Ocp

ID No.
:1929
DOC . No. : HSE/SR/05

REV
: 03
EFF.DATE : 15-12-2008
OPERATION CONTROL PROCEDURE

(ISO 14001: 2004 & OHSAS 18001: 2007)
BHARAT HEAVY ELECTRICALS LIMITED

Power Sector Southern Region
690, Anna Salai, Nandanam,
Chennai 600 035.
ID No.: 1929
Document No : HSE/SR/05
Rev
: 03
Eff. Date
: 15-12-2008
PS - SR

(ISO 14001: 2004 & OHSAS 18001: 2007)
Controlled/ Information
Copy No:
Issue Date: 15-12-2008
Copy Issued To
Issued By :
MR ( HSE)
Prepared by
Reviewed & Approved by
Name
D.DEVASAHAYAM
R.V.SANJEEVI
Designation
HSE AUDITOR
MR ( HSE)
Signature

POWER SECTOR -- SOUTHERN REGION
CHENNAI -- 600 035
ID No.: 1929
Document No
Rev
Eff. Date
DOCUMENT NO
REVISION NO
DATE
PREPARED BY
APPROVED BY
AUTHORISED TO USE BY
COPY NO
COPY
ISSUED BY
ISSUED TO
DATE OF ISSUE
: HSE/SR/05
: 03
: 15-12-2008
HSE/SR/05
03
15-12-2008
D.DEVASAHAYAM / HSE AUDITOR
R.V.SANJEEVI , MR{HSE}
MR (HSE)
CONTROLLED / INFORMATION COPY
MR (HSE)

(ISO 14001 : 2004 & OHSAS 18001 : 2007)
PS SR

Power Sector- Southern Region
690, Anna Salai, Nandanam,
Chennai-600 035
INDEX
OCP 01
OCP 02
OCP 03
OCP 04
OCP 05
OCP 06
OCP 07
OCP 08
OCP 09
OCP 10
OCP 11
OCP 12
OCP 13
OCP - 14
OCP 15
OCP 16
OCP 17
OCP 18
OCP 19
OCP 20
OCP 21
OCP 22
OCP 23
OCP 24
OCP 25
OCP 26
OCP 27
To define General Safety measures to be followed to improve the

Safety
To ensure Safety of officials and Workmen through use of Safety Helmets
Procedure for safe handling, Storage and disposal of hazardous waste.
To reduce chances of accidents / incidents through adherence of electrical
safety procedures.
Identification of proper Fire Safety measures.
Identification of Safety measures to be followed during the use of scaffolds and
ladders / Working at height./Working at confined space.
To ensure safety during handling and erection of heavy materials.
To define the general safety to be followed while using cranes/Trailers/ T&P s
To ensure proper storage, handling and transportation of Gas cylinders
To ensure safety during Gas cutting, welding, arc welding and heating.
To define and monitor the illumination levels at the different locations.
To define the requirement to be followed during the pre-commissioning and
commissioning stage.
To define a procedure for safety operation during Radiography.
To define a procedure for safe handling, labelling and storage of hazardous
chemicals.
To ensure safe handling of Mineral wool
To reduce stress level while continuous working on Computers through better
ergonomic posture.
To improve the conservation of energy
To define a procedure for providing proper First Aid.
To define a procedure for Fire safety in high rise buildings, offices and
go
downs
To define a procedure for Food safety
To define a procedure for Control of vehicular pollution.
To define a maintenance procedure for attending the leaking valves.
To define a procedure for health monitoring.
To define a procedure for proper identification, classification, reporting and
computation of accidents and incidents, trends.
To define general guidelines for Occupational Health Practices for BHEL
Construction sites.
To define a procedure for conducting work environment monitoring/
occupational Hygiene Monitoring.
To define a procedure for work capacity and strength testing.
OCCUPATIONAL HEALTH SAFETY AND

ENVIRONMENTAL OPERATIONAL
MANUAL
Operational control procedures
HSEOM-OCP-01
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define the general safety measures to be followed to improve the

safety
2. Scope
All activities and services of BHEL, PS SR
3. Responsibility
Site in charge who in turn will assign the responsibility to the activities
detailed below.
4. Performance Criteria Adherence to the safety measures

5. Cross Reference
Factory Act, 1948 / State Factory Rules

Register of OHS hazards and associated risk
6. Procedure
S No. Activity
Responsibility
1
Ensure use of Personal Protective Equipment like safety shoes, safety
helmets, safety belts, safety goggles, face shield, earplugs, hand
gloves etc. as per job requirement.
2
Openings in the floors must be covered.
Install handrails on platforms and stairs as soon as these are erected.
Temporary handrails should be provided on temporary platforms.
Check that there are no hindrances on walkways and sufficient

headroom is available.
Warning signs should be displayed at unsafe places.
Ensure adequate and safe means of access and exit from all work
places.
Never block accesses and exits routes to work places.
Due importance should be given to house keeping.
10
Ensure adequate illumination of all the work places and access / exit
routes.
11
Arrangement of emergency lighting is also called for to ensure safety

during power breakdown.
HSEOM-OCP-01
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
12
Hazardous activity area should be cordoned off using tapes with red
and white bands.
13
Provide one First Aid box each for every 150 workmen.
14
One vehicle should always be stationed at work site along with First
Aid Box.
15
Ensure adequate communication facilities between all work places and

the office of Site- In charge / Emergency control room and fire station
for handling emergency situation.
16
Train adequate number of employees at work site in First Aid and

Fire Fighting.
17
Make it a habit that supervisors explain to the workers all hazard

potentials and safety measures needed in the work; planned for the
day.
18
Display appropriate posters in locally understood languages regarding

safety at site
19
Conduct tool box meetings either daily or weekly once and

communicate about usage of PPEs & Safe erection procedures. Also
ensure that peb talks are given to the contract workers / employees to
motivate them in doing their works with utmost safety.
7. Records
Record Title
Register of accident /
incidents
Record No
Shall be given by Site
In charge
Responsibility
Shall be assigned by
Site In charge
Retention Time
3 years
8. Verification, Corrective and preventive action

Concerned site in charge shall ensure effective implementation of above procedure. In case of any
deviation from the procedure he shall undertake necessary corrective and preventive actions.

MANUAL
HSEOM-OCP-02
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To ensure the safety of officials and work men through the use of
identified / specified safety helmets
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Percentage reduction in head injuries due to use of safety helmets /
register of issue of safety equipments
5. Cross Reference

IS 2952
6. Procedure
S No. Activity
1
Ensure use of Safety Helmet by all the employees working at site and
the persons visiting the site for protection against head injury
2
Safety helmets shall conform to IS: 2925
Safety helmet should be compatible with working requirements e.g.

Helmet with chinstrap is useful for the person working in windy
condition or repeated bending or looking upward.
Helmet with head load ring is useful for the person carrying head
load.
Check the helmet regularly for any signs of damage of deterioration.

Replace the helmet immediately in case positive signs of damage or
deterioration are evident.
Wear the helmet right way round. It does not give proper protection
when worn back to front
Dont wear the helmet sloping up or down as it may significantly

reduce the protection it may provide.
Adjust the headband and the chinstrap so that there are no chances of
the helmet falling down.
Responsibility
HSEOM-OCP-02
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
Clean the helmet and its seat band regularly and change the sweatband
when required.
Never store the helmet in direct sunlight or excessive heat. Long-term

exposure can weaken the shell quickly.
10
Keep stock of helmets for visitors at site. Inspect the helmet before
handing it over to a visitor.
11
For colour code of Safety Helmet

i)
WHITE Colour for Engineers, Supervisors and Technicians
(BHEL & Contractors).
ii)
GREEN Colour for personnel (BHEL & Contractors).
YELLOW Colour for Contract workers (General)
RED Colour for Electricians (Contract Worker)
7. Records
Record Title
incidents
Record No
In charge
Responsibility
Site In charge
Retention Time
3 years


MANUAL
1. Purpose
HSEOM-OCP-03
REV : 03
DATE: 15.12.2008
Page 1 0f 2
To define the procedure for safe handling, storage and disposal of

hazardous waste
2. Scope
3. Responsibility
Site in charges
4. Performance Criteria Physical examination
5. Cross Reference
Hazardous Waste (Management and Handling) Rules, 1989 / 2000 /
2003
Environment Protection Rules, 1986 including amendments
6. Procedure
S No. Activity
Responsibility
1.
To ensure that while storing any category of hazardous waste the
following are taken into consideration:
It should not be stored on open ground. Hazardous waste should
be stored on concrete flooring with proper dyke facilities.
Hazardous waste should be as far as possible be stored under the
shed facilities
The area for storage of hazardous waste should be clearly
earmarked as hazardous waste storage area
No other material should be stored along with the hazardous waste
Hazardous waste if stored in drums (such as used oil, waste oil
etc) should be under the closed lids.
In case of spillage of the hazardous waste the same is to be cleaned
using the cotton or saw dust. The cotton waste shall also be
considered as a hazardous waste and to be disposed off in a
manner the hazardous waste is being disposed off. In case
there is a facility of boiler or incinerator the cotton waste, saw
dust should be burned off.
Under no circumstances the hazardous waste should be allowed to
be disposed off on open ground.
2
All the hazardous waste should be sold only to the MoEF or the
concerned State Pollution Control Board approved vendors only.
3
Necessary records for disposal of the hazardous waste should be
maintained (form 3)
4
To file the annual return of the hazardous waste in form 4
5
To ensure that manifest is given in form 9 to the transporters of the
hazardous waste.
6
The used batteries should be stored preferably on acid proof lining and
the same should be returned back to the original supplier.
7
While transporting the hazardous waste from the generation site to the
storage site and then to the transporting vehicle due care should be
taken to prevent any leakages / spillages. Trolleys should be used for

MANUAL
HSEOM-OCP-03
REV : 03
DATE: 15.12.2008
Page 2 0f 2
the transportation as far as possible.

All necessary information should be provided to the transporters of the
hazardous waste
9
Different collection bins / drums should be available for the hazardous
waste at the generation point itself. Hazardous waste should not be
mixed with any other category of the waste.
10
The drums containing the used oil or waste oil should always be
stored under the horizontal position. The other categories of the waste
should be under the closed lid or shed facility.
11
All accidents / incidents with respect to the hazardous waste should be
reported to the site in charge and also the HQ
7. Records
Record Title
Record No
Responsibility
Retention Time
Records of disposal of
3 years
the hazardous waste
8

MANUAL
HSEOM-OCP-04
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To reduce the chances of accidents / incidents through adherence to

electrical safety procedure
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Adherence to electrical safety procedure

5. Cross Reference
Indian electricity Act, 1953 / 2003

National electrical codes
Factory Act, 1948
6. Procedure
S No. Activity
1
All parts of electrical installation shall be of standard construction
conforming to relevant IS codes.
2
Install Earth trip device at main distribution board.
Earth all power cables.
Ensure earthing of all electrical construction equipment at two

locations on the body.
Certified electricians shall carry out all electrical connections and

wiring.
Ensure that all extension boards have earth wire connected and only
three- pin metal clad industrial type sockets are mounted on the board.
Never draw power from a socket by inserting wires into the socket.
Always use metal clad three pin plug tops for drawing power for
electrical hand tools.
Use only three core flexible wire for electrical hand tools. Connect
earth wire properly to the body of the hand tool as well as to the plug
top.
10
Never use earth as neutral.
Responsibility
HSEOM-OCP-04
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
11
Ensure that the flexible wires and power cables are properly insulated
and are laid so that the insulation does not get damaged due to
activities in the vicinity.
12
All cable terminations should be properly tightened.
13
Cover all power cables running on surface to prevent damage due to

movement of materials and vehicles.
14
Install proper distribution boards at different location to avoid

haphazard connection of electrical wires.
15
Frequent inspection should be carried out to identify damaged

insulation, loose connections, improper fuses; lack of earthing etc. and
remedial action should be initiated immediately.
16
Introduce permit system for electrical safety. While men are at work
on electrical lines or equipment for maintenance repair, main switch
should be cut off and fuses should be removed. Warning signs should
be displayed on the main switch.
7. Records
Record Title
incidents
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-05
REV : 03
DATE: 15.12.2008
Page 1 of 4
1. Purpose
Identification of proper fire safety measures
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Percentage reduction in accidents - incident related to fire / Availability

of identified fire extinguishers at the desired place.
5. Cross Reference

IS 2190
6. Procedure
S No. Activity
1
Ensure safe access to and means of escape from all site locations.
2
Construct temporary building like site offices and materials stores

with non combustible materials.
Keep adequate safe distance between temporary buildings.

Recommended safe distance of temporary sheds from main buildings
is approx 15M and 9M from each other.
Provide free space between each section of the stored materials to

allow access fro fire fighting.
Store inflammable materials separately.
Avoid using combustible materials for from work and scaffolding.
Remove combustible packing material from the site periodically to

avoid accumulation of fire load.
Clean site frequently at least once a week.
Display No smoking Posters in areas where inflammable materials

are stored.
10
Dont light any fire in or around storage areas for cooking or any other
purpose.
Responsibility

MANUAL
11
Inspect the work place thoroughly where welding and gas cutting
operations are to be carried out and remove any inflammable materials
around, before starting work.
12
Ensure that welding and gas cutting sparks do not fall on combustible
materials. In case it cannot be avoided, cover the materials with metal
sheet.
13
In case, welding or gas cutting has to be done on a vessel pipe or

container, which contains or had earlier contained flammable liquids;
ensure purging inserting and issue work permit before starting work.
14
Ensure that there is no leakage of gases from hoses or hose

connections fitted with the gas cylinders before starting gas cutting.
15
In case of electric welding, check that there are no loose connections

in welding cables and earth connection.
16
Do not leave electric circuits on or gas cutting torches burning when

not in use.
17
Inspect the area for smoldering materials after gas cutting /welding. If
found extinguish them.
18
Remove gas cylinders to stores when not in use.
19
Place fire extinguishers in conspicuous locations as near as possible to

escape routes.
20
Ensure that the fire extinguishers are clearly visible & easily
accessible and passage leading to them is free.
21
Mark the type of extinguishers and the class of fire for which these are
meant, conspicuously at each location.
22
Maintain the fire extinguishers in fully charged and operable

condition.
23
Inspect the extinguishers monthly to ensure that they have not been
actuated or tampered with and to detect any physical damage or
corrosion.
HSEOM-OCP-05
REV : 03
DATE: 15.12.2008
Page 2 of 4
HSEOM-OCP-05
REV : 03
DATE: 15.12.2008

MANUAL
Page 3 of 4
24
Recharge the extinguishers on expiry.
25
Maintain effective communication system to site in charge and fire

safety officer from all fire hazard areas.
26
Display telephone numbers and residential addresses of site in charge,

Fire safety officer, security officer, Fire brigade, doctor and police
near each telephone.
27
Post round the clock guards trained in fire fighting, at vulnerable

locations.
28
Form fire-fighting teams with site supervisors, sub contractors,

personnel and security guards. Impart adequate training to the firefighting teams.
29
Conduct fire-fighting drills at least once in a quarter.
30
Keep informed all the personnel at site in respect of

Raising an alarm in case of fire.
Action to be taken in the event of fire.
Safety measures for fire risk operations.
Location of fire extinguishers and their use for different kinds of fire.
Prepare emergency plan indicating individuals responsibility
in the event of fire and keep the individual properly
informed.
Guideline for selection of type, size and quantity of fire
extinguishers is annexed. However, exact requirement may be
determined in consultation with local fire authority and or the
underwriters.
7. Records
Record Title
incidents
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years

HSEOM-OCP-05
REV : 03
DATE: 15.12.2008

MANUAL
Page 4 of 4
ANNEXURE TO OCP: 05/00

CLASS OF
FIRE
TYPE OF
FIRE
EXTINGUISH
ER
A
Soda acid or
Fire involving water (gas
paper,
wood pressure or
textiles, rubber water (constant
etc.
air pressure and
Co2)
B
Fire involving
flammable
liquids
like
oils, solvents,
varnishes paint
etc
C
Fire involving
flammable
gases
D
Fire involving
metals like Mg,
Al, Zn, K etc
Mixed
Occupancy
Fire involving
mixed
materials
including
electrical
equipment like
generator
transformer etc
SIZE
4.5 Kg
Foam
Or
Dry chemical
powder
9
Liters
5 Kg
Co2
Or
Dry chemical
powder
Special dry
chemical
powder
9
Liters
Co2
Or
Dry chemical
6 Kg
10 Kg
5 Kg
10 Kg
QUAN
TITY
V/S
AREA
1 no for
600M2
or part
MINIMUM
IN
QUANTITY
ACCESSI
BILITY
WITHIN.
4 nos per
floor/room
15 M
1 no for
100M2
or pat
2 nos for
50 M2
or part
2 nos per
floor/ room
10 M
3 no per room
for bulk
storage
10 M
1no for
100 M2
or part
3 nos per
10 M
room for bulk
storage
2 nos
for 50
M2 or
part
-
3 nos per
room
10 M
2 nos for each

location
10 M

MANUAL
HSEOM-OCP-06
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
Identification of safety measures to be followed during the use of

scaffolds and ladders / Working at height /Working at confined space.
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Inspection records of scaffolds and ladders

5. Cross Reference

6. Procedure
S No. Activity
SAFE USE OF SCAFFOLDS

1
Provide scaffolds for all works that cannot be safety performed from
floor level.
Ensure that the scaffold materials are of metallic and of adequate

strength for the purpose it is to be used.
Check scaffold components for damage and defect before use.
Avoid using combustible materials for scaffolds.
For platforms, use planks of grade 1 quality at least 2 thick and 10

wide; free from all defects such as loose knots and splits.
Erect scaffolds level and plumb.
Use diagonal braces for stability of scaffolds.
Planks used for platforms should overhang the supports by

150 300 mm.
Hold the planks together by splicing at the bottom.
10
Secure the platform firmly with the scaffold.
11
Minimum width of platforms 2 M above floor level should be 900mm
Responsibility

MANUAL
12
Provide guardrails 1.5M high, consisting of top rail and mid rail for
platforms higher than 2 M from floor level.
13
Provide toe guards at the platform edges to eliminate hazard of tools

or other objects falling from the platform.
14
Inspect the erected scaffolds regularly, if the scaffolds are to be used

for a long period of time.
15
Keep the platforms free from any unnecessary obstruction material,

rubbish and oil spillage.
16
Use safety belt properly anchored to a permanent structure while

working on a platform higher than 2 M from floor level.
17
Do not allow persons to work from scaffold during storm or high

winds.
18
Do not use braces for climbing up or down a structure or a platform. A

safe and convenient means of access should be provided to all
platform levels.
19
Work permit system should be adopted before commencement of

work.
SAFE USE OF LADDERS

20
Use portable ladders for flights up to 4 M only.
21
Provide fixed ladders for flights above 4 M.
22
Place the ladder at an angle of 75 degrees (approx) from the

horizontal.
23
Extend ladder at least 1 M above the top landing.
24
Secure top and bottom of the ladder firmly to prevent displacement.
25
Ensure that the width of the ladder is not less than 300 mm and
distance between rungs is not more than 300 mm.
26
Provide landings of minimum size 600 x 600 mm at intervals not more

than 6 M for fixed ladders. Check the ladders daily for any defects.
HSEOM-OCP-06
REV : 03
DATE: 15.12.2008
Page 2 of 3

MANUAL
27
Ensure that the areas around base and top of the ladder are clear.
Getting on and off the ladder is more hazardous than using it. Use a
mudsill if the ladder is to rest on soft, loose or rough soil.
28
Do not use ladders of conducting material near power lines.
29
Stand no higher than the fourth rung from the top for carrying out any
job standing on a ladder.
30
Always face the ladder while climbing up or down.
31
Maintain three point contact while climbing up or down a ladder i.e.

two hands and one foot or two feet and one hand on the ladder at all
the times.
32
Avoid climbing up or down a ladder while carrying anything in hands.

Lift tools, equipment and materials with a rope.
HSEOM-OCP-06
REV : 03
DATE: 15.12.2008
Page 3 of 3
Working at Height :
33
34
35
Use Safety belt while working at height. Ensure life lines are installed
at higher locations where works are done.
Use Free fall arrestors of required numbers for going up and coming
down. Ensure, the work force is made familiar with the use of Free
fall arrestors
Ensure installation of Safety nets at appropriate elevations.
Working at Confined Space :

36
Ensure the work force is briefed about the confined space. Ensure
issue of permit.
37
Ensure a) enough ventilation b) 24 V lighting. c) Life line tied to the
body of the person working d) Appropriate PPE as decided by Area In
charge is used by work force. e) No Welding / Gas cutting carried out
during painting inside confined space. f) A person at the entrance to
the confined space for acting on any emergency.
7. Records
Record Title
Record No
Responsibility
Retention Time
Shall be given by Site Shall be assigned by
3 years
incidents
Incharge
Site Incharge

MANUAL
HSEOM-OCP-07
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To ensure safety during handling and erection of heavy materials
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Inspection records, test certificates

5. Cross Reference

6. Procedure
S No. Activity
HANDLING AND ERECTION OF HEAVY MATERIAL
1
Ensure proper maintenance of all the lifting machinery and tackles.

Record of maintenance carried out should be available.
Inspect daily, before start of work, all such equipment and record in a
Daily Inspection Register.
Test certificates of all the lifting machinery and tackles should be

maintained. Testing shall be done periodically s recommended by the
manufacturer.
Maximum safe working load shall be conspicuously marked on all the

lifting machinery and tackles.
Ensure that the lifting machinery and tackles are not loaded beyond
maximum safe working load.
Before lifting with a winch ensure proper anchoring of the winch and
the pulleys. The pulleys must be checked thoroughly for any defects.
Do not tie or attach lifting devices such as chain pulley blocks, maxpull or wire rope slings to the floor grills, working platforms or
guardrails.
When load is being lifted with lifting machinery, warn the persons in
the vicinity by sounding horns/ whistle.
Do not allow any body to stand under the load being lifted.
Responsibility
HSEOM-OCP-07
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
10
Never allow any person to ride on the loads being lifted.
11
Deploy only trained and authorized operators for operating the lifting
machinery.
12
Ensure that only skilled riggers are engaged for slinging the material
to be handled.
Use of safety helmet, safety shoes and hand gloves by the riggers must
be ensured
13
14
Only one person should give signals to the operator to lifting the
machinery
15
Ensure proper illumination of the area where material handling is in

progress.
16
Never carry out any welding in the boiler structure during drum
lifting operation. This can damage wire ropes used for lifting of
drum.
7. Records
Record Title
Records of testing of
lifting materials
Daily inspection
register
Record No
Responsibility
Retention Time
3 years

Incharge
Site Incharge
3 years

Concerned site in charge shall ensure effective implementation of above procedure after
consultation with all concerned. In case of any deviation from the procedure he shall undertake
necessary corrective and preventive actions.

MANUAL
HSEOM-OCP-08
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To define the general safety to be followed while using cranes/Trailers/

T&P s
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Records of incidents and accidents

5. Cross Reference

6. Procedure
S No. Activity
SAFETY IN USING CRANES
1
Try to locate the crane on as solid and level ground as possible.
2
Ensure that the earth is property compacted if the crane is required to

move or work in back-filled area.
In case there is doubt about bearing capacity of the earth, place 1

thick metallic plates or wooden sleepers under the crawler or tyres to
distribute load.
Deploy only trained and experienced operator with valid license to

operate the cranes.
Read the instruction manual of the crane thoroughly and keep the
crane operator informed.
Keep the machine in good operating condition especially clutches,

brakes and controls.
Ensure that boom and hoist cut off limit switches are operational.
Before starting the crane, see that all the guards of moving parts are
property fitted.
Shut of the engine when cleaning, adjusting or lubricating the

machine.
10
Do not over lubricate the parts. Clean over flowing lubricants
Responsibility

MANUAL
11
Keep the crane boom length as short as possible for maximum lifting
capacity and greater safety.
12
Do not work with the boom too close to the vertical, because a sudden
release of the load may throw the boom back over the cab
13
Depute only trained and experienced riggers for slinging the material
to be lifted.
14
Ensure that only one person gives signal to the crane operator.
15
Before lifting load, be sure about the weight of the material. When
lifting near capacity load, calculate entire load carefully including
hook block and slings; and check it against rated lifting capacity.
16
Test the hoist brake by raising the load a few inches and holding. It
should hold easily.
17
Dont pull sideways on the boom not even a little bit. Lift straight up
on every load
18
Never move a crane away from the load while handling near capacity
loads, to avoid boom failure or machine damage.
19
Ensure the soundness and capacity of the slings being used.
20
Before lifting or moving load, warn the surrounding personnel by

sounding horn
21
Swing the load very slowly and carefully. Avoid sudden jerks
22
Never swing load over ground crew.
23
Always watch the load and the signals from the signalman
24
While loading or unloading a truck, never swing the load over the
truck cabin.
25
Never allow any person to stand under the load being lifted.
26
Ensure that the reverse horn is operational. Crane helper should guide
the crane operator while reversing the crane.
HSEOM-OCP-08
REV : 03
DATE: 15.12.2008
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MANUAL
27
28
29
30
31
32
S No.
1
HSEOM-OCP-08
REV : 03
DATE: 15.12.2008
Page 3 of 3
Let the crane run idle for a little while, after the crane has done heavy
work. Do not stop the engine abruptly.
Do not move the crane with boom at very high angle, especially on
uneven terrain. This may result in the boom being thrown back over
the cab.
When the load is to be lifted to higher evaluation, tie the load with a
manila rope to guide the load while in the air, so that it does not strike
any building or structure during swinging.
Always keep the boom at least 6 feet from overhead wires.
If the boom his overhead wires accidentally, stay on the crane until the
boom is cleared or the current is cut off. Do not allow any one on the
ground to touch the crane. In case it is absolutely necessary to leave
the cabin, jump out; dont step down.
Do not leave the cabin with engine running or load in the air or under
any condition of load under hook connected to slings or wire rope.
Activity
SAFETY IN USING TRAILERS / OTHER T & P s
Ensure the trailers used for transporting materials are inspected and
certified for its fitness by Competent person.
Deploy only trained and experienced driver with valid license to

operate the Trailers.
Ensure inspection of the route through which the trailer has to move
to and fro is rigid / clear off pits / any other hindrance.
Ensure identification of all other T & Ps. Unused T&Ps should be

removed from the construction area once for all.
Responsibility
Always ensure T & Ps such as D-Shackles, Pulleys, hooks etc., are

marked with working load capacity and only such T &Ps are used for
construction activities.
7. Records
Record Title
Record No
Responsibility
Retention Time
3 years
incidents
Incharge
Site Incharge

MANUAL
HSEOM-OCP-09
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To ensure proper storage, handling and transportation of Gas Cylinders
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Physical inspection reports

5. Cross Reference
Gas Cylinder (Management and Handling) Amendment Rules, 2004

6. Procedure
S No. Activity
STORAGE AND HANDLING OF GAS CYLINDERS
1
Provide FLASH BACK arrestors both side of the Cylinder and Torch
2
It is advised to insist to the vendor to provide wall caps for all Gas
cylinders.
While procuring gas cylinders, check that every cylinder is labeled

with the name of the gas and the name and address of the person by
whom the cylinder was filled.
Check that a warning is attached to every cylinder containing

permanent or liquefiable gas.
Do not change colour of the cylinder.
The cylinder should not be filled with any gas other than the one it
now contains.
No flammable material should be stored in the vicinity of the cylinder

or in the same room in which it is kept.
No oil or similar lubricant should be used on the valves or other fitting

of the cylinder.
Please look for next date of test, which is marked on a metal ring
inserted between the valve and the neck of the cylinder, and if this
date is over, do not accept the cylinder.
Responsibility

MANUAL
10
11
Use trolleys and cradles of adequate strength, as far as possible, while

moving the cylinders.
Handle the cylinders carefully and dont allow the cylinders to fall
upon one another or subjected to any shock.
12
Use cage while lifting Gas Cylinder
13
Dont slide or drop the cylinders.
14
Always keep LPG and other liquefiable gas cylinders in an upright

position and see that they cannot be knocked over.
15
Ensure the Cylinder should be tied with a proper chain while stacking.
FIRE SAFETY INSPECTION.
16
Danger Board and No Smoking Board should be displayed at the Gas

Cylinder Storage area.
17
Smoking is strictly prohibited at the Gas Cylinder Storage Area
18
Sand bucket should be provided.
19
Three side covered shed to be provided.
20
Use only friction type lighter.
21
Suitable Fire Extinguishers should be provided and same may be not

crossed the validity date.
22
Specification of Fire Extinguishers should be displayed on the

Cylinders i.e. Type, Weight, Tested and date and Due date.
Secure the cylinders used in horizontal position so that they cannot
roll.
23
Store the cylinders in a cool, dry and well ventilated place under cover
and away from open flames or any potential source of heat.
24
Never store the cylinders in sun.
25
Storage room should be of fire resistant construction.
26
Storage room should be of fire resistant construction.
HSEOM-OCP-09
REV : 03
DATE: 15.12.2008
Page 2 of 3
HSEOM-OCP-09
REV : 03
DATE: 15.12.2008

MANUAL
Page 3 of 3
27
Keep the cylinders containing flammable gases separated from other

gas cylinders by an adequate distance.
28
Keep the filled cylinders segregated from the empty cylinders.
29
Check that the valves of the gas cylinders are tightly shut.
30
Repairing of gas cylinders is not permitted.
31
Remove the leaking gas cylinders to an open space where it is least

dangerous to life and property and inform the supplier.
32
Dont posses more than the following quantity of gas without a valid
license:
Liquefied Petroleum Gas
100 Kg (Flammable)
Dissolved Acetylene
15 Cylinders
(Flammable)
Oxygen, Argon, Nitrogen, Carbon dioxide
50 Cylinders
(Non-flammable, non-toxic gases) (Total)
Chlorine
50 Cylinders (toxic gases)
Hydrogen
125 Kg or 15 cylinder
(Flammable but non-toxic gases)
(Whichever is less)
7. Records
Record Title
Physical inspection
reports
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-10
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To ensure safety during gas cutting, welding, arc welding and heating
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Physical inspection records

5. Cross Reference
Gas Cylinder (Management and Handing) amendment Rules, 2004

6. Procedure
S No. Activity
GAS CUTTING/WELDING /HEATING.
1
Use trolleys and cradles of adequate strength, as far as possible, while
moving the cylinders.
2
Always keep LPG and other liquefiable gas cylinders in upright

position and ensure that they are not knocked over.
Check that the valves of the gas cylinders are lightly shut when not in
use.
Do not release gas from the cylinder unless pressure regulator is fitted
to its valve.
Use gas hoses specially designed for the purpose with standard colour
code.
Use proper clamps for hose connections, Check leakage from hose
connections before starting work. Never use steel wires for clamping.
Take care that there are no kinks in the hoses and the hoses are laid
such that nobody steps on the hoses and these do not get damaged due
to activities in progress in the vicinity.
Use flame flash back arrestors to avoid back firing in flammable gas
cylinders.
Open the valve of oxygen gas first and then flammable gas for lighting
the torch.
Responsibility

MANUAL
10
Use fiction gas lighters only for lighting the torch. Never use matches
or smoldering manila ropes or rags for lighting the torch.
11
Protect the gas cylinders and hoses from welding sparks or gas cutting
sparks falling on them.
12
Ensure that the valve key is easily accessible to close the valve
immediately in case of emergency.
13
Never crimp the hose for temporary shutting of gas. Always shut the
supply through pressure regulators.
14
Check the hoses daily for any visible damage. Discard the hoses in
which gas had backfired.
15
Remove the leaking cylinder of flammable gas immediately to an

open space where it is least dangerous to life and property. Intimate
the supplier of the cylinder.
16
Ensure use of aprons, gloves and other PPE as appropriate.
17
MANUAL ARC WELDING

Ensure proper earthing of the switch board from where power is
tapped for the welding machine
18
Ensure proper earthing of the welding machine by two independent

earthing connections.
19
Check that the terminations of the welding lead and earthing lead are
not loose at the welding machine, welding holder & the job.
20
There should not be more than one joint in the entire length of the
welding lead. The joint should be through proper junction box or lugs.
The joint should be insulated.
21
Lay the welding lead in such a manner that it does not get damaged
due to other activities in the vicinity.
22
Provide the welder with an appropriate container for depositing

welding electrode stubs, which should not be thrown indiscriminately
and allowed to fall from height.
HSEOM-OCP-10
REV : 03
DATE: 15.12.2008
Page 2 of 3
HSEOM-OCP-10
REV : 03
DATE: 15.12.2008

MANUAL
Page 3 of 3
23
Use of hand gloves and face shield by the welder must be ensured.
24
Welding glass must conform to IS code.
25
Workmen working in close association with the welder should also

wear protective coloured goggles.
26
27
Ensure that the hand gloves, welding holder and the job are not wet.
Welder and associated workmen working at height more than 2 M
must wear safety belts securely fastened to nearby structure.
28
Temporary platforms/ scaffolding should be of adequate strength with

handrails. Platform planks must be secured properly with the
scaffolding or the structure.
29
Take due care to see that welding sparks falling from height do not
endanger people and property at lower elevation. (Use
Metal sheet )
30
Ensure adequate lighting and ventilation while welding in confined

places. The activity should be watched through constant supervision.
Switch off power supply to the welding machine during non-working
period including short breaks.
7. Records
Record Title
Records of physical
inspection
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-11
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define and monitor the illumination levels at the different locations
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Adherence to Illumination levels mentioned in national building code

5. Cross Reference
National building code Lux levels

6. Procedure
S No. Activity
ILLUMINATION
1
Provide adequate illumination at all work places and their approach
passages/corridors. Refer recommended values of illumination for
different locations.
2
Ensure that artificial lighting do not cause excessive glare of

disturbing shadows.
Provide suitable guards for the lamps where necessary to prevent

danger, if lamp breaks.
Use 24-volt supply for hand-held lamps, especially in confined spaces.

Lamp guards are necessary for hand-held lamps.
Provide emergency lighting to minimize danger in case of power

failure.
Recommended values of illumination.

S,No. Location
Illumination
(Lux)
A Construction Area
1. Outdoor areas like store yards, entrance and exit roads .
2. Platforms
3. Entrances, corridors and stairs.
4. General illumination of work area
5. Rough work like fabrication, assembly of major items
6. Medium work like assembly of small
machined parts rough measurement etc.,
20
50
100
150
150
300
Responsibility
HSEOM-OCP-11
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
7. Fine work like precision assembly,

precision measurement etc
8. Sheet metal works
9. Electrical and instruments labs
B Offices
700
200
450
1.Outdoor areas like entrance and exit roads.

2. Entrance halls
3. Corridors and lift cars
4. Lift landing
5. Stairs
6. Office rooms, conference rooms, library reading tables.
7. Drawing table
8. Manual telephone exchange
20
150
70
150
100
300
450
200
7. Records
Record Title
Record No
Records of Illumination Shall be given by Site
monitoring
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-12
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define the requirements to be followed during the pre commissioning

and commissioning stages
2. Scope
3. Responsibility
detailed below.

5. Cross Reference

6. Procedure
S No.
1
Activity
Ensure that all construction materials, T & P, scaffolding, debris etc.
are removed around the system/equipment to be commissioned.
Ensure completion of all civil works around the system/equipment to

be commissioned.
Ensure proper approach road/gallery, platform, and stairs/ladders to

the system/equipment.
Stop welding/cutting operation in hazardous areas under

commissioning.
Ensure that all electrical installations are earthed properly before

charging power supply.
Follow the safety precautions mentioned in O & M manuals and

technical procedures.
Ensure one point control for issue of work permits.
Ensure that all the work permits have been returned before starting the
respective equipment.
Advance announcement on Public address system if available and /or

proper communication at all levels shall be ensured before switching
on power to any system or equipment.
Responsibility
HSEOM-OCP-12
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
10
Make available adequate fire safety measures before commissioning

any system.
11
Ensure that the commissioned equipment are gagged properly for

identification.
12
Never charge any accessible steam line, whether temporary or

permanent, without thermal insulation.
13
Provide earmuffs to all the personnel exposed to dangerous noise level

during steam blowing operation.
14
Ensure use of chemical resistant hand gloves, nose mask and safety
goggles by the personnel engaged in chemical cleaning activities.
7. Records
Record Title
incidents
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-13
REV : 03
DATE: 15.12.2008
Page 1 of 4
1. Purpose
To define a procedure for safety operation during radiography
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Adherence to BARC guidelines

5. Cross Reference
Radiation Protection Rules,

6. Procedure
S No. Activity
Exposure to penetrating radiation from Radioactive Isotopes and other
source is becoming more and more pronounced in the construction
field.
A couple of decades ago, radioactive sources, used, were
comparatively mild and less encountered. With the growing demand
of weld joint inspection, metal thickness / flaw determination, liquid
level measurement in High temperature / pressure process vessels etc.,
the use and application of the radioactive sources specially, Yradiation, has increased considerably.
However, the protection and procedure for work safety and personnel
protection have warranted very little basic changes.
Atomic Energy authorities have been alert and alive to the situation
Well organized and efficient monitoring, controlled operation and
rescue / recovery system has been developed and enforced. Some of
these are:
Authorized person obtains all Radioactive Isotopes from BARC
(Bhabha Atomic Research Centre, Mumbai) only.
Transportation and storage specifications and standards are rigidly
monitored and enforced by the authorities.
Any mishap, loss or damage is promptly attended to and rectified by
the authorities, immediately on receipt of information.
Responsibility

MANUAL
They promptly and formally collect all isotopes reaching their Halflife stage
1
Site requirements for the safe use of field personnel are as follows:
a.Isotope storage a designated and certified location should be
maintained properly with prescribed warning board and
fencing.
b. Personnel using the Isotope must be medically checked before
being permitted to handle and found fit.
c.They must have a valid BARC certificate for safe handling of
Isotopes.
d. They must use a film Badge or Dosimeter as prescribed by the
authorities while working with Isotopes.
e. Isotope attached to a metal pencil should be removed from
storage only for the optimum period of work.
f. Isotope MUST not be taken out of the container lead pot till
actual exposure stage is reached. The exposure time must be
calculated beforehand.
g. Ensure radiation monitoring equipment is working, when
exposure is in progress.
h. On expiry of the exposure time, the source must immediately be
put back in the container.
i. All personnel working with radiation sources must maintain the
prescribed safe distance at all stages of work.
j. Isotopes Pencil must be handled by a Collimator or monitoring
rod of specified length, to avoid any unsafe proximity to the
operators body.
k. Isotopes or the pencil should never be touched by hand or
allowed to come in contact with body.
HSEOM-OCP-13
REV : 03
DATE: 15.12.2008
Page 2 of 4

MANUAL
Page 3 of 4
l. The area of work must be cordoned for a minimum radius of

10m for a Y-ray Isotope of about 3 C (S.A) and more as the
strength Specific Activity of the source, demands.
m. Specified warning Boards MUST be installed adequately
around the cordoned area. If an isotope is damaged or lost:
2
If an isotope is damaged or lost.

a) Immediately seal the working / suspected areas for all traffic,
pedestrian or vehicle.
b) Do not remove any materials tools, containers, vehicles
from the suspected area
HSEOM-OCP-13
REV : 03
DATE: 15.12.2008
anything
Inform BARC Authorities Radiation Protection, Directorate of

Atomic Energy.
Keep strict watch till the authorities arrive.
The authorities will locate and dispose off the offending isotope.
On no account site people or any other persons except BARC

designated personnel should attempt to recover the lost isotope.
Suspected over exposure of any personnel must be reported to medical

center immediately on a routine basis:
All personnel attached to the radiography / radiometer crew must have

prescribed medical check ups.
Dosimeter / film badges must be returned to BARC for processing.

Safe exposure dosage for each individual over different time stages
fortnightly, monthly, annually are predetermined and compared
against actual exposures.
10
If a person is over exposed at any time he should be:

Taken off Radiography / Radiometry work.
Assigned other duties as advised by doctor. He has no cause for panic.

MANUAL
HSEOM-OCP-13
REV : 03
DATE: 15.12.2008
Page 4 of 4
A careful handling and strict observance of precautionary measures

renders isotope use totally safe.
7. Records
Record Title
Record No
Responsibility
Retention Time
3 years
Incharge
Site Incharge

MANUAL
HSEOM-OCP-14
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define a procedure for safe handling, labelling and storage of

hazardous chemicals
2. Scope
3. Responsibility
detailed below.

5. Cross Reference
Manufacture Storage and Import of Hazardous Chemical Rules, 1989 /

2000
Environment Protection Act, 1986 including amendments
6. Procedure
S No. Activity
Responsibility
Definition :
Manufacture, Storage and import of Hazardous Chemicals Rules 1989
under the Environment protection (EP) Act 1986 define Hazardous
Chemical based on toxicity, Flammability and explosivity.
1
Legal Requirements :
The Factories Act and the Environment Protection Act& the Rules
made under these acts require
Identification & Labeling, Obtaining Material Safety Data

Sheet & Disclosure of Information to the workers.
Training & Supervision
Safe Storage, handling & Disposal
Emergency Planning & Preparedness.
Monitoring of work Environment and Health of Workers
Obligations of Workers Under Factories Act

No worker in Factory Shall Willfully Misuse any appliance.
Misuse any appliance.
Do any thing likely to endanger himself or others.
Neglect to make use of any appliance Provided for Security, Safety
and health of employees.
Refuse to Undergo medical examination.
HSEOM-OCP-14
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
IDENTIFICATION& LABELLING
STORAGE
Label the Containers Clearly with contents, name & address of

Manufacture/ importer, Physical and health hazards &
recommended personal protective equipment.
Know how to use the information provided on the labels.
Do not handle any unlabelled container. Check with your
Supervisor.
Store chemicals in a cool, dry and well ventilated place away

from heat and ignition sources. Avoid storage in open sun.
store reactive chemicals separately.
Do not refill empty containers with any chemical other than the
one originally contained. Use containers on first In, first out
basis.
Keep flammable chemicals in closed containers.
Store poisonous substances. Such as cyanides, in locked
cabinets away from acids
HANDLING
Ensure electrical bonding and grounding and while transferring

flammable chemicals from one container another
Follow strictly the approved procedures for loading/ unloading.
Use personal protective equipment as necessary
Handle containers with care, using appropriate trolleys.
Keep cylinders up right
7. Records
Record Title
Physical inspection
records
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-15
REV : 03
DATE: 15.12.2008
Page 1 of 2
1. Purpose
To ensure safe handing of mineral wool
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria General Inspection

5. Cross Reference
6. Procedure
S No. Activity
Mineral wool is used for the insulation of boiler furnaces, piping
etc at site.
Mineral wool is generally supplied as mattress. The mattresses are
packed and sealed in high density polythene bags of thickness atleast
0.2 mm. The sealed bags are further put inside bituminous lined
polythene bonded hessian bags and sealed by machine stitching.
The mattresses inside the packing are provided with metal mesh
facings on one side/both side of the mattress. The metal mesh facing
are hexagonal wire netting made from GI/Stainless Steel wires
The mattresses and the wire netting are stitched with tying wire made
from GI/Stainless Steel wires.
Ensure wearing of hand gloves, nose pads before handling of the
packages
2
Transfer the required number of the mineral wool mattresses packages

from the storage area to the place of insulation work at boiler area.
(Do not take out the mattresses from the packing at the storage area.)
At the insulation work area, open the hessian bag and the polythene
bags without disturbing the mattress or kicking off mineral wool dust.
Ensure that the packing materials are put into the dust bin.
Take care that the loose end of the wire mesh or the tying wire do not
hurt.
Responsibility
HSEOM-OCP-15
REV : 03
DATE: 15.12.2008

MANUAL
Page 2 of 2
Apply the mattresses on the insulation area by handling the wool so

that no loose wool is scattered around the area.
Ensure that the spilled loose wool materials are collected and put into
the waste bin.
7. Records
Record Title
Records of general
inspection
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-16
REV : 03
DATE: 15.12.2008
Page 1 of 4
1. Purpose
To reduce the stress level while continuous working on computers

through better ergonomic posture
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Reduction in stress level due to better ergonomic postures

5. Cross Reference

6. Procedure
S No. Activity
1
Spending long hours at a computer keyboard can hurt. Many people
experience pain in their eyes, neck, arms, hands, back or legs. Many
people experience stress and anxiety.
Ergonomics, the science of designing workplaces so they fit the
person, can help reduce the stress of the repetitive motions you
perform at your job. Try adjusting your office furniture so that you can
keep your wrists straight while typing. (Typing with your wrists and
elbows lower than your fingers is very stressful for the tendons and
can put pressure on the main nerve in your hand.) Position your chair
high enough so that your elbows are even with, or slightly higher than,
your keyboard while you type.
2
When using a keyboard refer to the following diagram for

recommended posture. This arrangement will reduce chronic muscle
loading and thus fatigue.
Responsibility

MANUAL
3
4
Angles of 90 between the upper and lower leg and also between the
upper arm and forearm.
The feet are placed flat on the floor or other support with the thighs
horizontal;
Weight is taken on the buttocks and upper part of the thighs only;
The movement of the legs is not restricted;
There is no pressure at the back of the knees or underside of thighs;
The body is held comfortably erect with the back supported in the
lumbar region;
The relative height of the seat and the working surface should be so
adjusted that the shoulders are relaxed when the hands are resting on
the keyboard. The upper arms should hang naturally with the angle
between the forearm and upper arm about 90, and with a minimum of
wrist bending;
10
The top of the visual display unit screen should be located just below
the level of the operator's eyes;
11
The source material should be positioned at the same height as the

screen and at the same distance from the operator's vision, through the
use of a document holder.
HSEOM-OCP-16
REV : 03
DATE: 15.12.2008
Page 2 of 4

MANUAL
12
If your wrists ache, your fingers feel numb at night or you have
difficulty performing simple manual tasks, you may be suffering from
a repetitive Motion disorder (RMD). These injuries result when the
tendons and nerves in the hand or arm become inflamed and swollen
from excess strain.
13
There are a number of exercises which can be performed to relax tense

muscles. Below are a few suggestions.
14
Hands and wrists : Hand exercises play an important part in

preventing RMDs. Do the following two exercises daily to
strengthen wrist and hand muscles and relieve the strain of
performing repetitive motions.
a) Wrist Rotation
Make a fist and rotate your entire hand (from the wrist) in one
direction. Repeat 15 times. Switch directions and repeat 15 times.
Then, release your hands, and with fingers extended, do the same
rotations.
b) Hand Stretch
Make a fist, then extend your fingers as far apart as possible. Hold for
about 10 seconds. Relax. Repeat the entire sequence 5-10 times until
hands and fingers feel relaxed.
HSEOM-OCP-16
REV : 03
DATE: 15.12.2008
Page 3 of 4
HSEOM-OCP-16
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DATE: 15.12.2008

MANUAL
Page 4 of 4
c) Head and neck
Slowly turn head left, hold for 3 seconds. Turn right, hold for 3
seconds. Drop chin gently to chest, then look up. Repeat the sequence
5-10 times.
d) Shoulders
Roll shoulders forward 5 times, backward 5 times using a circular

motion
7. Records
Record Title
Records of survey for
stress level while
working on computers
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-17
REV : 03
DATE:10.08.2007
Page 1 of 5
1. Purpose
To improve the conservation of energy
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Energy monitoring results

5. Cross Reference
Energy Conservation Act, 2000

6. Procedure
S No. Activity
Fast depletion of precious resources of energy is quite alarming and
hence their conservation is imperative. Following are some simple
tips emphasizing upon use of efficient and energy saving equipment
and energy saving equipment and practices which would certainly
benefit all of us
1
ILLUMINATION
Switch off tube lights, lamps, fans etc when not required
Prefer task lighting instead of uniform one all over
Follow recommended illumination levels
Use energy efficient lamps & luminaries
Keep clean all lighting equipment & reflectors.
Optimize use of natural lighting
Prefer electronic ballast instead of conventional chokes
Prefer compact fluorescent lamps.
Use current / voltage reducer
AT THE WORK PLACE

General
Use high efficiency and optimum size equipment

Optimize use of plant utilities such as steam, cooling
water, compressed air etc.
Monitor and control all plant parameters strictly.
Install monitoring instruments like flow meter,
pressure & temperature gauges, ammeter, etc.
Responsibility

MANUAL
wherever necessary.
Carry out preventive maintenance. Remove the scaling
sedimentation regularly.
Stop all leakages Avoid unnecessary long distribution
pipelines.
Ensure monitoring of process waste & resource loss in
all the areas of construction activities and take required
Corrective / Preventive action to control/reduce/eliminate
them.
Pumps & Compressors & Cranes (Bulk consumption of Energy)

Ensue that the routine & preventive maintenance of these machinery
are carried out as per the schedule.
Pumps
Avoid throttling of pump discharge on continuous basis.

If possible, trim the impellers as per the specific
requirements.
Attend to pump leakage in the form of gland leakage /
flange leakage etc. .
Avoid sharp bends in the pipe line of the pump
immediately after the discharge.
Always operate the pump at its optimum operating
parameters to attain its maximum efficiency.
For smaller application / requirements, install smaller
pumps of required capacity. Do not operate larger
pumps for smaller requirements.
Ensure the pump bearings are properly lubricated.
Ensure that the pressure, temperatures, flow indicators,
ammeter, voltmeters & watt meters mounted on the
pump and motor system are calibrated and in working
condition.
Ensure auto opening of discharge valve on starting of the
pump, if provided in the starting sequence of the pump.
Ensure that the motor breakers are in good operating
condition. No loose connection in the cable connections.
If start / delta starters are provided, ensure that the
timings are set at the correct value for the change over
from start to delta.
Ensure that proper ventilation scope is provided for the
HSEOM-OCP-17
REV : 03
DATE:10.08.2007
Page 2 of 5

MANUAL
cooling of the motor.

Ensure that the vibration levels of the pump / motor are
within the level (Refer to the standard chart for this with
reference to speed of the pump).
Ensue couplings are in good condition.
Ensure proper rated voltage at the terminals of the
pump.
Cooling Towers
Avoid idle running of the compressors.

Ensure that the routine & preventive maintenance of the
compressors are regularly made.
Ensure that the cooling system in the compressors are
properly working. Coolers are to be periodically serviced
to remove fouling of cooling tubes.
In the case of belt driven compressors, ensure that the belts
are in proper tightness to avoid slippage.
Ensure that the driers provided for the drying of the
compressed air in proper working condition &
regeneration cycle operates as per the programme.
Ensure the vibration levels of the compressor & motors are
within the level (Refer to the standard chart for vibration
level.
Ensure that rated voltage is available at the terminal of the
compressor motor.
For smaller requirements of compressed air, do not operate
large size compressor.
Ensure that loading &unloading cycle of the compressor is
properly taking place. Safety valves are properly set &
operating.
Ensure proper oil level in the compressor oil case.
Ensure proper lubrication of the bearings of the motor.
As far as possible, group all the works connected to the
requirements of compressed air & operate the
compressor to meet that requirement.
Check all the leaking joints / ferrules / couplings and attend.
Ensure the usage of Teflon tape in the joints particularly in
the instrument air lines.
Ensure the periodical cleaning of the air filters in the
compressor / pipe lines.
Ensure that the pressure / temperature / flow indicators /
ammeters / voltmeter / watt meter provided on the
compressor system are properly calibrated and working.
HSEOM-OCP-17
REV : 03
DATE:10.08.2007
Page 3 of 5

MANUAL
Cranes
Ensure that the routine & preventive maintenance of the
cranes are carried out as per the schedule.
Ensure that the consumption of fuel (Diesel) is clearly
accounted in relation with works carried out / hours of
operation of the crane.
Ensure that the works are planned in advance and as far as
possible crane utilization is made to the optimum.
Different agencies to work in close co-ordination with each
other.
Avoid idle running of the crane.
As far as possible avoid using crane for lifting smaller size
object unless it is warranted for critical constructional
activities.
Ensure that the crane operator is trained in the crane
operation and is in possession of OCP No. 08 for Safety
in using cranes.
Ensure that all the pulleys are properly lubricated.
Cooling Towers & Refrigeration system:
Use thermostatic controller for cooling lower fan.
Use high efficiency drift eliminator and FRP blades
Use PVC fill instead of concrete or lumber
Optimise need of refrigeration and refrigeration temperature.
Dont use week or broken insulation.
Store chilled water / ice during off-peak hours and use it
during peak hours.
Motive load:
Avoid idle / redundant running of motors.
Use star delta changeover
Use soft starter for high torque
Control of maximum demand
Improve load factor to maximum

Improve power factor by installing capacitor bank and
automatic power factor correction system
HSEOM-OCP-17
REV : 03
DATE:10.08.2007
Page 4 of 5
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DATE:10.08.2007

MANUAL
Page 5 of 5
Install automatic demand controller system

Select optimum sanctioned demand. Minimise peak
demand.
In the Kitchen
Keep the entire cooking material ready before lighting the
stove.
Let cold materials attain room temperature before cooking
Soak the grains and cereals before you cook them
Avoid use of excessive water in cooking
Use utensils broad base. Use lid on cooking utensils
Prefer small burner and light flame.
Ensure stable, bright & blue flame. Reduce flame when
boiling starts.
Use only ISI mark stoves and kerosene wicks
Use pressure cooker, Cook different types of food
simultaneously by using separators.
Avoid often reheating of food. Store food in insulated
containers.
On the Road
Get the vehicle regularly serviced and engine tuned

Maintain correct type pressure
Clean air-filter regularly
Drive in correct gears and at optimum and uniform speed.
Keep your foot off the clutch and use it only while
changing gears.
Avoid idle running of engine.
Make the vehicle lighter. Reduce unnecessary load.
Plan your trips and route and avoid rush-hour traffic.
Prefer cycle than fuel-operated vehicles.
7. Records
Record Title
Records of energy
monitoring
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-18
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To define a procedure for providing proper first aid
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Availability of trained first aid personnels

5. Cross Reference

6. Procedure
S No. Activity
1
First Aid refers to the emergency treatment given to a person suffering
from an accident or sudden illness until a doctor attends. First Aid has
three important aims viz,preserve life, promote recovery and prevent
worsening of the casualtys condition
1
TIPS FOR FIRST AID
ARTIFICIAL RESPIRATION (MOUTH TO MOUTH):
If breathing has stopped, artificial / manual respiration can be
performed but former method will be carried out by experienced
person.
2
Basic Life Supports: Airway, Breathing, Circulation.

Airway:
Lay victim on his back. If any foreign matter is in his mouth, turn
head to one side, force mouth open and wipe it out with fingers. Tilt
head as far back as possible by holding the crown of the head with one
head with one head and pull the chin. This makes air passage clear to
his lungs
Breathing:
Keeps his head tilted backward and separate lips with thumb. Open
your mouth widely and place it tightly over his mouth. Press your
cheek against his nostrils to prevent air leakage. Watch the victims
chest as you blow, when it rises take your mouth away and let him
breath out naturally. Listen to the air being exhaled. Make the first
ten breathes deep and at a rapid rate to give a good quick supply of life
giving oxygen
Responsibility

MANUAL
Circulation:
If victim doesnt respond to the above method start the circulation

method. Stop blowing for a moment and press your hand ( by keeping
hand on hand) between navel and breast bone. Release hand pressure
hand again blow air. Repeat the procedure. Never interrupt
circulation more than 5 seconds.
ELECTRIC SHOCK:
Remove the patient from the source of danger. Make a rapid
examination to ensure that the air passages are free, and clean them if
necessary. Restore natural breathing by artificial respiration if
breathing has ceased.
CUTS AND WOUNDS:

stop bleeding by Direct Pressure: Direct finger pressure into the
wound in cases of larger bleeding wound. Toumlquet use only as a
last resort) Wipe out the wound with clean sterile cloth. Avoid
touching the wound with hands or unsterile material. Clean the
wound by running water. Apply ready-made adhesive bandage or
sterile gauze and roller bondage as needed. Keep the patient quiet and
get medical help.
BURNS:
Act quickly; put the affected part in cold water; Pour the water over
burns that can not be immersed. Cover with a sterilized dressing and
get medical help immediately.
SUFFOCATION:
Remove the patient from the source of danger; Make a rapid
examination to ensure that the air passages are free, and to clean them
if necessary. Restore natural breathing by artificial respiration if
breathing has coased.
EYE INJURY:
Removal may be attended with the help of someone if foreign body is
not embedded. In case of chemical burns, wash eyes with water for
15 minutes & apply sterile bandage. Dont apply oil or ointment.
Send the victim to a doctor.
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MANUAL
Page 3 of 3
POISONING:
Remove the victim from the site taking precautions for the personal
safety of the rescuer. Make the victim lie down and keep him quiet
and warm. Remove contaminated clothing immediately and wash
affected skin with plenty of water. Seek medical treatment when
anyone has symptoms apparently due to swallowing, inhalation or
contact with skin or eyes.
FRACTURE:
Arrange the limbs in as natural position as possible without causing
undue discomfort to the patient. Apply splints of any rigid material
long enough to extend beyond the joints above and below fracture.
Fasten splints firmly with bandage at least at three places. Transport
the victim on the rigid frame to hospital. In neck fracture cases it is
advisable to got a doctor to the scene for danger to life is great.
7. Records
Record Title
Records of training
provided to first aiders
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-19
REV : 03
DATE: 15.12.2008
Page 1 of 8
1. Purpose
To define a procedure for fire safety in high rise buildings, offices and
godowns
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Physical inspection results

5. Cross Reference
National building code of India Part IV- Fire protection

Tariff advisory committee building regulations
Development control regulations / bye laws of municipalities
6. Procedure
S No. Activity
1
INTRODUCTION
Large and devastating fires took place in numerous high rise buildings
causing loss of life and property. It is difficult to fight a high rise
building fire as it quickly spreads upwards (due to Chimney Effect)
and the external fire fighting appliances may not be able to reach
higher floors. Evacuating people especially invalids, old persons and
children, without panic poses practical difficulty in most cases.
Fire loss can be prevented through careful observance of

precautionary measures
LEGISLATION / REGULATIONS
Development Control Regulations / Bye-laws of Municipalities.
Natural Building Code of India, 1983 Part IV Fire Protection,
Amendment 3 of 1997.(for buildings 15 m and above in
height).
Tariff Advisory Committees Building Regulations(for buildings
above 22 m in height)
PLANNING STAGE
Layout should ensure adequate fire separation between buildings
to minimize fire spread possibility.
Enough space to be provided for movement of fire fighting
vehicles / ambulances.
Responsibility

MANUAL
DESIGN STAGE
Enclosure of 2 hr fire resistance for staircases AND LIFT
WELLS.
Wide staircases and lobbies to permit orderly evaculation in
emergency. Pressurization of these areas will keep them free
of smoke.
Critical areas such as refuge areas to be protected by fire proof
doors.
Fire-lift for exclusive use of ire fighters.
Electrical wiring in metal conduits.
Emergency switches at ground floor for disconnecting power,
floor-wise.
In central air conditioning (A/C) system, provide automatic fire
dampers ( in the common duct) for each floor or occupancy.
Individual A/C system for each occupancy or for each floor is
preferred to central A/C system.
Openings in the cable passageways (from duct to floors) to be
closed.
Alternate power supply for staircase & corridor lighting circuits,
fire lifts and stand by fire pump.
Fire detection & alarm system, hose reels, wet risers, yard
hydrant, automatic sprinklers and water reservoir as per
National Building Code.
OCCUPATION STAGE
Minimize combustible materials for furnishing. Use fire

retardant material for false ceiling, partitions and
upholstery.
Develop a simple, written fire safety plan which should

include precautions for fire prevention at occupants level,
fire control by the building maintenance / security team
and the emergency plan covering evacuation procedure.
All occupants should know clearly how to identify / raise

fire alarm, call fire brigade, tackle fire and evacuate safety.
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MANUAL
MAINTENANCE STAGE
Ensure good maintenance of fire appliances
Check periodically availability of dedicated water for fire
fighting
Undertake fire drills and mock exercise for evacuation.
Have stringent controls against over loading of electrical
circuits, accumulation of chemicals and flammables,
and storage of materials in the staircases, lobbies and
fire escape stairways.
DURING FIRE EMERGENCY

Keep the doors and windows shut to prevent ingress of
heat and smoke.
Evacuate without panic, but quickly. Do not waste time in
collecting things.
Do not use lifts as they may malfunction.
If fire is in an upper floor, proceed to lower floors and
eventually to outside the building. If fire is in a lower
floor, use judgment and decide the evacuation
direction. Try to reach refuge area, if provided in the
building.
Remember that floor level will be free from smoke for
longer time.
FIRE SAFETY IN GODOWNS

Fires in godowns account for a major chunk of total number of
outbreaks in industrial occupancies and almost invariably assume
serious proportions resulting into not only colossal but also damage to
surrounding environment and community.
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MANUAL
PRINCIPAL CAUSES
Surreptitious smoking
Spontaneous ignition
Use of naked flames or cooking
Faulty electrical installations
Storage of incompatible hazardous goods
Carrying out dangerous operations such as welding,
cutting, spray painting, etc. in godowns or adjacent
buildings.
Frequency of fire outbreak and loss suffered as a result, could be

considerably reduced if proper attention is paid to following safe
practices.
10
STORAGE
Ascertain beforehand fire hazards of the materials you store.
Assume the material to be hazardous if complete information
is not available.
Store the materials susceptible to water damage, on skids, pallets
and such elevated platforms of at least 20 cm above the
ground. Prefer non-combustible material for such platforms
Ensure that safe floor load limits given in IS 875:1964 are not
exceeded.
Ensure adequate ventilation where flammables are stored, handled
or used.
Dont allow even temporary storage of goods if it obstructs across
to godown doors, aisles, fire exits, and fire equipment.
Store incompatible chemicals separately.
11
HANDLING
Ensure label on every chemical container. Dont use or handle
unlabeled container but report them. Follow the
instructions on the label and in the Material Safety
Data Sheet.
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MANUAL
Follow approved procedures for material handling, goods

movement and loading / unloading.
Ensure electrical grounding and bonding of the containers labeled
FLAMMABLE before pouring, dispensing or transferring
any liquid from them.
Strictly follow work permit instructions when welding, cutting
and other such hot work are undertaken in areas where
flammable are present.
Dont drag containers labeled FLAMMABLE. Handle them with
care and use appropriate trolleys.
Switch on fan motor before using chemical hood.
Use rubber cradle while transporting unpackaged glass bottles of
chemicals.
12
EQUIPMENT AND APPLIANCES

Use certified flameproof forklift trucks where highly flammable
goods are stored or handled.
Never fill or empty fuel tanks of petrol / diesel powered mobile
material handling equipment.
Ensure that induction system of all petrol motors is provider with
flame arrestor.
Ensure that fuel-operated material handling equipment carry
suitable types of fire extinguishers.
Prefer non-flammable refrigerants for refrigeration systems.
13
ELECTRICAL INSTALLATIONS
Dont overload electrical circuits
Avoid temporary connections
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MANUAL
14
HSEOM-OCP-19
REV : 03
DATE: 15.12.2008
Page 6 of 8
Locate all switches and control equipment outside the

godowns storing fibrous good, flammable liquids,
nitrocellulose and fireworks or explosives. Dont use flexible
lighting pendants and portable lamps but ensure use of
flameproof fittings in such situations.
See that no light fitting has a clearance of less than 75 cm from the
highest stacking level.
FIRE SAFETY IN OFFICES
The traditional image of office work being always safe deceptive, the
main risk to life and property in offices is from fire. Besides loss of
life, injury to office workers and damage to property, critical data and
irreplaceable office records, loss of which can give a severs blow to
the organiasation, are vulnerable or poorly managed fire faire
Hazants in model offices.
15
COMMON FIRE HAZARDS

Paper records, plastic tapes and floppy discs
False ceiling, wooden furniture, carpet, etc.
Non-standard and faulty powered office equipment
Defective and loose electrical wiring
Overloading of electrical circum
Free use of extension cords, ungrounded plugs and unfused
multiple outlet adapters
Microwave oven hot plate, cooking fuel (LPG), etc., in office
canteens
Following are some simple tips which if followed, would certainly help to minimise incidents
of office fires or at least their severity:
FIRE PREVENTION
16
GENERAL CONSIDERATION:
Practice good house keeping. See that all trash cans and
recycling containers are emptied on a regular basis.
Ensure the office and storage closes are free of excess
combustible material Limit their quantities to an acceptable

MANUAL
level and store them only in approved cabinets.

Keep beat producing equipment such as copiers, computers,
coffee makes, hot plates etc away from anything that might
burn.
Dont smoke at places other than permitted areas and discard
ashes in ashtrays only.
Ensure that air vents on computes and other heat producing
equipment are not covered or restricted causing inadequate
airflow, which could cause a fire.
Dont place space heaters under desks. Locate them in an open
and away from combustible.
17
ELECTRICAL CONSIDEDERATIONS
Dont overload circuits. Install additional circuits if needed.
Turn off electrical equipment/appliances while leaving the
office.
Use only grounded appliance plugged into grounded outlets.
Disconnect electrical appliance if it malfunctions or gives off a
strange smell and call the maintenance personnel.
Never plug one extension cord into another.
Take electrical equipment with defective cords, out of service
until the cord is replaced.
Avoid use of electrical extension cords. Use them only in
situations where fixed wiring is not feasible. If their use is
necessary, ensure that they are not run through doors, walls,
floors or any other location where they could be damaged.
Examine extension cords regularly and ensure that they are not
frayed or defective.
Follow correct specifications when replacing fuses in equipment
Always prefer standard equipment bearing ISI mark.
18
FIRE EMERGENCY
Be Prepared
Ensure that emergency numbers are pasted on your telephone.
Know how to use fire extinguishers and activate fire alarms.
Dont block fire equipment and fire exits.
Ensure that fire equipment is maintained in working condition
by periodic inspection and maintenance.
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MANUAL
Page 8 of 8
Report missing and damaged extinguishers immediately.

If Fire Occurs
Dont panic; remain calm.
Notify anyone in the immediate area and fire brigade.
Activate the nearest fire alarm.
Turn off the electrical equipment in the immediate area, if
possible.
Confine the fire by closing doors and windows.
Attempt to extinguish the fire only if it is safe to do so.
Stay low if there is smoke or heat
Dont use elevators. Always use staircases; do not congregate in
the stairways. Always move down and out.
Dont go back for your things if you are asked to leave.
Assemble outside. Do not re-enter the building until notified.
Dont enter the area if you suspect that a life-threatening
condition still exists.
Take affected persons to a safer place and get medical help
promptly.
Practice good housekeeping Prevent office fires.
7. Records
Record Title
Record No
Responsibility
Records of physical
inspection
Incharge
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-20
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To define a procedure of food safety
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Records of ill health due to food poisoning

5. Cross Reference
The Prevention of Food Adulteration Act and Rules, 1955

6. Procedure
S No.
Activity
Responsibility
Millions of people around the world fall sick as a result of consuming
contaminated food and water.
Food Contaminating Agents: Bacteria, viruses, parasites, pesticide
veterinary drug residues, food additives, naturally occurring toxin
industrial contaminants, etc.
Legal Requirements: The Prevention of Food Adulteration Act, 195

and Rules, 1955
thereunder require
Analysis of food samples by public analysis
Prescribing food quality standards
Notice of food poisoning by medical practitioners
Labeling of food giving name, trade name, composition, best
before or manufacture date, etc.
Restriction on dose of irradiation for onions, potatoes, spices
mangoes, rice, dried fruits, meat and meat products, etc.
Prohibition of use of inorganic colouring matters
Restriction on use of synthetic food colours (azo, xanthene, etc)
iec-creams, cakes, fruit drinks, etc.
Restriction on use of poisonous metals such as lead, copper
arsenic, tin, zinc, cadmium, mercury, chromium, and nickel
Restriction of use of insecticides on foodstuffs
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.

MANUAL
Following are some simple tips to ensure sate and hygienic food WHEN YOU SHOP
Buy raw and as ready-to-eat food from safe and hygienic sources
Prefer packaged foods and bottled beverages.
Insist on Agmark / SI certified food products.
Check for Expiry or Best before date.
Ensure that food articles are packed in clean and hygienic
wrappers / containers.
Avoid fruits with damaged skin.
Buy perishable foods last & take them straight home to
refrigerator.
STORAGE & HANDLING

Refrigerate of freeze perishable foods quickly after purchasing.
Store leftovers at temperature either below 100C or above 600C.
Keep raw meat, poultry, eggs, seafood and their juices away from
ready-to-eat foods.
Avoid storing cooked food. To possible extent, prepare food
freshly and serve immediately.
Protect food from insects, rodents and animals.
Store non-perishable foodstuffs in closed containers away from
pesticides, disinfecting agents or other toxic chemicals.
Never store foodstuffs in containers which have previously held
toxic chemicals such as insecticides, paints, varnishes,
thinners, etc.
Avoid contact between raw foodstuffs and cooked foods through
hands, files utensils or unclean surfaces.
FOOD PREPARATION
Keep the food preparation premises meticulously clean. Keep
scraps of food & crumbs in safe covered place and dispose
them of quickly.
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.
Ensure safe water for food preparation. Boil it if is quality is
doubtful.
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MANUAL
Page 3 of 3
Wash fruits and vegetables thoroughly using plenty of safe water

particularly if they are eaten raw. If possible, peel the, off.
Cut vegetables and fruits first, then raw meat and poultry.
Wash cutting boards and utensils with hot soapy water after
cutting raw meat and poultry products and before slicing
vegetables.
Re-cook the cooked food on addition of any new ingredient.
Reheat leftovers thoroughly at least at 700C before consumption.
6
CONSUMPTION
Wash hands thoroughly using soap before eating.
Use clean dishes and utensils to serve food.
Never taste food that looks or smells strange to see if you can
still use it. When in doubt, do not use it.
Dont eat cooked or perishable foods that have been kept in the
refrigerator for too long i.e. more than 2-3 days.
Prefer pasteurized or boiled milk.
Prefer restaurants licensed by municipal administration.
Avoid food exposed to dust and files and shops and hawkers.
Consult physician on any instance of food borne illness such as
diarrhea. Vomiting, abdominal pain, headache etc.
7. Records
Record Title
Records of ill health
due to food poisoning
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-21
REV : 03
DATE: 15.12.2008
Page 1 of 4
1. Purpose
To define a procedure for control of vehicular pollution
2. Scope
3. Responsibility
Site in charge who in turn will assign the responsibility to the

activities detailed below.
4. Performance Criteria
Conduction of PUC monitoring
5. Cross Reference
Central Motor Vehicle Rules, 1989

6. Procedure
S
Activity
No.
1
INTRODUCTION
The exhaust fumes coming out of the tail pipe of vehicles contain many
polluting substances which is a major contributor for environmental
damage and diseases. One research study says that 2.5 million people are
estimated to die prematurely each year from pollution related ailments. It
is estimated that currently our country is losing over 10% of its G.D.P in
costs associated with damage to the environment and degradation of the
countrys natural resources.
Air pollution and other health hazards caused by vehicles have reached as
alarming proportion in the country. The vehicle population in the country
has grown from 0.3 million (1951) to 25.34 million (1993) and
contributing now around 50 to 60% of the total air pollution in the cities.
This is mainly contributed by cars, two wheelers as they have old and ill
maintained engines, in which nearly 30% of the fuel remains unburned.
2
VEHICULAR POLLUTANTS
The main pollutants omitted in the automatic exhaust gases are carbon
monoxide (CO), lead aerosol, nitrogen oxides, sulphur oxides and
heterogeneous groups of hydrocarbons. Apart from this, smoke (0.01 to 1
micron) Mists (2 to 200 micron) and particulate matter (1 to 200 micron)
are also formed due to incomplete combustion and solid impurity contents
of the fuel. In particular the diesel operated vehicles emit more toxic
pollutants.
Responsibility

MANUAL
HSEOM-OCP-21
REV : 03
DATE: 15.12.2008
Page 2 of 4
EFFECTS OF POLLUTANTS
Human Health:
Carbon Monoxide: Hinders oxygen supply from blood into the

issues as it combines with the iron in the hemoglobin and thereby
replacing oxygen in the hemoglobin, leading to variety of
ailments.
Respirable particulate matter: 0.2 to micron size of particulate

matter can go directly into the lungs causing bronchal problems
and allergic asthma.
Lead: It attacks the blood, kidneys and central nervous system It

can cause anemia, kidney failure, permanent brain damage and
finally death also.
Environment:
The pollutants such as SO2 & Nox form acid rain and affect sometimes,
vegetation, soil surfaces, darken sky through formation of smoke leading
to limited visibility and corrode metals. The plants are damaged by acute
injury in which pollutants attack the cells resulting in chronic effects
related to disruption of chlorophyll synthesis and thereby affecting the net
yield of crops / fruits.
SOURCES OF VEHICULAR POLLUTION
Vehicular emissions originate from changes in driving cycle (transport of
steady state)
Engine conditions (injection and aspiration techniques, maintenance, total
milage) fuel composition (sulphur content, aromaticity, volatility),
incomplete combustion and air / fuel ratio. Main places where pollution
originates from the vehicle include engine crankcase, exhaust system, the
carburetor and the fuel tank. The emission of particulate matter increases
with decrease in air / fuel ratio, increase in load and temperature
Malfunction of engine devices, especially fuel injection system increases
the omissions of the main exhaust equipments.
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MANUAL
Page 3 of 4
POLLUTION CONTROL MEASURES

Following measures may be adopted to reduce the emission:
Modification of engine design to improve fuel combustion

efficiency
Exhaust gas recirculation for ensuring complete combustion
Use of particle traps for removing particulate matter.
Use of alternate & container fuels (CNG, LPG,Methanol etc.)
Improvement in traffic congestion.
Implementation of strict Inspection / maintenance programmes.
Avoiding idling at the traffic junctions / signals.
Thermal reactors for complete oxidation of CO & HC
Cataytic converter to reduce emissions for unburned HC and CO
Use of unloaded gasoline
Use of low smoke tube of lot 2 stroke and mixed lubricating
engines.
Adopting cleaner vehicle standards.
Introduction of efficient rapid mass transport systems.
Driving vehicles at 50 60 KMPH range.
SATUTORY REQUIREMENTS
Limits for vehicular emissions:
Type of Vehicle
Diesel driven
2 / 3 wheeler
petrol driven
(Reference mass
R IN KG)
Rs 150
150< Rs 350
Rs 350
CO
14 g / KWH
HC
3.5 g/KWH
12 G/KM
12.18(R.150)200
3 G / KM
8 g / km
8.4(R.150)200
12 g / km
NO
8 g
KWH

MANUAL
Page 4 of 4
LIMITS FOR PETROL DRIVEN VEHICLES:

Reference Mass rw in
Co (g/km)
kg
RW 1020
14.3
1020 < RW < 1250
16.5
1250 < RW S 1470
18.8
1470 < RW S 1700
20.7
1700 < RW s 1930
22.9
1930 < RW s 2150
24.9
rw 2150
27.1
HSEOM-OCP-21
REV : 03
DATE: 15.12.2008
HC(g/km)
2.0
2.1
2.1
2.3
2.5
2.7
2.9
PUC Check All vehicles ( one year after 1 st registration) need to

undergo the Pollution Under Control (PUC) test at the testing facilities
authorized by RTO every six months and ensure the compliance with
the emission limits.
7. Records
Record Title
PUC certificates
Record No
Responsibility
Retention Time
Shall be given
Shall be assigned by Site
3 years
by Site Incharge Incharge

MANUAL
HSEOM-OCP-22
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DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define a maintenance procedure for attending the leaking valves
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Physical inspect records

5. Cross Reference
6. Procedure
S No. Activity
1
Ensure that a maintenance schedule is prepared for attending to all
leaking valves
2
Ensure availability of proper sizes of glands for different types of

valves.
Ensure walkdown checks are carried out at regular intervals to identify

all the leaking valves at the earliest.
Ensure that the valve technicians are provided with required training
to attend to leaking valves.
Ensure that the required instruction manuals of valves are available at

the work site for reference.
When glands are replaced, ensure that the glands are not lightly put
affecting the free operation of the valve.
Ensure that correct tools are available while attending gland leakage
particularly in special valves.
Leaking valves are to be attended at the earliest to avoid damage to the

stem of the valve.
Valve leaking / passing to be avoided by suitable lapping of the disc &

Seal.
10
Blue matching, wherever possible to be made between valve disc &

Seal before assembling the valve. (Particularly High pressure Valves)
Responsibility
HSEOM-OCP-22
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MANUAL
Page 2 of 2
11
Operational observations are to be properly interrelated to the valve

leaking / passing and the leaking / passing valves are attended.
12
Wherever the valves are operated by electrical drive ensure that the
valves are closing tightly preferably on torque closing to avoid
passing.
13
Advise the Customer to arrange for required spares for valves in

advance so that the maintenance of the valve can be taken up without
any delay.
14
While attending to body leakage of vales, care must be taken to lap the
eroded surface of the mating surface and for careful fitting of sealing
rings.
15
It is to be ensured that the maintenance crew is given the task of

attending to the leaking / passing valves with message that the valves
attended thus results in Energy Saving.
7. Records
Record Title
Physical inspection
records
Record No
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-23
REV : 03
DATE: 15.12.2008
Page 1 of 3
1. Purpose
To define a procedure for health monitoring
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Pro active methods for detection of diseases

5. Cross Reference

6. Procedure
S No. Activity
1
SCOPE
The Company operates a Medical Scheme that takes care of the
specific Outpatient & Inpatient Treatment in case of illness. For
Inpatient treatment, a few leading hospitals have been recognized
where employees and their dependents can take treatment and the bill
is settled directly by the Company.
The Company has a full-fledged Dispensary and a Part Time Medical
Officer is posted for consultation.
Apart from the above, the Company adopts number of other
Preventive Measures which are outlined below
2
Preventive Health Measures

Preventive Health Check-ups for HQ employees:
1.
This will include Specific tests / Vaccination.
2.
Visit of PTMO to Sites to cover Site employees to undertake

Health Programmes. During the Visit of PTMO to Sites, he
will be available for consultations, carries out basic tests such as
blood test, urine test, etc. Specifically, tests for detecting certain
diseases are also conducted.
3.
Specific Programmes to cover Lady Employees exclusively.
4.
Lectures by eminent doctors on varied topics of diseases /

health, to create Health Awareness.
Responsibility

MANUAL
5.
Preventive health check-ups for HQ Employees:

1.
2.
3.
4.
5.
6.
7.
8.
9.
Comprehensive Medical Check-up

Micral II Test for detection of renal damage
Bone Densitometry Test
Pulmonary Efficiency Test
Hepatitis B Vaccination
Stress Management
Uterus removal and its effects on human system
Harmone and Mineral Replacement Therapy
Early detection of Breast Cancer.
Articles on Health:
1.
2.
Notice Board is maintained where articles on Health

Awareness, Diseases are displayed every week in English as
well as Tamil which is a local language.
Articles displayed in Notice Boards in English & Tamil

Posters displayed in Dispensary.
Health Care for Retired Employees:

1. Lectures
2. Tests.
Periodic Update on Issues related to Health through Intranet facility
Work Environmental Monitoring Planned

Services of Occupational Health Centre of BHEL (T) is being
requisitioned to undertake Site Visit and thereby identify areas where
Preventive Health Check-ups can be planned. This visit will be made
in few projects and at PSSR HQ.
Preventive Health Check-up at Sites:

Medical Check-up for employees & dependents at various PS SR Sites
Specific Programmes for Ladies

1. Pap Smear Test for Ladies
2. Dexa Test to detect Osteoporosis
HSEOM-OCP-23
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Page 2 of 3

MANUAL
10
HSEOM-OCP-23
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DATE: 15.12.2008
Page 3 of 3
3. ECG Screening
4. Mammography Test
Lecture by Eminent Doctors
Some of the Topics of Lectures
1.
2.
3.
4.
5.
7. Records
Record Title
Records of
monitoring
Smoke Cessation
Prostatic Problems
Demo on Diabetic Meal Planning
Cardiology
Acupressure
Record No
health Shall be given by Site
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-24
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DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define a procedure for proper identification, classification, reporting

and computation of accident and incident trends
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Progress in accident prevention campaign / making people safety

conscious / Analysis of accidents records
5. Cross Reference

6. Procedure
S No. Activity
1
This operation control procedure is issued with the following
objectives in view
To help in evaluating the relative need for taking accident
prevention measures in different functional areas particularly
at construction site.
To help in making an appraisal of the progress of an accident
prevention campaign and making people safety conscious.
To provide encouragement when methods used for the
prevention of accidents are successful: and
To enable comparisons to be made.
2
ACTIVITY:
ACCIDENT (PERSONAL INJURY / PROPERTY DAMAGE)
REPORT
Accident (personal injury / property damage) Report shall be prepared
and sent to PS SR, Safety Dept. in the Accident (Personal injury /
property damage) Report form.
MONTHLY MAIN POWER STATUS REPORT:

Monthly Man Power Status Report shall be prepared and sent to PS
SR Safety Dept. in the Safety Report Form.
WEEKLY SAFETY REPORT:

Weekly Safety Report shall be prepared and sent to PS SR Safety
Responsibility
HSEOM-OCP-24
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DATE: 15.12.2008

MANUAL
Page 2 of 2
Dept. in the Weekly Safety Report Form.

QUARTERLY FIRE SAFETY REPORT:
Quarterly Fire Safety Report shall be prepared and sent to PS SR
Safety Dept. in the Quarterly Fire Safety Report Form.
CLASSIFICATION AND ANALYSIS OF ACCIDENTS /

INCIDENTS
Classification and analysis of accidents / incidents to be carried out
referring to IS:3786 / 1983 and reported to Site / I/c and Regional HQ,
quarterly.
7. Records
Record Title
Analysis records of
accidents and incident
Records of accidents
reported
Record No
Responsibility

Incharge
Site Incharge
Retention Time
3 years


MANUAL
HSEOM-OCP-25
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DATE: 15.12.2008
Page 1 of 12
1. Purpose
To define general guidelines for Occupational health practises for

BHEL construction sites
2. Scope
3. Responsibility
Site in charge who in turn will assign the responsibility to the

activities detailed below.
4. Performance Criteria
5. Cross Reference
Adherence to the guidelines

BHEL Occupational health practises
6. Procedure
S
Activity
Responsibility
No.
1
BHEL site construction activities encompass a wide variety of operations
such as welding, Grinding, Machining, Fabrication, Material Loading,
Unloading, Earth Moving, Erection of structures, Vessels, Pipelines etc.,
workmen in these activities generally consists of skilled tradesmen like
welders, Fitters, Machinists, Turners, Crane Operators etc. Gases, Fumes,
Dusts, heat are a common place during such activities. Workers engaged in
these activities are exposed to a multitude of hazards and there is a potential
risk of developing occupational & work related disorders and diseases
2
Pre-employment health screening and periodic health screening are

essential in these work places to maintain the health of workmen

MANUAL
Table Nos. 1and 2 summarize the nature of hazards and their main
occupational occurrence in various types of occupations in construction
sites.
S.No Physical Hazard Principal
Effects
Occupational
Occurrence
1
Heat
Preheating before
1. Heat hyperpyrexia
welding in confined
2. Heat exhaustion
spaces
3. Heat syncope
4. Heat Cramps
2
Noise
Grinding
Noise induced hearing
Sandblasting
loss.
Tube making
Most of the jobs in
construction
activities
3
Non-ionizing
radiation Ultraviolet rays
Infra-red rays
Ionising
radiation
Gamma rays, Xrays
Illumination
Welding.
Jobs with red hot
surfaces
Are eye Photo

dermatitis
Non-destructive
testing
Blood Cancer
Cataract etc.
Poorly illuminated
or over illuminated
work areas
Eye strain.
HSEOM-OCP-25
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Page 2 of 12

MANUAL
HSEOM-OCP-25
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DATE: 15.12.2008
Page 3 of 12
Table 2
MAIN CLASSES OF DUSTS IN CONSRUCTION SITES WITH
PRINCIPAL
OCCUPATIONAL OCCURRENCE AND EFFECTS
S.No
I
II
Principal
Type of Dust
Occupational
Occurrence
Quartz and Mixtures containing quartz
Mineral ores,
Sand blasting.
Fluorspar, rock
Welding /
grinding
Metals and metal
compounds:
a. Aluminum,
1. Welding
Aluminum oxide
2. Flame
cutting
b. Chromium,
Chromic oxide,
chromate
1. Welding
2. Flame
cutting
c. Iron, Iron oxide
Welding.
Flame cutting
Grinding
d. Lead oxide
e. Manganese
Flame cutting of
lead painted
material.
Soldering
Welding with flux /
electrodes
containing
Effects
Silicosis
Chronic nonspecific ling

disease (CNSLD)
Ulceration and
perforation of
nasal septum,
bronchial asthma,
CNSLD,
carcinoma of nasal
cavity (only
hexavalent
chromium is
carcinogenic)
Siderosis
Lead Poisoning
Mn poisoning

MANUAL
Page 4 of 12
f.
oxide
manganese
Nickel
Welding using
electrodes
containing Ni
g. Vanadium
pentoxide
S.No
Power stations
(cleaning of residue
in oil burning
furnaces)
Gases / Chemicals Principal

Occupational
Carbon Monoxide
(CO)
CO2 Welding
Carbon dioxide
(CO2)
CO2 Welding
Ozone (O3)
Inter-gas-shielded arc
welding
HSEOM-OCP-25
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Bronchial
carcinoma,
carcinoma of nasal
cavity.
Allergic rhinitis,
Br. Asthma,
CNSLD,
dermatitis
Graphite.
Effects
Chemical
asphyxia
Simple asphyxia
Lung fibrosis
Delayed
pulmonary
oedema,
4
Oxides of nitrogen
Arc-welding
bronchospasm,
respiratory
failure.
HEALTH SCREENING AT WORK PLACE IN CONSTRUCTION SITES
The medical examination of workers consists in making a health
assessment that is as complete as possible, enabling physical and medical
fitness and unfitness to be defined, with a view to adapting the worker to
his work and at the same time to prevent any deterioration in his health that
might be connected with his job.
Thee are 3 occasions during which these health assessment are made:
Pre employment medical examination
Periodic medical examination
Medical examination upon return to work after an accident (or)
illness.
Respiratory insufficiency at rest and during effort is the first aspect

MANUAL
HSEOM-OCP-25
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DATE: 15.12.2008
Page 5 of 12
requiring to be checked, particularly in relation to the workers

occupational and medical history. Auscultation quickly reveals whether
there are any changes indicating bronchial dilation, asthma., chronic
bronchitis or emphysema. Radiological examination is indispensable since
it allows kinetic and anatomical study of the respiratory system. X-ray is of
particular assistance in detecting the existence of broncho pulmonary
disorders and also in determining the morphological state of the heart and
its vascular pedicle. Lung function tests using spirometer and peak flow
meters should be carried out which will serve as base line data for future
comparisons in those who are going to be exposed to respiratory hazards
such as dusts, gases and fumes
This medical examination should be supplemented by determining whether
there are sings of splenomegaly, adenopathy, goiter, pregnancy stretch
marks of puberty anomalies. All the above constitute basic examination
and should be supplemented as necessary by further examinations.
Emphasis should be laid on the following examinations for the specific
occupations in construction sites before employment as shown in Table 3:.
Table 3
S.No Occupation
Specific examinations / Caution
1.
Welders
1. Special emphasis on visual acuity,

examination of lens, fundus
2. Lung function tests
3. X-ray chest
4. Audiometry
5. Respiratory questionnaire
2.
Tuners, fitters
and
machinists
1.
2.
3.
4.
3.
Crane
operators,
Drivers
Nondestructive
testing
4.
Visual acuity
Lung function tests
X-ray chest
Autiometry
Visual acuity, Depth perception

Audiometry
Special emphasis on CVS, CNS
Detailed haemogram is a must

MANUAL
7
8
10
HSEOM-OCP-25
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Page 6 of 12
5.
Manual jobs
Fitness assessment tests such as VO2 max
6.
Canteen
workers
Emphasis on Communicate diseases, personal

hygiene, VDRL TEST.
Routine parameters are done in addition to the specifies.

PRE-EMPLOYMENT MEDICAL EXAMINATION
The pre-employment medical examinations just as important as the
examination of the occupational qualifications of a worker who applies for
a job.
At the end of pre-employment medical examination, the occupational
physician must be in a position to determine
Whether the worker is suffering from any disease that is dangerous

for his fellow workers.
Whether the job for which the worker is applying or which is being
offered to him entails any risk to his health.
Whether there are any particular jobs to which he should not be

assigned or posts for which he is better suited.
Pre-Employment Medical Examination General lay out

Main objective is to study the workers physical, sensorial, physiological
and psycho affective characteristics
11
Physical Characteristics:
The essential physical characteristics that can be measured are height,
weight, chest measurements, the dynomometric performances of the
most frequently used muscle groups (lumber, scapula dorsal,
manual) etc.
12
Sensorial characteristics:
These are very significant factors to be considered generally on preemployment medical examination.
Visual acuity should be studied both near and distant, together with the
field of vision, oculomotor function, colour vision and the possible need to
correct vision defects, since jobs demand excellent visual acuity.

MANUAL
HSEOM-OCP-25
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DATE: 15.12.2008
Page 7 of 12
Normal colour vision is important for jobs such as electrical fitting, the
reading of coloured details etc. For motor vehicle operation. Combination
of these requirements is important.
Hearing should also be examined. Good hearing is essential in some types
of work such as contact with Customers, vehicle driving etc
Base line audiometry is essential for all those who are going to be exposed
to noise in work areas which would enable future comparisons.
13
Function testing;
The correct functioning of the various systems of the body should also be
checked. By a simple inspection, requiring hardly any equipment,
information can be gathered on the state of:
The locomotor apparatus, by seeing anomalies of the spine (Kyphosis,
scoliosis), the thorax (rickets), the lower limbs (Unequal length of limbs,
deformities), waling, bending and stretching, rotation of the head:
The abdominal wall (hernia)
The skin, by checking whether there are any acute or chronic lesions of
occupational or other origin.
The upper respiratory tract and the oral cavity
14
Major system examinations:

The urinary tract is examined by urine analysis. Tests for sugar, albumin
and blood should be done.
The cardio-vascular system is examined by checking blood pressure and
heart by auscultation and if necessary ECG can be done.
15
The respiratory system should be examined, without forgetting that cardiovascular and respiratory systems together form a single functional unit.
The pre-employment schedule is only a guideline. There cannot be fixed
standards of medical examination which would determine the fitness or
otherwise of the individual.

MANUAL
HSEOM-OCP-25
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DATE: 15.12.2008
Page 8 of 12
16
Actual requirements must be well rationalized and requirements must be

derived. This may vary from industry to industry. Major organ disorders
must be looked for and communicable diseases must be investigated.
17
Since disease like epilepsy cannot be found out during thee examination,
the candidates disclosure about his prevailing health status assumes
greater significance.
PERIODIC MEDICAL EXAMINATION IN CONSTRUCTION
SITES
Periodic medical examination in industry help the occupational physician in
many ways:
18
As a screening examination, it identifies conditions which, if treated, can

improve the quality and / or length of life of the worker.
It assesses the workers ability to continue in their jobs without endangering
themselves or others.
It is a means of identifying workers who may be suffering from a
compassable disease.
It provides an opportunity for health education
19
Periodic medical examinations have been a traditional function of

occupational health practice and is deeply entrenched among the services
customarily provided. Periodic medical examinations of specific hazardexposed population have become common place and often mandatory
under the factories act and factories rules.

MANUAL
20
HSEOM-OCP-25
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Page 9 of 12
Major occupations, the parameters to be applied during periodicity of

medical examinations are furnished in Table 4.
Table - 4
MAJOR OCCUPATIONAL GROUPS, MINIMUM ANS SPECIFIC
SCREENING PARAMETERS AND PERIODICITY.
(Periodic health screening of vulnerable groups)
S.No Occupational groups
1
Specific
screening
parameters
Welding and gas cutting: Routine health screening
3
Mild steel / Carbon Respiratory questionnaire
Years
steel, and gas metal arc
welding widely used. Lung function test using
Contents of fumes will
spirometry
vary depending upon Plethysmography
composition of electrode
including CO single
and the base metal.
breath
test-gas
transfer factor.

MANUAL
Submerged are welding

(usage of low
hydrogen covered
electrode and selfshielded flux cored
electrodes.
Welding of stainless
steel and high alloy
steels.
Routine health screening.

Respiratory questionnaire
Lung function tests using
spirometry.
Plethysmography
3
including CO single Years
breath test-gas transfer
factor.
Urinary fluorides.
Routine health screening.
Respiratory questionnaire
Lung function tests using
spirometry.
Plethysmography
including CO single
breath test-gas transfer 3
factor.
Years
Blood
and
urinary
chromium, Ni and Mn
HSEOM-OCP-25
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Page 10 of 12
Remarks:
1.
High quantum of metal fumes in plasma are welding.
2.
Medium to high Quantum of metal fumes in shielded metal are

welding, low hydrogen electrode welding, gas metaln are
welding.
3.
Fluorides are high in welding using low hydrogen covered

electrodes and sub-merged are welding.
If noise is above 90 dBA in 8 hours, one a year AUDIOMETRY IS A

MUST.
Table 4 (Contn.)
MAJOR OCCUPATIONAL GOUPS, MINIMUM ANS SPECIFIC
SCREENING PARAMETERS AND PERIODICITY.

MANUAL
Page 11 of 12
(Periodic health screening of vulnerable groups)

S.No Occupational
Specific
screening
groups
parameters
2.
Turners, fitters and 1. Routine health
machinists
screening
2. Lung function test
using spirometry
3. X-ray chest
4. Audiometry*
5. Emphasis on skin
examination for
machinists.
3
Crane Operators, Routine health screening
Drivers
Detailed visual examination
including field of vision
and depth perception.
Audiometry*
CVS
and
CNS
examination.
4
Non
destructive Routine health screening
testing
Detailed haemogram (Hb,
RBC count, peripheral
smear, platelet count,
clotting time etc.
5
Canteen workers
HSEOM-OCP-25
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Periodicity
3 5 Years
2 3 Years
Every year
1. Routine
health
Screening
6 months
2. Emphasis
on 1 year
communicable disease.
3. Stools for ova and cyst
4. VDRL test (optional)
If noise is above 90 dBA in 8 hours, annual AUDIOMETRY IS A MUST.
NOTE: The screening parameters and periodicity suggested are based on

the center at BHEL TRICHY experience over the last eighteen years.
General Parameters employed in periodic Medical examinations:
Specific tests and examinations are detailed in Table 4 help the physician
to assess the impact of specific hazard on the human system. At the same
time, it is essential to overall health status of these employees undergoing
periodic medical examination. Table-4 mentions routine health screening
and this routine health screening includes:

MANUAL
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DATE: 15.12.2008
Page 12 of 12
Basic laboratory test such as haemoglobin, blood sugar (fasting) lipid

profile, urine analysis etc.,
Investigations like X-ray chest vitalograph, vision testing using
orthoraqter, ECG/ Testing (12 lead) etc., (if they do not come under
specific tests).
9
WELL PERSON SCREENING IN CONSTRUCTION SITES

Employees exposed to potential hazards are covered under periodic Health
screening Engineering industries another group of employees who are
engaged in sedentary type and bulk of them are in assorted type of
occupations where in no special hazards problem exists.
Executives, Supervisors, ministerial staff, auxiliary workers and other
unskilled and semi-skilled workers constitute this group.
Due to altered life-styles, stress and other known and unknown factors,
major diseases like hypertension, diabetes mellitus, hyperlipidemia, heart
diseases and obesity and widely prevalent in industries.
These diseases invariably produce complications resulting in disabilities
causing decreased productivity. Early detection and adequate control of
these diseases is very important.
Compliance in treatment for hypertension and diabetes has been proved to
be very successful for the primary and secondary prevention of heart
attacks in industry. This is better achieved by well person screening by
early identification of new cases and effective follow-up through
hypertension, diabetes mellitus screening programmes.
This protocol includes the routine health screening parameters such as 1
and 2 in the previous page. The periodicity of well person screening will
depend upon the average age of the working population and the magnitude
of the existing problem.
Upto 40 years of age :
Once in 3 years
Upto 50 years of age :
Once in 2 years
Above 50 years of age:
Once every year.
Special tests such as blood urea, creatinine, albumins in urine can be done
for the hypertensive and diabetic groups.
Stress ECG need not be a part of routine health screening and high risk

MANUAL
10
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Page 13 of 12
groups can be referred to the specialists for this facility.

MEDICAL EXAMINATION UPON RETURN TO WORK AFTER AN
ACCIDENT OR ILLNESS.
This is more or like pre employment medical examination excepting for the
fact that the individual is in employment. Here the problem is not
merelyphysiological or pathological, it is more of psychological.
We cannot lay down very strict standards for fitment of the affected
individual. To place an individual after an injury or disease, it is essential
to have a correct prognosis.
Disability evaluation, assessment of aptitude and adaptability, facilities for
modifications of work site, flexibililty of personal rules and the trade union
in evolvement are key factors in the successful outcome of this programme.
Since the affected individuals are returning from specialized health care
services, there may not be any need for fresh tests during this medical
examination.
Accurate description of the illness or injury or disability and the practical
job requirements (physical, physiological and psychological demands)
would greatly help the occupational physician during this medical
examination. Based on the above the occupational physician will
specifically indicate the area, where the employee can be posted upon
return to work after an incident
7. Records
Record Title
Record
Responsibility
Retention Time
No
Audit reports
Shall be
Shall be assigned by Site Incharge
3 years
given by
Site
Incharge

MANUAL
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DATE: 15.12.2008
Page 1 of 2
1. Purpose
To define a procedure for conducting work environment monitoring /

occupational hygiene monitoring
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Availability of monitoring devices / records of monitoring

5. Cross Reference

6. Procedure
S No. Activity
Responsibility
1
Monitoring of work environment in engineering / construction
industries is of paramount importance. The prevailing hazards must
be recognized, evaluated and controlled. Dusts, fumes, gases and
vapours, heat, noise, vibration and radiation are all too common in
engineering industries.
An industrial hygiene specialist takes care of the work environment by
carrying out walk through surveys and in-depth survey. Static
sampling and personal sampling are the commonest methods of
evaluating the work environment.
Periodic review of these monitoring programmes helps to revalidate
the work environment findings and this helps the physician to plan his
health promotion programmes.
2
Evaluation of Air contaminants:

Personal samplers
Dragger multigas detector
Dragger polymeter
Casella long period air sampler
Gravimetric dust sampler
Real time aerosol monitor
Phase contrast microscope
Evaluation of heat stress:

WBGT INDEX METER (Mini lab)
HSEOM-OCP-26
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MANUAL
Page 2 of 2
Evaluation of Noise
Precision Integrating sound level meter
Personal noise dose meters.
Evaluation of Illumination and radiaton:

a) Lux meter
b) U V digital meter
c) Gamma radiation survey meter
Evaluation of Vibration
Whole body vibration meter.
Threshold limit values (TLV) such as time weighted dosage

concentrations of all pollutants in the industry should be made
available. If dangerous pollutants are present their STLV (Short term
TLV) and ceiling limit values must be ascertained
The Occupational physician should be fully aware of the presence of

these pollutants and its effects.
7. Records
Record Title
Records
of
environment
monitoring
Record No
work Shall be given by Site
Incharge
Responsibility
Site Incharge
Retention Time
3 years


MANUAL
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Page 1 of 5
1. Purpose
To define the procedure for work capacity and strength testing
2. Scope
3. Responsibility
detailed below.
4. Performance Criteria Examination records

5. Cross Reference
6. Procedure
S No. Activity
1
Rationale
Fitting the job to the Man requires knowledge of two things the
capacity of the individual and the demand of the job. While job
demands may be known beforehand, it is necessary to measure the
individuals work capacity before an optimum job-person fit can be
achieved.
Jobs and individuals are therefore to be described in common units on
common scales. Description of the job in terms of production or
output dimensions and of the individual in terms of personal
characteristics (height, age, sex) is not adequate for such a scientific
approach.
Above all, the method of screening should be objective, rational, and
unbiased
2
Work capacity
Evaluation of physical work capacity is based on estimation of the
Maximum Oxygen Uptake capacity (referred to as VO2 (max). In an
occupational health environment, this estimation is best done by a
submaximal test, using the individuals physiological response (Heart
Rate and Oxygen Consumption) to graded dynamic work.
This is supported by the following percepts of industrial and work
physiology:
At submaximal levels of work, heart rate, oxygen consumption
and ventilation rate are linearly related to each other,
regardless of the nature or type of the job performed.
Responsibility

MANUAL
The presence or absence of thermal stress has no effects on the

oxygen consumption associated with the job. However, heart
rate is linearly related to the increase to the increase in thermal
stress.
Maximum heart rate attained by an individual is independent of
the state of health or degree of fitness, and depends only on
age.
Physiological responses of unfit or unhealthy individuals are different
from those of normal individuals when performing similar graded
dynamic work.
3
Equipment
A motorized treadmill or bicycle ergometer is ideal for providing
graded dynamic work, but stepping up and down with a specific
frequency on a step of standard dimensions is also suitable.
Heart rate is best counted electronically from an ECG monitor.
Availability of an on-line ECG display helps to avoid artifacts in
heart rate counting, and is an additional safety feature. Otherwise,
heart rate is to be determined by auscultation or palpation of the
carotid pulse, and measurement of the time taken for 10 beats.
Oxygen consumption is measured by recording the ventilation rate
and the oxygen content of the inspired and expired air,
Lightweight portable devices (e.g. OXYLOG) are also available
which facilitate field (shop-floor) measurements. A low accuracy
alternative is to use available data on oxygen consumption levels
for different stages in the exercise protocol
Method
The predicted Maximum Heart Rate (pred.HR max) of the
individual is calculated from the age.
Heart rate and oxygen consumption are measured in steady-state
conditions while the individual performs work at three
submaximal levels, or till 85% of the Pred.Hrmax is reached.
This ensures safety of the test procedure.
HSEOM-OCP-27
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Page 2 of 5

MANUAL
The measured heart rate oxygen consumption points are piotted

on a graph paper (or a computerized plotting software is utilized),
and he best-fit line so obtained is extrapolated to the level of the
pred.Hrmax. The oxygen consumption corresponding to the point
of intersection is the VO2 (max).
The job Demand level of the oxygen consumption is usually
estimated by measuring the heart rate during work and
interpolation in the heart rate oxygen consumption line derived
above, or by direct measurement of the oxygen consumption
during work.
5
Standards
The VO2 (max) of Indian industrial workers is around 2.0 liters/min.
For fitting the job to the person, a job Demand: Maximum work
Capacity ratio of 50% is adopted. In the individuals VO2 (max)
should be atleast double the demand level of the intended job.
Strength Testing
This approach is based on the direct relationship between
probability of injury and percentage of strength capacity utilized
by the individual in the performance of the job. For example, if a
job requires a lifting a weight of 50 Kg, an individual with a lifting
capacity of 50 Kg would be more prone to injury than one with a
lifting capacity of 100 Kg (100% utilization Vs 50% utilization)
The strength of individuals is measured and the individual strength
capacity is matched with the job requirements for the purpose of
employment or placement decisions. This approach has the
advantage of flexibility, with results being easily generalisable
across a number of job positions.
Equipment
Maximum Voluntary Contraction (MVC) levels are determined using
a load cell and digital strength meter. These can also be estimated (or
expressed in arbitrary units) using calibrated spring loaded exercise
equipment (e.g. BULL WORKER
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MANUAL
Method
Strength capacity of the back, legs and arms are evaluated by
measuring the MVC levels in different standard postures.
The strength Demand level of the job is best determined by
recording of working postures (angles and distances) and
calculation (manual or computerized) using biomechanical models
(such as Chaffin, 1969, 1970 and tichauer, 1973).
Standards
Similar to working capacity, a job Demand: Strength Capacity
ratio of 50% is adopted. In other words, the individuals MVC
should be atleast double the demand level of the intended job.
10
Overview
Persons failing within 10% of the cut off levels can be
considered marginal. They can be given the benefit of
possible measurement error, and should be retested.
The advantage of this approach is that one test is all that is
necessary to evaluate an individual for a number of job
positions. Based on the test results of individual work capacity
and strength capacity, and date on job demands, person-job
matching can be performed for a wide variety of jobs.
It must, however, be pointed out that the test of an individual
reflects the working and strength capacity at the time of
screening. No claims can be made about at that point about
acceptability after 1,2 or 10 year later. Changes are always
possible, not only in the individual, but also in the job and
work-place.
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MANUAL
HSEOM-OCP-27
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Page 5 of 5
The approach outlined above meets the required criteria of

being objective, rational and unbiased. It also ensures that
neither the test the job performance will tax the individuals
physiological system beyond safe limits.
7. Records
Record Title
Examination records
Record No
Responsibility
Retention Time
3 years
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ID No.

DOC . No. : HSE/SR/05

OPERATION CONTROL PROCEDURE

BHARAT HEAVY ELECTRICALS LIMITED

OPERATION CONTROL PROCEDURE

Issue Date: 15-12-2008

Reviewed & Approved by

BHARAT HEAVY ELECTRICALS LIMITED

OPERATION CONTROL PROCEDURE

BHARAT HEAVY ELECTRICALS LIMITED

To define General Safety measures to be followed to improve the

OCCUPATIONAL HEALTH SAFETY AND

To define the general safety measures to be followed to improve the

All activities and services of BHEL, PS SR

4. Performance Criteria Adherence to the safety measures

Factory Act, 1948 / State Factory Rules

Openings in the floors must be covered.

Install handrails on platforms and stairs as soon as these are erected.

Temporary handrails should be provided on temporary platforms.

Check that there are no hindrances on walkways and sufficient

Warning signs should be displayed at unsafe places.

Never block accesses and exits routes to work places.

Due importance should be given to house keeping.

Arrangement of emergency lighting is also called for to ensure safety

OCCUPATIONAL HEALTH SAFETY AND

Operational control procedures

Ensure adequate communication facilities between all work places and

Train adequate number of employees at work site in First Aid and

Make it a habit that supervisors explain to the workers all hazard

Display appropriate posters in locally understood languages regarding

Conduct tool box meetings either daily or weekly once and

8. Verification, Corrective and preventive action

OCCUPATIONAL HEALTH SAFETY AND

All activities and services of BHEL, PS SR

Factory Act, 1948 / State Factory Rules

Safety helmets shall conform to IS: 2925

Safety helmet should be compatible with working requirements e.g.

Check the helmet regularly for any signs of damage of deterioration.

Dont wear the helmet sloping up or down as it may significantly

OCCUPATIONAL HEALTH SAFETY AND

Operational control procedures

Never store the helmet in direct sunlight or excessive heat. Long-term

For colour code of Safety Helmet

8. Verification, Corrective and preventive action

OCCUPATIONAL HEALTH SAFETY AND

To define the procedure for safe handling, storage and disposal of

OCCUPATIONAL HEALTH SAFETY AND

the transportation as far as possible.

OCCUPATIONAL HEALTH SAFETY AND

To reduce the chances of accidents / incidents through adherence to

All activities and services of BHEL, PS SR

4. Performance Criteria Adherence to electrical safety procedure

Indian electricity Act, 1953 / 2003

Install Earth trip device at main distribution board.

Earth all power cables.

Ensure earthing of all electrical construction equipment at two

Certified electricians shall carry out all electrical connections and

Never use earth as neutral.

OCCUPATIONAL HEALTH SAFETY AND

Operational control procedures

All cable terminations should be properly tightened.

Cover all power cables running on surface to prevent damage due to

Install proper distribution boards at different location to avoid