyors except via proper access ways
provided.
b. Riding on moving conveyors is strictly forbidden.
c. Standing on the supporting frame of the open conveyors while loading or removing
material or when clearing blockages is strictly prohibited.
d. In case of closed conveyors and especially when the belt is moving, no person
should be allowed to step on to the cover plate. In case the work requires standing or
sitting on the cover plate of closed conveyor, a strong wooden plank of sufficient
length should be put across the frame and properly secured for men to stand or sit on
for the execution of the work.
e. Touching of moving belts, moving rollers, idlers with hand or with sharp tools is
strictly prohibited.
f. The walk ways alongside conveyors must be kept always free of spillage and other
material and must be maintained in a non-slippery condition.
g. The emergency stop switches and pull wires, wherever provided, should be
periodically checked and maintained in good conditions.
h. Lubrication, adjustments and repairs on the belt conveyors should be undertaken
periodically.
i. The personnel employed on the maintenance of the conveyors must take particular
care not to leave tools, cotton waste etc. on the conveyor belt.
j. Do not start any section of a conveyor without personally ensuring that no foreign
materials are lying on the conveyor belt and that no worker is in position of danger.
k. Maintenance jobs on conveyors shall be undertaken only under authority of safety
work permit.
l. Smoking or use of naked lights near the conveyors handling inflammable material
and coal is strictly prohibited.
m. Appropriate posters and notices will be exhibited near the conveyors warning
personnel against wearing loose clothes.
n. Notices should also be exhibited at prominent places indicating the method of
stopping the conveyor in case of emergency.
13 Compressors, Pressure Vessels And Pipe Lines
i. Fired and unfired pressure vessels, equipment and their connected pipe-lines are in
widespread use in Power Plant. These vessels and pipe lines may contain air,
explosive and noxious gases, corrosive liquids, steam and solids. They may operate
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 under high and super high pressure or under full or partial vacuum and in some
instance pressure or temperature changes in the vessels may be acute and in rapid
succession.
ii. In view of the above, all employees who are working on such equipment and vessel
either for operational or maintenance jobs should be strict in observance of operation
instructions and maintenance procedure, laid down of every item of such equipment.
iii. Every part of the Plant or machinery operated at a pressure greater than atmospheric
pressure should be thoroughly examined by a competent person periodically and also
after extensive repair etc. and necessary records of all such equipment and tests
carried should be maintained as required by Factories Act.
iv. No maintenance work on any pressure vessels equipment etc. should be undertaken
without obtaining a safety permit to start the job. Before opening a vessel, it must be
brought to atmospheric pressure.
v. It must be ensured that the release valve and cocks are open. At least by two pressure
gauges it must be ensured that the pressure inside the unit or vessel is atmospheric.
vi. When manhole covers or cover plates of vessel are to be removed, all bolts or stud
nuts should be slackened evenly a few turns at a time until all are slackened off
about half way. Covers should then be eased from seating to ensure that inspite of
the precautions taken by depressurizing the unit; the cover may not fly off due to any
pressure behind the covers. When the cover is clear from its seating, bolts or stud
nuts should be opened out to remove the covers.
14 Road Traffic Rules
1. These rules apply to the use of roads within the Thermal Plant boundary. These are in
addition to the applicable Government rules. These rules are not inclusive of any safety
instructions specifically applicable to different vehicles such as dumpers, mobile cranes,
tractors etc.
2. The vehicular traffic must be kept to the left of the road except when passing a bicycle or a
parked vehicle, which should be passed on the right. There shall be no cutting of corners.
3. The speed limit for all vehicles on main roads within the Thermal Plant is 25 km per hour.
4. Normal traffic signal should be used by all drivers.
5. There shall be no overtaking of one motor vehicle by another inside the Thermal Plant
except in the following cases:
i. Slow moving vehicle like crawlers etc. can be overtaken.
ii. Fire engines and ambulance vans may overtake vehicle when on emergency duty.
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 The driver of a vehicle should check his vehicle every day before using it and ensure that
the following are in good order to avoid any road accident.
a. Brakes.
b. Headlights
c. Rear end stoplights
d. Tyres
e. Windshield and wipers
f. Horns
g. Rear view mirror
No one shall drive a motor vehicle on the Thermal roads unless he has a license to drive
that vehicle.
The trial running of a motor vehicle to test its brakes or steering mechanism on the
Thermal road must be done only by a person designated by the supervisor.
A motor vehicle must be loaded only according to the Government rules. The loading
beyond and sides or the front of the vehicles or beyond 1 meter at its back is strictly
prohibited. Also care should be taken not to load the vehicles up to a height which may
entangle with overhead obstructions. Where this is not possible for any particular work, a
responsible person from the concerned section must accompany the vehicle until the
material has been unloaded.
Trucks carrying lengthy material hanging outside the tail board of the truck should carry
red flags tied at the end of the materials.
Persons must not attempt to board or alight from a motor vehicle in motion. The driver
must make sure before starting his vehicle that no one is alighting or boarding.
Vehicles must be started, stopped or turned gently and not suddenly.
Roads must always be kept free of obstruction. During road repair work or any excavation
work along the road, proper barricades and suitable caution notices should be displayed.
No vehicles should be parked within 9 meter of any corner or rail crossing or road
junction or a fire hydrant. Drivers must not leave their vehicles with engine running.
15 Pedestrians
1. Walk on the right side of Thermal Plant roads to see the approaching vehicles.
2. Avoid taking short cuts through process unit’s areas.
3. Do not walk through restricted areas without approval of the appropriate unit supervisor or
his delegate.
16 Rules for Bicycle Traffic
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1. Double riding on a bicycle within the Thermal Plant is prohibited.
2. The practice of riding on a bicycle while leading another in one hand is prohibited.
3. Always ride in a single file.
4. Give proper hand signals.
5. Keep the bicycle in good condition with proper brakes.
6. Triple riding on a motorbike/scooter inside the Thermal Plant is strictly prohibited. The
security personnel should report any violation of traffic rules by any employee of the
corporation to the head of the department under whom the employee is working.
The traffic accidents must be reported to the fire & Safety division whether injuries are
caused to personnel or not. Necessary action to deal with traffic collisions between motor
vehicles and fixed or moving objects shall be taken up by the Fire and Safety Division.
This division shall report the accident under the Factories Act, if necessary.
17 Rail crossings:
1. All vehicles, including dumpers, bicycle & pedestrians’ should stop at every unmanned
rail crossing, watch out on either side and cross the rails only when there is no traffic on
the rails.
2. Crossing of rails except at levels crossing is prohibited.
18 Safety in the Railway Yard:
A. Locomotives:
a. Only authorized and competent personnel should be employed on locomotives.
b. Keep driving motors stopped while fueling.
c. Do not move the locomotive with light off when natural light is insufficient.
d. Do not stand on the buffers of the locomotive.
e. Actuate the warning devices such as whistle a number of times when approaching a
crossing, a building entrance etc.
B. Railway Tracks and Crossing.
a. Do not sit or sleep near a railway track.
b. Do not place or dump any material within 2.0 mtr. from either side of a railway
track.
c. The gateman must close gates provided on the level crossing, before the engine or
the wagons move on the track.
d. Exhibit notices, showing ‘Danger’ or ’Crossing signs’ on either side of the tracks
near a railway crossing.
e. Red lights should be provided at such crossing during the night.
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 f. Do not leave a wagon across walkways.
g. Do not allow a vehicle to park near such crossing.
h. Look both sides before crossing rails.
i. Do not get tripped or slip on rails by signal wires or point rods while crossing.
C. Shunting Operations
a. Only authorized and competent person should be employed on shunting operations.
b. Fly shunting is strictly prohibited. Wagons should be brought to a full stop before
the same are cut or coupled together.
c. Make sure that all workers are clear off the ‘Danger Zones’.
d. Do not leave stationary wagons without securely braking them.
e. No movement of wagons should be done without the permission of the supervisors.
f. No person shall pass over or sit on the coupling between the two wagons while the
same are in motion.
g. Do not cross rails by crawling or passing underneath a train or a wagon. Also do not
sit or sleep underneath a wagon.
h. Do not move or push a wagon at the buffers always push from outside the rails.
i. No adolescent shall be employed in moving, loading or unloading of wagons.
j. Use scotch blocks/car blocks/rail clamps for stopping the wagons to avoid accidental
movement. These devices should not be put before the running wagons. First place
the scotch block etc. in position and when the wagon be pushed.
k. Do not use weak, deteriorated and unsmooth scotch blocks. Make shift tools should
not be used for stopping the wagons.
l. Do not move wagons with door open fully or partially
m. Keep clear of the flapper doors while opening the same. Falling door may strike you.
n. Do not move the wagons near tippler & within the areas demarcated by the caution
boards “no shunting beyond this limit”.
o. Shunting between the above limits should be with the permission of in-charge of
marshalling yard/Assistant in-charge of marshalling yard.
p. Signal should be given by authorized and competent persons only.
D. Loading and Unloading.
a. Do not sit or sleep in loaded wagons. You are likely to be sealed and dispatched
along with the material.
b. Do not place or pile the unloaded material near or on the railway track. It may derail
the wagons.
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 c. Brake down the wagon properly, when it is being loaded, otherwise it may run away
and you will fall down from the flapper door on which you are standing.
d. Use car blocks for keeping the wagon in position while loading or unloading.
e. Keep the platform clear of loose material otherwise are may slip and fall into the
track.
f. No movement of wagon should be done either by engine or manually near the
wagons which are under loading or unloading.
g. Where gang planks are used for loading and unloading, the same must be secured
properly to avoid slipping of the planks.
h. Do not use stones as car blocks.
i. Do not move the wagons with crow bars, unless supported with wooden
blocks/wedge for leverage. Otherwise, your fingers may be crushed.
19 Safe Handling and Storage of Compressed Gas Cylinders.
Compressed gases pose chemical and physical hazards. Gases can be toxic, inflammable,
oxidizing, corrosive, inert or combination thereof. Being in gaseous form and pressurized,
it can quickly contaminate a large area in the event of a leak. Therefore, familiarity with
the chemical hazards of the gas is necessary. Additional hazard due to compression of
gases is that it can make the cylinder to act as rocket. Following are the measures to use
compressed gas cylinders safely.
A. General Requirements.
1. Contents of the gas cylinder should be clearly identified.
2. Do not deface or remove any markings, tags or stencil marks used for identification of
contents attached by the vendor.
3. Cylinders which do not bear a legibly written, stamped, or stenciled identification of the
contents should be segregated and returned to the vendor as soon as possible.
4. No person shall in any way interfere with or change the colour painted on a gas cylinder.
5. Do not use cylinder as rollers, work supports or jacks.
6. Caps used for valve protection must not be removed except when the cylinder is in use. A
cylinder cap should be screwed all the way down on the cylinders neck and should fit
tightly.
B. Leaking Cylinders.
1. If a cylinder containing poisonous gas is leaking, immediately leave the room, close the
door (s), pull the nearest fire alarm, evacuate the area and inform from a safe place to the

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 concerned. The supplier should be contacted for disposal of the cylinder once the
emergency situation is stabilized.
2. If a cylinder containing flammable or oxidizing gas is leaking, follow the same steps as
above, but turn off all sources of ignition in the room prior to leaving, if the shut offs are
accessible. Never attempt to extinguish /off the gas supply, explosive atmosphere could be
created.
3. If the leaking cylinder contains inert gases, place the cylinder in a well-ventilated location,
preferably an outdoor cylinder storage area and contact the vendor for removal.
4. If a cylinder or valve is noticeably corroded, the vendor should be contacted and their
instructions followed. Any other damage that might repair the integrity of the cylinder
should be called to the attention of the vendor before the cylinder is returned.
5. All gas lines leading from a gas cylinder should be labeled clearly to identify the gas
carried.
6. The practice of transferring compressed gases from one commercial cylinder to another is
NOT permitted.
C. Transporting Cylinders
1. Always use a suitable hand cart or similar device and the cylinder must be firmly secured
for transporting and unloading. DO NOT roll or drag a cylinder to move it or allow
cylinder to strike each other or any other surface violently.
2. Protective valve caps must be secured when moving cylinders. DO NOT lift or move the
cylinder by the cap.
3. Ropes or slings should not be used to suspend cylinders unless the vendor has made
provisions for such lifting and attachment points are provided on the cylinder.
4. Do not use a lifting magnet for loading or unloading any cylinder.
D. Storing Cylinders
1. All cylinder storage areas must be prominently marked with the hazard class or the name
of the gasses to be stored, e.g. Flammable Gas Storage Area, and “No Smoking” signs
posted where necessary.
2. Always secure gas cylinders upright (with valve end up) to a wall, cylinder hand truck,
cylinder rack or post, unless the cylinder is specifically designed to be stored otherwise.
3. Where gases of different types are stored at the same location, cylinders (empty or full)
should be grouped by the types of gas, e.g. flammable, oxidizer or corrosive. Inert gases
can be stored with any other type of gas.

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4. Filled cylinder should be stored separately from empty cylinder. Cylinders should be used
by the “first in, first out” guideline.
5. Cylinders should be stored in a well-ventilated area well away from sparks, flames or any
source of heat or ignition such as ovens, furnaces, boilers, incinerators, etc. Also ensure
that cylinders are not subjected to direct rays of the sun. Do not use tarpaulin or any other
cover in direct contact with cylinders as a protection against the sun rays.
6. Cylinders should not be exposed to continuous dampness, stored near salt or other
corrosive chemicals or fumes. Corrosion may damage cylinders and cause their valve
protection caps to stick. Cylinders containing corrosive chemicals should be periodically
checked to ensure that the valve has not corroded.
7. Avoid prolonged storage of cylinders in corridors.
8. Never store cylinders in elevator lobbies, stair lowers or any other location which could
obstruct the safe Exit pathway of the building occupants.
E. Precautions in General Use
1. Never tamper with or attempt to repair or alter cylinders, valves or any safety relief
devices. Return cylinders to the vendor for all repairs.
2. Do not attempt to remove a stuck cap by using a lever in the cap ports. The lever may
accidentally open the valve when the cap turns.
3. Do not place cylinders where they might become part of an electric circuit or allow them
to come into contact with an electrically energized system.
4. Use “Snoop” soapy water for leak detection equipment to ascertain that there are no leaks
in the gas transport system.
5. Use pressure regulators which are equipped with pressure relief devices.
F. Utilizing Compressed Gases
1. Before using the gas, read all label information and the data sheets associated with the use
of that particular gas.
2. Before attaching cylinders to a connection, be sure that the threads on the cylinder and the
connection mate, are of a type intended for gas service.
3. The threads and mating surfaces of the regulator and hose connections should be cleaned
before the regulator is attached. Wipe the outlet with a clean, dry, lint-free cloth.
Particulate can clog the regulator fitter (if so equipped) or cause the regulator to
malfunction.

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4. Always use the proper regulator for the gas in the cylinder. Always check the regulator
before attaching it to a cylinder. If the connections do not fit together readily, the wrong
regulator is being used.
5. Attach the regulator securely with the secondary valve closed and preferably with the
regulator flow backed off (counter clockwise) before opening the cylinder valve wide.
6. Do not permit oil or grease to come in contact with cylinders or their valves, especially
cylinders containing oxidizing gases.
7. Always use a cylinder wrench or other tightly fitting wrench to tighten the regulator nut
and tube connections. Use “backup” wrenches to minimize stress on tubing and fittings
where appropriate.
8. Teflon tape should never be used on cylinder connections or tube-fitting connections. Use
Teflon only on pipe threads where the seal is made at the threads. All other connections
have metal to metal face seals or gasket seals.
9. Open cylinder valves SLOWLY. Point the valve opening away from yourself and other
persons. Never use a wrench or hammer to open or close a hand wheel type cylinder
valve. If the valve is frozen and cannot be operated by hand, return the cylinder to the
vendor.
10. Before a regulator is removed from a cylinder, close the cylinder valve and release all
pressure from the regulator.
G. Special precautions for using flammable gases
In addition to the above guidelines, the following measures should be taken when
handling flammable gases.
1. Cylinders containing flammable gases (empty or full) should be separated from cylinders
containing oxidizing gases by a minimum distance of 1 meter or fire resisting partition
wall in between them.
2. Do not store flammable or oxidizing gases near highly flammable solvents, combustible
materials or near unprotected electrical connections, gas flames or any other source of
ignition.
3. It is preferable to store flammable gases in a ventilated, fire resistant enclosure. If this is
not possible, flammable gas cylinders should be stored in a well ventilated space.
4. The quantity of flammable gases in a laboratory should be kept to a minimum.
5. It is preferable to use flow restrictor or surge protectors on flammable gas cylinders so that
there cannot to be a sudden large flow of gas if a rupture or other unexpected release
happen in the system.
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H. Special precautions for using poisonous gases
In addition to the general guidelines, the following measures should be taken when
handling poisonous gases:
1. Poisonous gases must be stored in a ventilated enclosure, e.g. fume hood
2. Gas detection systems may be required in laboratories utilizing poisonous gases.
3. The quantity of poisonous gas in a laboratory should be kept to a minimum.
4. Flow restrictors are required on most poisonous gas cylinders.
5. Ensure the pressure-relief devices vent directly to a laboratory exhaust system.
I. Special precautions for using oxidizing gases
In addition to the general guidelines, the following measures should be taken when
handling oxidizing gases:
1. Do not permit oil or gases to come in contact with cylinders or their valves, especially
cylinder containing oxidizing gases. Regulators and tubing used with oxidizing gases must
be specially cleaned to remove oil and other reducing agents. Explosions may occur when
pressurized oxidizers, e.g. oxygen, come into contact with grease or oil.
2. Cylinders containing oxygen or oxidizing gases, e.g. chlorine, (empty or full) should be
separated from cylinders containing flammable gases by a minimum distance of 1 meter or
fire resistant partition wall in the between them.
3. Do not store oxidizing gases near flammable solvents, combustible materials or near
unprotected electrical connections, gas flames or other sources of ignition.
12.5 Food Safety
1. Millions of people around the world fall sick as a result of consuming contaminated food
and water.
2. Food Contaminating Agents: Bacteria, viruses, parasites, pesticide & veterinary drug
residues, food additives, naturally occurring toxins, industrial contaminants etc.
3. Legal Requirements: The Prevention of Food Adulteration Act, 1954 and Rules, 1955
there under require:-
a. Analysis of food samples.
b. Prescribing food quality standards.
c. Notice of food poisoning by medical practitioners.
d. Labeling of food giving name, trade name, composition, best before or manufacture
date, etc.
e. Restriction on dose of irradiation for onions, potatoes, spices, mangoes, rice, dried
fruits, meat and meat products etc.
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 f. Prohibition of use of inorganic coloring matters.
g. Restriction on use of synthetic food colors (azo, xanthenes, etc.) in ice-creams,
cakes, fruit drinks, etc.
h. Restriction on use of poisonous metals such as lead, copper, arsenic, tin, zinc,
cadmium, mercury, chromium and nickel.
i. Restriction of use of insecticides on foodstuffs.
j. Restriction on use of solvent in extraction of cocoa, oils, fats, etc.
Report even slightest doubt about the quality of foods to Food and Drug Administration
and local health authorities.
Following are some simple tips to ensure safe and hygienic food in Canteens:
1. Buy raw as well as ready-to-eat food from safe and hygienic sources.
2. Prefer packaged foods and bottled beverage.
3. Insist on Agmark/ISI certified food products.
4. Check for ‘Expiry’ or ‘Best before’ date.
5. Ensure that food articles are packed in clean and hygienic wrappers/containers.
6. Avoid fruits with damaged skin.
7. Buy perishable foods last & take them straight Plant to refrigerator.
A. Storage & Handling
1. Refrigerate or freeze perishable foods quickly after purchasing.
2. Store leftovers at temperature below 10 ºC.
3. Keep raw meat, poultry, eggs, seafood and their juices away from ready-to-eat foods.
4. Avoid storing cooked food. To possible extent, prepare food freshly and serve
immediately
5. Protect food from insects, rodents and animals.
6. Store non-perishable foodstuffs in closed containers away from pesticides, disinfecting
agents or other toxic chemicals.
7. Never store foodstuffs in containers which have previously held toxic chemicals such as
insecticides, paints, varnishes, thinners, etc.
8. Avoid contact between raw foodstuffs and cooked foods through hands, flies, utensils or
unclean surface.
B. Food Preparation
1. Keep the food preparation premises meticulously clean. Keep scraps of food& crumbs in
safe covered place and dispose them of quickly.

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 2. Wash hands thoroughly before you start preparing or serving food and after every
interruption especially if you have changed the baby, used the toilet or been in contact
with pets.
3. Ensure safe water for food preparation. Boil it if its quality is doubtful.
4. Wash fruits and vegetables thoroughly using plenty of safe water particularly if they are
eaten raw, if possible, peel them off.
5. Cut vegetables & fruits first, then raw meat and poultry.
6. Wash cutting boards and utensils with hot soapy water after cutting raw meat and poultry
products and before slicing vegetables.
7. Recook the cooked food on addition of any new ingredient.
C. Consumption
1. Wash hands thoroughly using soap before eating.
2. Use clean dishes and utensils to serve food.
3. Never taste food that looks or smells strange to see if you can still use it. When in doubt,
do not use it.
4. Don’t eat cooked or perishable foods that have been kept in the refrigerator for too long
i.e. more than 2-3 days.
5. Prefer pasteurized or boiled milk.
6. Avoid food exposed to dust and flies

12.6 Snake Bite-First Aid and Antivenom

First –Aid
1. Put a tight bandage above the wound. This is very important.
2. Make a cross cut on the wound with a blade.
3. If possible, wash the wound with plenty of water for 10 minutes.
4. Advise victim to remain calm.
5. Rush the victim to medicate/hospital.
12.7 Standards/Guidelines for Control of Noise Pollution from Stationary DG Sets.
The Ministry of Environment and Forests (MoEF), Government of India has specified
following standards/guideline for control of noise pollution from stationery Diesel
Generator (DG) sets under Rule -3 of the Environment (Protection) Rules, 1986.
1. Noise standards for DG sets (15-1500 KVA)
The total sound power level, Lw, of a DG set should be less than, 94+10 log10 (KVA), dB
(A), at the manufacturing stage, where KVA is the nominal power rating of a DG set.
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2. Mandatory acoustic enclosure treatment of room for stationary DG sets (5 KVA and
above).
a. Noise from the DG set should be controlled by providing an acoustic enclosure or by
treating the room acoustically.
b. The acoustic enclosure/acoustic treatment of the room should be designed for
minimum 25 dB (A) insertion loss of for meeting the ambient noise standards,
whichever is on the higher side (if the actual ambient noise is on the higher side, it
may not be possible to check the performance of the acoustic enclosure/acoustic
treatment. Under such circumstance the performance may be checked for noise
reduction upto actual ambient noise level, preferably, in the night time). The
measurement for insertion loss may be done at different points at 0.5m from the
acoustic enclosure/room, and then averaged.
c. The DG set should also be provided with proper exhaust muffler with insertion loss
of minimum 25 dB (A).
3. Guidelines for the users of DG sets (5 KVA and above).
a. The manufacturer should offer to the user a standard acoustic enclosure of 25 dB (A)
insertion and also a suitable exhaust muffler with insertion loss of 25dB (A).
b. The user should make efforts to bring down the noise levels due to the DG set,
outside his premises, within the ambient noise requirements by proper fitting and
control measures.
c. The manufacturer should furnish noise power levels of the unsilenced DG sets as per
standards prescribed above.
d. The total sound power level of a DG set, at the users end, shall be within 2 dB (A) of
the total sound power level of the DG set, at the manufacturing stage, as prescribed
above.
e. Installation of a DG set must be strictly in compliance with the recommendations of
the DG set manufacturer.
f. A proper routine and preventive maintenance procedure for the DG set should be set
and followed in consultation with the DG set manufacturer which would help
prevent noise levels of the DG set from deteriorating with use.

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114
CHAPTER-13

PERSONAL
PROTECTIVE
EQUIPMENT

115
116
PERSONAL PROTECTIVE EQUIPMENT
13.1 Introduction
Accidents can be avoided in the following two ways:
a. By eliminating or reducing the hazards.
b. By providing proper protective equipment and ensuring their use by concerned
personnel.
Our endeavor should be to eliminate hazards completely but it may not be possible in all
cases and hence the necessity arises for providing personal protective equipment as a
second line of defence. It is very necessary that the selection of the protective equipment
is proper. Most of the injuries can be eliminated or minimized by utilizing proper
equipment required for the jobs.
13.2 Protective equipment can be divided into two categories:-
a. Respiratory protective equipment.
b. Non-respiratory protective equipment
13.2.1 RESPIRATORY PROTECTIVE DEVICES (BREATHING APPARATUS)
Oxygen Deficiency
Every living organ needs constant supply of oxygen. Cells in the brain and the nervous
system, if starved of oxygen for more than 4 to 6 minutes can be severely damaged and
even died due to permanent damage.
Oxygen deficient atmosphere is a major hazard in the industry. Table below gives the
signs and symptoms of a person at rest at different levels of oxygen deficiency.
Oxygen content in air Sign and symptoms of person at rest
12% to 14% * Respiration deeper, pulse up, co-ordination
poor
10% to 12% * Respiration fast & shallow, giddiness, poor
Judgment, lips blue
8% to 10% * Nausea, vomiting, unconsciousness, ashen
face
6% to 8% * 8 min- 100% Fatal +6 min- 50% fatal, 4-5
min –Recovery with treatment.
4% * Coma in 40 sec, convulsion, respiration
ceases death

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 It is important that one should not enter atmosphere containing less than 19 %
oxygen without a breathing apparatus set.
The air we breathe is sometimes contaminated with dust, vapours, toxic fumes or
gases. Various types of respiratory protective equipment are provided which enable us to
breathe in uncontaminated air even in the presence of contamination.
Each type of equipment has a definite purpose but its limitations must be kept in
mind. These will not provide protection in an atmosphere contaminated by a substance,
which can be absorbed by skin. The details of the Respiratory Protective equipment are as
under:-
A. Fresh Air Breathing Apparatus
Necessity
It must be used in all cases when it is necessary to enter an enclosed area where:-
1. Carbon Monoxide or any other combustible/toxic gas is present even in slight
concentration.
2. Canister cannot be used because the concentration exceeds the limit for canister.
3. There is a heavy smoke.
4. There is an oxygen deficiency.
B. Demand Flow Air Line Breathing Apparatus.
Introduction
It is constant flow air line respirator which provides complete respiratory, eye and facial
protection and is designed for use with a factory compressed air line or a low pressure air
compressor.
Application
It is used for extended work in a toxic or oxygen deficient atmosphere either in a factory
from the works air lines or in an outside location form a low pressure air compressor.
Applications include tank cleaning, zinc spraying and paint spraying or as a maintenance
breathing apparatus.
C. Colour codes
Table of colors assigned to canisters or cartridges (IS 8318-1977).
Atmospheric contaminants to be protected against.
Contaminants Color assigned
(As per BIS)
Acid gases White
Organic vapours Black
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 Contaminants Color assigned
(As per BIS)
Ammonia gases Green
Carbon monoxide gas Blue
Acid gases and organic vapours Yellow
Acid gases, ammonia and organic vapours Brown
Acid gases, ammonia, carbon monoxide Red
and organic vapours Other vapours
and gases not listed above Olive
Radioactive materials Purple
(Except Tritium and noble gases)
Dusts, fumes and mists Orange
(Other than radioactive materials)
Notes:
A purple stripe shall be used to identify radioactive materials in combination with any
vapour or gas. An orange stripe shall be used to identify dusts, fumes and mists in
combination with any vapour or gas.
D. Dust respirator
Dust Respirator may be used for all operations where annoying or irritating gases or dust
may be present in such small quantities that the canister gas mask is not needed.
13.2.2 NON-RESPIRATORY SAFETY DEVICES
13.2.2.1 Face and eye protections
A. Eye protection
To protect the eye and face against injuries from flying objects, splashing liquid and
harmful rays that cannot always be controlled at the source. Safety goggles, face shields
etc are provided. Nearly all eye injuries can be prevented by the use of eye protections.
B. Chipper goggles
These goggles provide protection against impact from flying objects while chipping,
cutting, grinding and performing striking operations such as breaking concrete.
C. Gas tight goggles
These goggles provide protection against splashes, sprays and mist of injurious liquids
such as chemicals, oil etc. they are required to be worn in areas where possibilities of a
splash exist.

119
D. Burning and gas welding goggles
For injurious light rays from acetylene burning and welding, specially shielded goggles
with special lens provide protection for this operation. The shade of lens varies with the
operation.
How to use
For maximum protection and comfort, goggles must be properly adjusted to fit the face.
The head band should be worn tight enough to hold the goggles firmly to the face.
Care of goggles
1. When goggles are not in use, keep them properly.
2. Keep your goggles and lenses clean.
3. Be sure head bands are in good conditions, get defective bands replaced.
4. The lens must be securely held in the frames. Inspect them for pits or scratches, which
may cause eye strain.
5. Be sure to use the correct type of goggles for the hazard involved. Consult your supervisor
in case of any doubt.
13.2.3 Face Shields
Certain operations present a hazard to the face as well as to the eyes. In such cases, face
shields provide suitable protection. The head band is the only adjustable feature on the
face shield. It should be adjusted so as to hold the shield in place. Since the shield is of
plastic, it is easily scratched. It should be replaced when these scratches cause interference
with the vision.
Selection of eye and face protective equipment

Operation Hazards Recommended protector

Burning, Sparks, harmful rays, molten Welding goggles (eye-cup type or
cutting, gas, metal flying particles plate type tinted lenses)
welding
Chemical Splash, acid burns, fumes Clear goggles and/or shield
handling
Chipping Flying particles Clear goggles (chipper)
Electric arc Spark intense rays molten Welding hood (with tinted lenses)
welding metal
Furnace Glare, heat Cobalt glasses or face shield
operations (chipper goggles)
Laboratory Chemical splash, glass Clear goggles or face shield
breakage
Machining Flying particles Clear chipper goggles or face
shield
120
13.2.4 Head Protection
Safety helmets are rigid headgears of different materials designed to protect the
workman’s head –not only from impact but also from flying particles and electric shock or
any combination of the three.
13.2.5 Hand protection
1. Protective gloves are required to be used for protection of the hands against the injurious
effect of chemical, heat, heavy material, oil, electricity etc.
2. Rubber gloves give protection to the hands against the injurious effect of chemicals.
3. PVC gloves give protection against chemicals and solvents chemicals or oil should be
washed from the gloves after use.
4. Canvas gloves should be used while handling material or working on equipment where
there is possibility of getting cuts and abrasion on hand.
5. Electrical gloves should be used by employees while working around high voltage lines.
These should be thoroughly inspected before use.
6. Asbestos gloves should be used for protecting hands against heat.
13.2.6 Foot protection
Rubber boots are used to protect against chemical, splashes. Safety shoes are used to
protect against heavy weight.
13.2.7 Body protection
PVC aprons
These provide protection for the body when working with chemicals aromatics or
solvents.
13.2.8 Hearing protection
Any unwanted sound is called noise. It consists of invisible vibrations that enter the ear
and create an auditory sensation. Sound can be conducted through solids, liquids or gases.
Some important properties of noise in evaluation its effect on man’s hearing are intensity,
frequency and duration. The louder the noise, the more it is damaging. Also the longer the
noise exposure, the greater is the damage to the human hearing mechanism.
A. Ear plugs
This type of plug is inserted into the ear canals and varies considerable both in design and
material. Materials used are rubber, soft or hard plastic or cotton.
B. Ear muffs
These cup or muff type devices cover the external ear to provide an acoustic barrier.

121
13.2.9 Safety Belts
Description
All employees must use safety belts to give protection in performing jobs at elevated
locations where adequate protection against falling is not available. Safety belt and body
harness with a life line fastened at the back should always be used whenever one works on
an elevated location or enters into the tanks or bins so that he can be easily lifted and
brought out. Belt and harness for this purpose may be chrome-tanned leather or cotton
webbing. Webbing is much stronger than leather and if it is impregnated with rubber or
wax, it works reasonably well in the vicinity of chemicals tanks, Well tanned leather is not
easily attacked by most chemicals but it should not be left in contact with chemicals for
long.
Maintenance and inspection
Life belts must be inspected carefully before each use. Fabric belts must not be used if the
outer plies are cut or worn out or if there is any sign of damage from chemicals. All belt
hardware must be inspected and replaced if these show any sign of wear. The life line
must also be carefully inspected for any sign of damage or wear. If in doubt replace the
rope. Be sure that the life line is securely attached to the sling of the belt. If a life belt is
exposed to or comes in contact with chemicals during use, clean it immediately. Keep the
belt clean, dry and in good condition your life may depend on it.
13.3 Safety equipment and their specific use:
FIRE
Because of highly inflammable nature of crude oil and various petroleum products, fire is
a major hazard in a Thermal Plant. While fire under controlled conditions and coal serves
the industry in various ways by imparting energy for various process needs, uncontrolled
fires can become most destructive, causing loss of life, property and facilities.
Fire is produced as a result of chemical reaction between oxygen and carbon or
hydrocarbon releasing heat and light energies. There are 3 basic items, which are
necessary to cause a fire, viz fuel vapour, oxygen and a source of ignition. This
combination causing combustion is known as
“Fire Triangle” and is illustrated in the following figure.
Temp.

Fuel O2
122
 Keeping in view the serious consequences due to fire in any area of Thermal Plant
installation, “Fire Protection” is the key objective. Every care should be taken to prevent
the occurrence of the fire rather than extinguishing it after it occurs. The occurrence of fire
can be prevented if we don’t allow formation of fire triangle by eliminating at least one of
its sides.
Only the fuel and the oxygen sides of fire triangle can be removed easily. The fuel air
mixture formation can be avoided by preventing air from getting into any system
containing hydrocarbons. The source of ignition can also be controlled to some extent by
proper guarding and a number of other means such as:
1. All hot work should be carried out under fully authorized “Hot Work” permit and all
specific conditions should be met.
2. Smoking is strictly prohibited in oil handling areas of Thermal Plant.
3. No vehicle should be allowed to enter the Thermal Plant area without a valid permit.
4. No make-shift electrical connection should be made as they can also produce ignition
hazard.
Since air is one of the sides of fire triangle, it is very important to keep it away from
hydrocarbons except in specified situation. There is a possibility of formation of pockets
of explosive mixture, and a major hazard can occur if the explosive mixture catches fire
due to static electricity which is produced because of agitation of two phases present in the
reactor.
5. For burning of a gaseous mixture, in addition to three sides of fire triangle, a fourth
condition is necessary, i.e. the fuel and oxygen must be present within certain
concentration limits. These limits are known as “Explosive Limits”, and usually expressed
as the volumetric percentage of fuel in fuel-air mixture, which upon ignition are capable of
propagating flames from one point of ignition throughout the entire mixture. Any process
facility must be completely purged of air before being placed in hydrocarbon services.
Care must be taken not to let air leak in to any system operation under vacuum. When a
vessel is taken out of service, one must ensure total drainage of hydrocarbons, positive
isolation, purging with steam, flushing with water and proper ventilation of air by opening
manhole covers before allowing entry of any person for maintenance work.

123
124
 CHAPTER-14

CHECK-LISTS
FOR
CONSTRUCTION
&
OPERATION OF
PLANT

125
126
14.1 CHECKLIST FOR SAFETY IN CONSTRUCTION
14.1.1 Excavation

1. Carrying out ground investigations (including soils and services etc.)

2. Planning for shoring and work system.

3. Providing means for removal of water and soil.

4. Carrying out site inspection and prevention of excessive loading from the excavation
edges.

5. Providing gangways for crossing trenches.

6. Providing safe access in excavations.

7. Ensuring no children are left at excavation sites.

8. Providing fencing and warning lights.

9. Providing means for rescue in the event of earth collapse.

10. Providing effective supervision.

14.1.2 Pile Driving
1. Inspecting piling machines for firm grounding.
2. Carrying out inspection of machine for machine guarding .
3. Taking precautions in hoisting piles into position.
4. Providing tight fitting clothes and personal protective equipment’s to employees.
14.1.3 Scaffolds
1. Installing according to scaffolds requirements.
2. Inspecting by competent person.
3. Ensuring no overloading of scaffolds/platforms.
4. Securing scaffolds with bracing and ties.
5. Ensuring scaffolds free from defects.
6. Inspecting working platforms of the scaffolds.
7. Inspecting both guard rails and toe boards.
8. Ensuring spacing between guard rails are properly maintained as per standards.
9. Providing means of access to working platforms.

127
14.1.4 WORKING AT HEIGHTS
1. Covering all floor openings.
2. Providing railings on open sides and lift openings.
3. Securing access staircase/ladders.
4. Providing scaffolds.
5. Inspecting hoists, lifts, cranes & lifting gear.
6. Co‐ordination between the working teams is being done.
7. Guarding dangerous parts of machines.
8. Providing safe foothold for work construction.
9. Providing safety belts, helmets and other PPEs and ensuring their use.
10. Providing provision for tying up safety belts.
11. Providing effective supervision to ensure safe operation and practice.
12. Welding/cutting is permitted only after taking safety precaution.
13. Providing means of protection against fall of objects.
14. Providing means of protection against fall of persons.
15. Providing means of access to higher elevations.
16. Providing waste disposal means.
17. Providing lighting, emergency lights and ventilation.
18. Inspecting all the ladders and staircases.
19. Providing safe access to move around the floor.
20. Providing fire protection means.

14.1.5 ELECTRICAL SYSTEMS

1. Ensuring safe component/equipments are used.
2. Providing earth leakage circuit breakers on all electrically operated power
tools/equipments.
3. Inspecting power tools before use and ensuring defective tools are discarded.
4. Using 3 core cable and 3 pin plugs for all portable tools and ensuing its earthing.
5. Authorized electrician is only attending all electrical jobs.
6. Ensuring double earthing to all equipments.
7. Ensuring all the electrical system are as per Indian Electricity Rules.
8. Disconnecting and removing all unwanted cables and wires from electrical system.
9. Identification Marks and Numbers are clearly being marked on all electrical distribution
boards, switchboards, motors etc.
128
 10. All electrical system components being protected against damage.
11. All electrical joints are being tested to meet the standards.
12. Hand lamps are provided with suitable guards.
13. Providing Personal Protective Equipments including electrical safety shoes, rubber gloves
etc.
14. Ensuring unauthorized person shall not have access to electrical system.
15. Protecting all live parts.
16. Ensuring all fuses are of actual current rating.
17. All the joints are being properly insulated and protected against mechanical damages.
14.1.6 WELDING AND CUTTING
1. Providing required Personal Protective Equipments to welders and ensuring their use.
2. Ensuring to protect fall of welding sparks down on the persons working below and
combustible material.
3. Combustible material near vicinity of welding / cutting work being protected.
4. Fire extinguisher is kept ready for use in case of emergency.
5. Adequate precautions being taken while welding/cutting operation is done in confined
space.
6. Inspecting all the gas cylinders and ensuing the storage, handling and transportation for
safety.
7. Inspecting all welding machines and ensuring their cables are properly connected.
8. Inspecting electrode holders.
9. Frames of arc welding machines are effectively earthed.
10. Providing refusal (rejection / waste) boxes to keep refused (rejected) electrodes and other
waste material.

14.1.7 Lifting Machines and Tackles

1. All the lifting equipments are tested and certified by competent person/authority.
2. Safe working load marked on all lifting equipments and tackles.
3. Records for all lifting equipments are being maintained .
4. Ensuring only authorized person are using lifting machine.
5. Checking lifting equipments before use.
6. Ensuring safe working load does not exceed.
7. Assessing the load to be lifted.
8. Ensured that lifting and placement of material is done properly.
129
 9. Ensuring standard signals are followed.
10. Inspecting all hoists and lifts & cranes.
14.1.8 DEMOLITION
1. Inspection of the area and structure to be dismantled.
2. Disconnecting all the service lines eg. electricity, water, gas etc.
3. Supporting the uncontrolled collapse of walls, pillars and other structure.
4. Proper means such as chutes are provided to carry the waste material from floor to
ground level.
5. The area is fenced and caution boards are provided.
6. Personal Protective Equipments are issued to the workers and ensuring their use.
7. Effective supervision is provided till completion of the demolition and ensured
demolition is done systematically.

130
14.2 CHECKLIST FOR WORKING AT HEIGHT
The following points should be checked and compiled with before start of work at height.

(Please put tick (√) mark in the appropriate box)

LOCATION OF WORK :
DATE:
NOT REQUIRED
SR.
POINTS TO BE CHECKED DONE (WITH
NO.
REMARKS)
1. Work area below is temporarily cordoned /
barricaded.
2. Openings in Walkways and platforms (if any) are
properly barricaded.
3. The scaffold erected has iron pipes and clamps in
good condition.
4. Diagonal / lateral bracings pipes are provided to
ensure stability
5. Planks / sheets as temporary platform are tied
properly using binding wires
6. Metallic Planks / sheets used in temporary
platforms are in good condition
7. Temporary platforms are having side railing and
toe guards.
8. Working platforms and walkways are free from
oily and greasy surface.
9. Access ladder is provided to reach the work
location.
10. Wooden bellies and wooden planks are not used
as scaffold
11. The slings / pulley blocks / ropes being used are
tested for fitness and certificates are available
12. Portable electrical equipments are checked for
healthiness including earthling / fiber body
13. Proper illumination available at work location.
14. Workers are wearing Helmet, Shoe, Safety belt
15. For anchoring of Safety Belt at height, rigid
support / life line is provided.
16. Fall arrestors are provided to workers at height in
good condition.
17. Safety nets are provided below the work location.

131
 18. Workers having height experience with physical
fitness are only engaged for work at height.
19. Workers are briefed on Safety Precautions to be
taken (Do’s / Don’ts)
20. Lone workers are not allowed at height, at
uneven, narrow and confined space. Extra care in
taken in such cases.
21. Supervisory staff of agency is available during
the work

Date:________
Signature :__________________
Name of safety officer of Plant/Agency:_____________

132
14.3 OTHER CHECKLISTS FOR ELECTRICAL WORKS
The following points should be checked and complied with before start of work involving
electrical power supply
(Please put tick ( √ ) mark in the appropriate box)

LOCATION OF WORK:
Date:

Sr. Done Not Required

Points to be checked
No. (with remarks)

1. Electrical equipment /tools are in sound condition

and inspected /tested for its healthiness

2. Body earthing is provided to machine / electrical

hand tool
3. The switches / Fuses/ Plug top used are of
appropriate rating.
4. The power cable is having three cores in case of
single phase and four cores in case of 3 phase
supply.
5. The joints in power cables are properly insulated

6. For Welding cable , job earth and joints are proper

7. Electrical machine/tools cables are free from

obstruction , contact with water and hot sparks

8. ELCB is provided in the supply system

9. Use of 24 volts hand lamp in confined space /vessel

10. Permit to work has been taken

11. Proper access and illumination are available to
switch boards and work location

12. Safety tags are provided

13. Engagement of experienced and authorised workers
for doing the work
14. Workers are briefed on safety precautions to be
taken

133
 15. Use of Helmet, Shoes, Gloves , Face shield and
Safety belt (height work) by worker

16. Worker is not exposed to rain and not standing on

wet /water logged location

17. Second person is available with the engaged worker

18. Agency supervisor deployed

Checked by

Counterchecked by

Name of Engr/ Supvr: ( Agency ) Signature:

Name of Engr: ( HPGCL) Signature:

134
 14.4 CHECKLIST FOR WORKING INSIDE CONFINED SPACE
The following points should be complied with before start of Work / Repair inside confined space.

Please put tick (√ ) mark in the appropriate box

Location of work

Date

Not Reqd.
Sr.
Points to be checked Done (with
No.
Remarks)
1. The valves on inlet pipes to tank/ vessel are in closed condition
2. The closed valves on inlet pipes are locked
3. Manholes in tank/vessel are in open condition and are cordoned
4. Oxygen content is checked for the space inside tank /vessel and
oxygen content is more than the minimum specified (20%)
5. The space inside tank /vessel is free from toxic / poisonous gases
6. Forced Ventilation arrangements for Air Circulation inside
Tank/vessel has been provided
7. For Height works inside confined space
• Diagonal /lateral bracings are provided to pipe scaffold to ensure
stability
• Access ladder is provided to reach the work location
• Planks /sheet used in temporary platform are in good condition
and are tied properly using wires
8 . Workers are wearing Helmet/Shoe / Safety belt in good condition
9 . Dust mask / respirator is provided to workers for protection against
dust / fumes
10 Experienced workers are engaged for work
11 Portable electrical equipment /fiber body checked ,for its healthiness
including earthing
12 Workers are briefed on Safety Precautions to be taken (Dos/ Don’ts)

13 24 volts hand lamps provided for inside at work location

14 Supervisory staff of agency is available

Checked by Counterchecked by
Name of Engr/ Supvr: Name of Engr: ( Agency )
( HPGCL)
Signature: Signature:

135
14.5 CHECKLIST FOR TRACK HOPPER

Sr.
POINT STATUS REMARKS
No.
01 Availability of spray system above wagon Available / Not available
at whole length of Track Hopper
02 Healthiness of spray system above wagon OK /Not OK
at whole length of Track Hopper
03 Track Hopper Service Bay checker plate Properly fixed / not fixed
condition
04 Writing of SWL on Hoist at Bottom level Written / Not written
05 Writing of Test date on Hoist at Bottom Written / Not written
level
06 Writing of SWL on Hoist at Top level Written / Not written
07 Writing of Test date on Hoist at Top level Written / Not written
08 Availability of Fire extinguishers inside Available / Not available
Track hopper
09 Availability of Ventilation system Available / Not available
10 Healthiness of Ventilation system OK / Not OK
11 Healthiness of Stair steps up to Bottom OK / Not OK
level
12 Healthiness of Hand rail at stair up to OK / Not OK
Bottom level
13 Availability of Toe guard at landing Available / Not available
platform of staircase
14 Availability of Limit switch at plough Available / Not available
feeder
15 Availability of Stopper at both end of Available / Not available
each rail of plough feeder
16 Availability of PA system at Top and Available / Not available
Bottom of Track Hooper
17 Healthiness of PA system at Top and OK / Not OK
Bottom of Track Hooper

18 Insulation condition of power cables for OK / Not OK

plough feeders
19 Sump pump working condition Working / Not working
20 Fencing / Covering of sump pit to avoid Available / Not available
falling of man and materials
21 Illumination at Bottom land Proper / Not proper

136
 22 Emergency lighting arrangement at Available / Not available
Bottom level for both wall side

23 Availability of Hinge door / Table skirt at Available / Not available

plough table
24 Availability of Pull cord at whole length Available / Missing
of conveyor at both sides
25 Working condition of Pull cord OK / Not OK
26 House keeping at Top level Satisfactory / Not
satisfactory
27 House keeping at Bottom level Satisfactory / Not
satisfactory
28 Use of PPEs by Working People Satisfactory / Not
satisfactory
29 Tail pulley Guard Available / Not available

Checked by:

Signature:
Name:
Designation:
Date:

137
14.6 CHECKLIST FOR CRUSHER HOUSE
Sr.
POINT STATUS REMARKS
No.

01 Statutory testing of Lift

Done / Not done

02 Capacity of Lift
Written / Not written

03 SWL of Lift
Written / Not written

04 Date of testing
Written / Not written

05 Healthiness of Lift
Working / Not working

06 Statutory testing of Hoists

Done / Not done

07 SWL of Hoists
Written / Not written

08 Date of testing
Written / Not written

09 Hoist level at Crusher house floor

Normal / More

10 House keeping at different floors

OK / Not OK
Satisfactory / Not
11 Use of PPEs by workers
satisfactory
Availability and provision of 24 volt
12 supply arrangement at crusher house
floor Available / Not available
Availability and provision of 24 volt
13 supply arrangement at Vibro feeder
floor Available / Not available
Tightness of inspection gate of
14
crasher OK / Not OK

15 Healthiness of floor end railing

OK / Not OK

16 Healthiness of dust extraction system

Working / Not working
Dust leakage at different floor, (if
17 leakage observed, name of equipment
to be mentioned) Yes / No

18 Cleanliness of cable tray

Clean / Not clean
138
 Availability of fire extinguisher at
19
different floors Available / Not available
Healthiness of fire hydrant line at
20
different locations OK / Not OK
Availability of required pressure in
21
fire hydrant line at different locations Available / Not available
Emergency Stop Bottom at crasher
22
floor Available / Not available
Availability of Emergency Stop
23
Bottom at Vibro feeder floor Available / Not available
Availability of Pull cord at both sides
24
of belt feeder Available / Not available
Healthiness of Pull cord at both sides
25
of belt feeder OK / Not OK

26 Guard for movable pulleys

Available / Not available

27 Guard of coupling
Available / Not available

28 Approach to different locations

Available / Not available

29 Illumination of different floors

Good / Not good

30 Healthiness of Stair steps

OK / Not OK

31 Healthiness of Hand rail at stair case

OK / Not OK
Working of PA System at different
32
floors OK / Not OK

Checked by:

Signature:
Name:
Designation:
Date:

139
14.7 CHECKLIST FOR BUNKER

Sr.
POINT STATUS REMARKS
No.
Availability of Dust
01
extraction/Ventilation system Available / Not available
Healthiness of dust
02
extraction/Ventilation system OK / Not OK

03 Seat Belt condition Properly covered / Not

covered

04 Grizzly hole condition

OK / Not OK
Cleanliness of Cable tray / Electrical
05
panel OK / Not OK

06 Cleanliness of walkway Satisfactory / Not

satisfactory

07 Availability of Limit switch at tipper

Available / Not available
Availability of stopper at both end of
08
each Rail Available / Not available

09 Use of PPE by workers Satisfactory / Not

satisfactory
Availability of Spray system over
10
conveyor Available / Not available
Healthiness of Spray system over
11
conveyor OK / Not OK
Availability of Fire hydrant point at
12
different locations Available / Not available
Healthiness of Fire hydrant point at
13
different locations OK / Not OK

14 Statutory testing of Hoist

Done / Not done

15 SWL written on Hoist

Written / Not written

16 Test date written on Hoist

OK / Not OK

17 Healthiness of floor end railing

OK / Not OK
140
 Availability of Pull cord at whole length
18
of conveyor at its both sides Available / Not available

19 Healthiness of Pull cord

Working / Not working
Availability of sway switch at different
20
locations Available / Not available
Healthiness of sway switch at different
21
locations Working / Not working
Availability of Fire Extinguishers at
22
required location Available / Not available
Availability of Tail Pulley / Head Pulley
23
Guard Available / Not available

24 Availability of Coupling guard

Available / Not available

25 Illumination in Bunker area

Sufficient / Not sufficient
Availability of Emergency Push Bottom
26
at head pulley Available / Not available
Working of PA System at different
27
floors OK / Not OK

Checked by

Signature:

Name:
Designation:
Date:

141
14.8 CHECKLIST FOR COAL YARD INCLUDING STACKER, RECLAIMER AND
CONVEYORS

Sr.
POINT STATUS Remarks
No.
01 Illumination OK / Not OK

02 Tightness of Rail Track. Proper / Not proper

03 Availability of stopper at both end of Available / Not

each Rail. available
04 Availability of Emergency stop button at Available / Not
lower level of Stacker / Reclaimer. available
05 Healthiness and laying arrangement of OK / Not OK
power cables.
06 Hand Rail conditions where ever is OK / Not OK
required at Reclaimer and Stacker.
07 Approach to Reclaimer / Stacker up to OK / Not OK
Operator’s cabin.
08 Provision of Fire hydrant and their OK / Not OK
healthiness in piles.
09 Availability of Sufficient / Required Available / Not
water pressure in hydrant line. available
10 Availability of Pull cord for whole length Available / Not
of conveyor on both sides. available
11 Healthiness of operation of Pull cord. OK / Not OK

12 Condition of Drainage system in piles. OK / Not OK

13 Any spontaneous fire. Found / Not found

14 Housekeeping of the area. OK / Not OK

15 Water sprinkler system in pile. Available / Not

available
16 Use of PPEs by working personnel. Satisfactory / Not
satisfactory
17 Availability of Fire Extinguishers at Available / Not
Reclaimer and stackers. available

142
 18 Availability of sway switch in different Available / Not
location along the conveyor. available
19 Healthiness of sway switch in different OK / Not OK
location along the conveyor.
20 Availability of Phone / PA System at Available / Not
Reclaimer and Stacker. available
21 Healthiness of Phone / PA System at OK / Not OK
Reclaimer and Stacker.
22 Writing of SWL on Hoist. Written / Not written

23 Writing of Test Date on Hoist. Written / Not written

24 Guard for Head pulley, Tail pulley and Available / Not

coupling of conveyors available

Checked by

Signature:

Name:
Designation:
Date:

143
14.9 CHECKLIST FOR MARSHALLING YARD

Sr.
POINT STATUS Remarks
No.
01 Signalling system in the track
OK / Not OK
02 Cautioning for speed limit at different
locations Proper / Not proper
03 Exchange of token system for single line Available / Not
operation available
04 Loose shunting of wagons not to be done
OK / Not OK
05 Proper brake system and head light in loco
OK / Not OK
06 Idle engine should
OK / Not OK not
07 Alignment of track to be checked regularly
OK / Not OK
08 Regular supervision of track by trained
gangmen to ensure healthiness of track OK / Not OK
09 Fish plates, bolts and pendrol should be
checked for its tightness OK / Not OK
10 Spreading of uniform and required number
of blast / stone for strengthening of tracks Available / Not
available
11 Points and curves to be checked periodically
OK / Not OK
12 Regular inspection of bridges and culverts
specially during monsoon period OK / Not OK

13 Medical check up (Eye sight and Hearing)

for drivers, points man and controller Done / Not done

14 Regular training for MGR staff

Done / Not done
15 Maintenance of Loco and Wagons
Done / Not done

Checked by
Signature:
Name:
Designation:
Date:

144
CHAPTER-15

WORK
PERMIT

145
146
15.1 WORK PERMIT
A. Importance of Safety Permit System
In Thermal Plant, it is necessary to have a practicable and sufficiently safe system of
isolation of Plants and equipment containing highly flammable, toxic, poisonous and
corrosive materials so that the hazards are eliminated and the maintenance jobs are carried
out with a higher factor of safety. This can best be achieved by a proper and effective
safety work permit procedure which also fulfills the requirement under section 36 and 37
of the factories Act 1948. For the proper isolation of Plants, it is, therefore, very
necessary that we have a well laid down safety permit system and all the employee are
educated for the follow up of this system. There must not be any relaxation in the
observance of safety rules for the well knit safety efforts and the safety permit system
must be scrupulously followed. Here it becomes necessary to elaborate as to what safety
permit procedure is and how best we can improve upon our procedures. Once the
importance of this system is felt by one and all, our objectives for the safe maintenance
jobs will automatically be achieved.
B. What is Safety Permit?
It is written authorization for a maintenance job to be done on a system or on equipment
after all practicable steps have been taken to ensure the safety of men, material and
machines before the job is started and such safe conditions are maintained while job is
performed. It may not be always possible to achieve cent percent safe conditions but the
system ensures the best possible means of achieving the safe working conditions.
However, it may sometimes be difficult to avoid some calculated risk and under such
circumstances, it is always advisable to ensure all preparations and precautions.
C. Why it is necessary to issue a written permit?
It ensures a positive and clear communication. It doubly ensures that all the steps
necessary to achieve safe conditions of work have really been taken before the job is
started and further all the precautions will be taken while performing the job. In the words,
no reliance is placed on verbal instructions and communication as these are subject to
human errors.
15.2 ISOLATION AND PREPARATION OF EQUIPMENT
A safety work permit has to be issued by the operation personnel to the maintenance
personnel enlisting all the precautions, which are to be taken when the work is in progress.
In general the following types of jobs need isolation and also a work permit:

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1. All hot jobs like hot jobs in vessel, piping, equipment etc. which is likely to contain or
had contained explosive gas, liquid or poisonous chemicals.
2. Working on or adjacent to tanks containing inflammable or corrosive substances.
3. Working on electrical system
4. Working on the roof of tank or Plant building
5. Working on any underground drain or on industrial sewage system.
6. Entering vessels or confined place for inspection of maintenance jobs.
7. Jobs involving execution, road cutting, dike cutting.
When the necessity arises for a person to enter into the vessel; the following procedures
should be followed.
A. Equipment electrically isolated and tagged
It should be ensured that electrical switches are locked out and caution notice attached.
Whenever local locking arrangement is provided in the field, the same should be used.
B. Equipment blinded/disconnected/close/isolated/wedged open
Equipment/vessel should be completely isolated during working period in order to ensure
that there is no change in the work environment with respect to presence of
toxic/flammable gases, liquid, hazardous chemicals etc in the course of work.
C. Equipment properly drained/de-pressurized
Equipment under pressure should be de-pressurized after isolation. This will be followed
by draining/ purging/ water flushing etc. as the case may be.
D. Equipment properly steamed/purged
Purging of equipment (Vessels, pipelines, compressors) is done to free them from
flammable hydrocarbons and toxic gases, steam, inert gas, nitrogen are used for gas-
freeing of vessels and pipes in Thermal Plant and processing unit. Other means of purging
is by displacement with water and final traces of gas removed by air educator. All high
point vents should be unplugged, while purging. Purging may be done continuously or in
batches to conserve purge medium. It should be done in a systematic manner to cover the
entire equipment/Plant and continued till the allowable level of toxic/flammable gas
concentration.
E. Proper ventilation and lighting provided
Where natural ventilation is not available, fans/air educators are provided. Some types of
works like welding may generate fumes. Facilities may be required for the speedy
dispersal of these fumes. Only approved reduced voltage extension lights (24 volts) are to
be allowed for work inside vessels, from consideration of personal safety.
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 F. Proper means of Exit provided
Proper means of Exit is required in case of emergencies developed on account of the work
or otherwise. Availability of an alternate route of escape should be considered.
G. Precautionary tags/boards provided
To prevent any unwarranted entry in the work area and also to caution other personnel
taking actions which may endanger people working on the permit job, precautionary
tags/boards are to be provided. Examples, ‘No Entry’ sign on roads or ‘Caution- Men At
Work Inside’ on the manhole of a vessel.
H. Standby person provided for vessel entry.
Whenever a vessel is being entered or work is being carried out in confined space, it may
be necessary to keep standby persons at the manhole or entry point holding the rope
connected to the safety belt of the person inside. In case of any emergency inside or
outside the vessel the standby will be able to pull the person out.

15.3 TYPE OF WORK PERMITS:

Based on the nature of work, the work shall be undertaken after issue of work permit.
Before commencement of any work, permit must be obtained.
A. CONFINED SPACE OR GASEOUS AREA
Confined space in the Thermal power stations context is defined to have the following
four main characteristics.
1. The space has limited or restricted opening for entry or Exit. Making it difficult for an
individual to enter with life saving equipment or to rescue an individual in case of
emergency.
2. The space is not designed for continuous human occupancy.
3. The space may contain known or potentially hazardous atmospheres. Oxygen deficiency,
presence of flammable/explosive, toxic or otherwise injurious, asphyxiating or
incapacitating substances.
4. A space where conditions of engulfment of any other recognized serious safety or health
hazards may develop or exist.
5. Typical confined space may have one or more of the characteristics. Common confined
spaces in Thermal Plants include storage tanks, stills vessels, boilers, ducts, sewers,
pipeline, utility manholes, scrubbers, columns, tunnels etc.

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 6. All these confined spaces need to be entered occasionally for various reasons including
inspection and testing of equipment. Process and materials cleaning to remove undesired
materials or to prepare for different usage, repair and maintenance operations and rescue
of injured or incapacitated individuals.
7. A vessel entry permit must be obtained to enter in vessel.
8. Toxic gases other than petroleum gases may be encountered in the Thermal Plant.
Breathing apparatus must be worn or other precautions to be observed.
9. In all case it should be ensured that oxygen level is at least 19.5% and the concentration of
toxic gases below the threshold limits. Breathing apparatus of suitable type should be
prescribed by the person issuing the vessel entry permit.
Emergency procedures
A detailed procedure to deal with emergency situation related to confined space entry and
step-by-step instructions for rescuing an individual from the confined space must be
prepared in advance and communicated to all people connected with such operations.
The individual entrant in the confined space must be equipped with full body harness and
life line which can be attached to a pulley/and wrench or hand operated hoist to facilitate
rescue by stand-by-person/rescue team.
At least one stand-by-person stationed outside the space should maintain continuous
communication with the confined space occupant. Stand-by person must be equipped with
suitable rescue equipment with lifeline and preferably trained in first aid.
Stand by person should also be in contact with rescue team as the situation warrants it.
When suitable demand rescue stand by personnel should not enter the confined space
without securing additional help from other stand by rescue personnel. This ensures that
the rescue operation receives continuous monitoring.
Appropriate first aid and rescue teams should be alerted before confined space entry work
begins indicating date, time, place and expected activity duration. This ensures that some
team members are available to respond as needed.
15.4 Training
A comprehensive training programme must explain the following:-
1. Entry permits system, posting of sign and designation of personnel responsible for
assigned tasks.
2. Calibration and testing of air monitoring equipment.
3. Preparations and protocol for atmosphere monitoring.
4. Blanking off and disconnecting pipelines and isolation of hazardous energy sources.
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5. Purging and use of forced mechanical ventilation.
6. Use of personal protective equipment.
7. Use of rescue equipment and techniques.
8. First aid procedures.
9. Specific responsibility of confined space entrant standbys & rescues personnel etc.
Training of contractor, supervisor and their men
Usually the cleaning or other works in the confined spaces at Thermal Plant are being
carried out by contractors, supervisors and workers need to be given basic safety training
demanded by such work like.
1. Entry permit system and potential dangers in confined spaces. Danger of unauthorized
entry into confined spaces
2. Specific responsibility of confined space entrants, standby and rescue personnel and
communication system.
3. Use of rescue equipment and techniques.
4. Use of personal protective equipment.
Suitable training aids/modules and methodologies to cover all such contractors and their
workmen who are required to work in the confined spaces.

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152
CHAPTER 16

PERFORMA

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 (HARYANA POWER GENERATION CORPORATION LIMITED)

PRELIMINARY ACCIDENT REPORT

Department:………………………………………………… Date:
……………………………………….
Name of Injured : ………………………………………………
Designation : …………………………..
Date of birth/age : ………………………………….
Father’s Name : ……………………………………….
Permanent home address :
……………………………………………………………………………………
Date & hour of accident : ………………………………………
Shift : …………………………………….
Exact Place of accident:
….………………………………………………………………………………….
Equipment involved :
……………………………………………………………………………………….
Describe briefly, how accident occurred:
………………………………………………………………………………………………………
……………………………………………………………….
………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………………………………………………………
Nature & extent of injury = (e.g. Fatal, cut, burn, chemical splash, particle in eyes, blunt injury,
Fracture etc.)
:……………………………………………………………………………………………………
Body Part (s) affected (e.g. right leg, left hand, right eyes etc.)
:…………………………………………………………………………………………………
OFFICER INCHARGE/Executive Engineer:-
Name:-
Signature
TO BE FILLED BY MEDICAL OFFICER
I have examined Shri ………………………………………………. at …………… hours
The nature and extent of injuries are as under:
 The injured is advised rest for: ………………………… days(s)
w. e. f. …………………………
 Injured is fit to resume his normal duties/light work.
 Injured is referred to hospital/admitted in company’s dispensary.

MEDICAL OFFICER

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 (HARYANA POWER GENERATION CORPORATION LIMITED)

Work Permit from Safety Department

Working at Height
Permit Book Date
No. No.

Department:
Description of work:
Check clearance from Shift Charge Engineer, if required:
Expected Outage hours:
Sr. No. Safety Checks Yes No Not Applicable
1. Temporary Working Platform
2. Guardrails
3. Adequate Ladders
4. Adequate Illuminations
5. Non Slippery Footwear
6. Helmet
7. Safety Harness/Belt
8. Crawl Boards/Safety Nets (For fragile
roof working)
Remarks of Safety Department:
…………………………………………………………………………
………………………………………………………………………………………………………

PTW ISSUED BY PTW ISSUED TO

NAME NAME
DESIGNATION DESIGNATION
SIGNATURE SIGNATURE
DATE DATE
TIME TIME

PTW RECEIVED BY PTW CANCELLED BY (SAFETY)

NAME NAME
DESIGNATION DESIGNATION
SIGNATURE SIGNATURE
DATE DATE
TIME TIME

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NOTE :

1. The permit shall be issued by Contractor’s Engineer to Contractor’s Supervisor.

Supervisor shall fill all the columns of the format.

2. This requirements relating to issue of Permit shall be checked by Contractor Safety

Officer at least in 25% of all cases.

3. The Permit is to be issued only after explaining the workers of hazards of working at
height and required safety measures.

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 (HARYANA POWER GENERATION CORPORATION LIMITED)

Work Permit from Safety Department

Working at Confined Space

Permit No. Book No. Date

Department:
Description of work:
Check clearance from Shift Charge Engineer, if required:
Expected Outage hours:
CLEARANCE from SAFETY I/C:
SAFETY CHECKS:
1. CLEAR CUT INSTRUCTION TO THE WORKER/CONTRACTOR.
2. ADEQUATE VENTILATION (TO AVOID/MINIMIZE THERMAL STRESS & DUST
EMISSION)
3. ADEQUATE ILLUMINATION.
4. WARNING SIGN/CAUTION NOTICE FOR OPENINGS.
5. PROPER FIXING OF ROPE LADDERS.
6. CONTINUOUS SUPERVISION FROM OUTSIDE WITH COMMUNICATION
SYSTEM.
7. USE OF PPES i) Nose Mask: Yes/No/N.A. ii) Safety Belt: Yes/No/N.A. iii) Shoes:
Yes/No./N.A iv) Goggles: Yes/No/N.A v) Helmet: Yes/No/N.A
Remarks of Safety
Department:……………………………………………………………………….
………………………………………………………………………………………………………
…………………………………………….
PTW ISSUED BY PTW ISSUED TO
NAME NAME
DESIGNATION DESIGNATION
SIGNATURE SIGNATURE
DATE DATE
TIME TIME

PTW RECEIVED BY PTW CANCELLED BY (SAFETY)

NAME NAME
DESIGNATION DESIGNATION
SIGNATURE SIGNATURE
DATE DATE
TIME TIME

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 (HARYANA POWER GENERATION CORPORATION LIMITED)
PERMIT TO WORK
OPERATION DEPARTMENT
Book No. _______________
Permit No. __________
Equipment _______________________
Type of Main BD/PM _____________________
Unit ___________________________________
I hereby declare that the following equipments are isolated and safe to work. Caution notice has
been fixed to all (Details of isolation to be mentioned below):
………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………………………………………………………
…………………………………………………………………………………………….
Description ISSUED BY ISSUED TO
Name in Block Letter
Designation
Signature
Date
Time
BREAK DOWN INFORMATION
Stopped at: Date _______________ Time ___________________
Duration of outage: ____________________ Hrs.
PTW RECEIVED BY PTW CANCELLED BY
Name Name
(in Block Letter) (in Block Letter)
Designation Designation
Signature Signature
Date Date
Time Time
Actual Duration of outage:
Remarks of Department at Work (at the time of cancellation of PTW)

Signature

IN CASE OF EMERGENCY CALL: 1) Dispensary: ………………….

2) Safety : ………………….

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 (HARYANA POWER GENERATION CORPORATION LIMITED)
Form No. 18

Notice of accident / dangerous occurrence

1 Name of occupier (or factory) :…………………………………………………………….
2 Address of works where accident
Or dangerous occurrence
happened:…………………………………………………………….
3 Nature of Industry :…………………………………………………………….
4 Branch/ Department
Place where the accident or dangerous
Occurrence happened :…………………………………………………………….
5. Injured person’s Name and
Address
:…………………………………………………………….
6. (a)Sex:………………………. (b) Age:………….
(c)Occupation of injured
person:…………………………………………………………….
7. Local E.S.I. Office to which the
Injured person is attached :…………………………………………………………….
8. Date and hour of accident or
Dangerous occurrence
:……………………………………………………………. (a)Hour at which he started
work:…………………………………………………………….

On day of accident. _________________________

10 (a) Cause or nature of accident or dangerous occurrence

(b) If caused by machinery:
(i) Give name of Machine and part
Causing the accident :…………………………………………………………….
(ii)State whether it was moved by
Mechanical Power at that time
:…………………………………………………………….
(c) State exactly what injured person
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 was doing at that time :…………………………………………………………….
11 Nature and extent of injuries (e.g. fatal,
Loss of finger, fracture of leg, sealed,
Scratch followed by sepsis)
:…………………………………………………………….
12 If accident is not fatal, state whether
injured person was disabled for
48 hours or more :…………………………………………………………….
13 Name of Medical Officer in attendance
Or injured person :…………………………………………………………….
I certify that to the best of my knowledge and belief the above particulars are correct in
every respect.

Signature of XEN In-Charge Signature of occupier or (Name)………………………...

Name & Designation of occupier
…………………………….
……………………………………………..
……………………………..
Address …………………………
………………………… ………………………………………………..
Note- To be completed in legible handwriting or
preferably typewritten.

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 (HARYANA POWER GENERATION CORPORATION LIMITED)

FORM No.2-A

Notice of change of Engineer Incharge

(Prescribed under Rule 15-A)

(1) Name of factory with current license number ______________

(2) Postal address
(3) Name of outgoing Engineer Incharge
(4) Name of new Engineer Incharge with the postal address of
his residence and telephone number if installed
(5) Date of appointment of the new Engineer Incharge

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INFORMATION SHEET FOR THE REVISED RENEWAL OF LICENSE
DETAILS OF RENEWAL APPLICATION DETAILS OF ORIGINAL LICENSE
License
Application No. Registration No.
Application date
__/__/20___ License Date
License
For the year 20__ Serial No. _____
District ___________ License Renewals
RENEWAL DETAILS OF LICENCE FOR THE LAST RENEWAL
Renewal Power Fee
Renewals No. Date of Renewal No. of workers Amount Received Balance
H.P. Rs.
(1a). FULL ADDRESS & SITUATION OF FACTORY/Thermal Plant
Factory Name
Plot No./Milestone/Village Works-1
Sector/Colony/Road/P.O. Works-2
City/Teshil Fax
Distt. E-mail
Pin Code Website
(1b.) FULL ADDRESS WHICH COMMUNICATINS RELATING TO THE FACTORY/Thermal Plant SHOULD BE
SENT
Plot No./Milestone/Village
Sector/Colony/Road/P.O. Works-1
City/Teshil Works-2
Distt. Fax
Pin Code E-mail
(2) NATURE OF MANUFACTURING PROCESS/PROCESSES
Carried on in the factory during the last twelvemonths (in
case of factories already in existence) POWER STATION ELECTRICITY
To be carried on in the factory during the next
twelvemonths (in case of new factories) POWER STATION ELECTRICITY
(3). PRINCIPAL PRODUCTS MANUFACTURED DURING THE LAST 12 MONTHS/ TO BE MANUFACTURED
Product Name Electricity

Approximate value Approximate production capacity

(4). WORKER DETAILS

Maximum no. of workers proposed to be employed on any one day during the year
Maximum no. of workers employed on any one day during last twelve months
No. of workers to be ordinarily employed in the factory
(5). POWER DETAILS

Nature of power installed Electricity

Nature of power proposed to be installed Electricity Amount of power installed 1360 MW
Maximum amount to power (HP) proposed to be used (HP) Amount of power proposed Nil
to be installed

(6). FULL NAME & RESIDENTIAL ADDRESS OF THE PERSON WHO SHALL BE THE Incharge OF THE
FACTORY/Thermal Plant FOR THE PURPOSES OF THE ACT.

Title 1st Name Sh. Middle Name Last Name Suffix, if any
Plot No./Milestone/Village
Sector/Colony/Road/P.O. Works-1
City/Teshil Works-2
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Distt. Fax
Pin Code E-mail

(7). FULL NAME & RESIDENTIAL ADDRESS OF THE OCCUPIER

Suffix,
Title 1st Name Sh. Middle Name Last Name if any
Plot No./Milestone/Village
Sector/Colony/Road/P.O. City/Teshil
Pin Code Distt.

(8). FULL NAME & RESIDENTIAL ADDRESS OF THE OWNER OF THE PREMISES OR BUILEING

Title 1st Name Sh. Middle Name Last Name Suffix, if any
Plot No./Milestone/Village PLOT NO.-
Sector/Colony/Road/P.O. City/Teshil
Pin Code Distt.

(9a). BUILDING PLAN APPROVAL DETAILS (9b). POLLUTION CONTFOL BOARD APPROVAL DETAILS

Building approved plan P.C.B. approved date

Building approved date P.C.B. approved no.

(10) DETAILS OF PAYMENT MADE FOR THE RENEWAL APPLICATION

Amount of Fee
Paid in Treasury Paid Date
Vide Challan no. Challan Date

DECLARATION
I certify that the information furnished above is correct to the best of my knowledge and nothing of
importance has been concealed while furnishing it.

Signature of Engineer
Incharge Signature of Occupier

164