Safety, Health & Environment At a glance

Safety, Health & Environment At a glance LARSEN & TOUBRO LIMITED HEAVY ENGINEERING DIVISION SAFETY DEPARTMENT

SUBJECT PAGE No. Personal Protective Equipment 2 Welding and Gas Cutting 4 Grinding 7 Gas Cylinders 9 Working At Height 11 Scaffolding 12 Ladders 14 Working In Confined Space 16 Material Handling By Cranes, Lifting Tackles, 17 and Chain Pulley Blocks Electrical Safety 22 Hydro testing 23 Radiation Hazards 24 Fire Protection 25 First Aid 29 Waste-Management 30 Stress-Relieving 31 Emergency Contact Numbers 32 TABLE OF CONTENT SAFETY

PPE (Personal Protective Equipment) Safety helmet of approved type must be worn at all times by all personnel at work. When working above 2 meters from ground level, where adequate scaffolding can’t be provided must wear a Safety Belt. Safety Goggle should be used while doing gas cutting, chipping. Face Shield should be used while doing grinding, welding, SAFETY

PPE (Personal Protective Equipment) Safety shoe must be worn at all times by all personnel at work. Welding screen should be used while doing arc welding. Working in areas subject to excessive noise must wear ear muffs or Ear Plugs. Face Shield should be used while doing grinding, welding, SAFETY

Do’s To move the cylinders use trolleys or cradles Keep the LPG and other liquefiable gas cylinders in upright position, ensure that they are not knocked over Keep the valves tightly shut when the cylinders are not in use Use gas hoses with standard colour code Use clamps for hose connections, check leakage from hose connection before starting work Ensure that there are no kinks in the hoses and the hoses are laid out in a manner that nobody steps on the hoses Use flame arrestor to avoid back firing First open the oxygen gas and then the flammable gas Use only friction gas lighters for lighting the torch Protect the gas cylinders and hoses from welding sparks or gas cutting sparks falling on them Welding and Gas Cutting SAFETY

Ensure the easy accessibility of the valve key Check the hose daily for any visible damage. Discard the hose in which gas has backfired Remove the leaking gas cylinder to an open space immediately. Intimate the supplier of the cylinder immediately For arc welding machines ensure proper earthing of the switchboard from where the power is tapped Earth the welding machine with at least two independent earthing connection Check for any loose connection before starting the work The welder should be equipped with suitable PPE which should include gloves and welder glass Workmen working near the welding operation should wear coloured goggles Welding and Gas Cutting SAFETY

Ensure that the hand gloves are not wet Welder and associated workmen working at a height of more than 2 m should wear safety belts Take care that the welding sparks do not endanger people below, while working at heights Switch off the welding machine even while taking a short break Don’ts Do not release gas from the cylinder unless pressure regulator is fitted to its valve Do not crimp the hose for temporary shutting of the gas Do not make more than one joint on the entire length of the welding lead Do not throw the welding electrode stud. They should be collected and disposed off properly after the work is over Welding and Gas Cutting SAFETY

Do’s Do check all wheels for cracks or other damage before mounting. Do check machine speeds against approved operating speed of the wheel. Use blotters provided with wheels. Do make sure that wheel hole, fits machine arbor properly and that flanges are clean flat and of proper type for the wheel you are using. Do always run wheel in protected area for at least one minute before grinding. Do use the wheel guard furnished with the machine Do always wear protective safety glasses or face shield. Grinding SAFETY

Don’ts Don’t use wheels which have been dropped or otherwise damaged. Don’t use a grinding wheel that has a rated speed less than the speed of the grinder. Don't use excessive pressure when mounting wheel between flanges. Tighten nut only enough to hold wheel firmly. Don’t use heavy side grinding pressure on any straight wheel. Don’t handle machine carelessly. Don’t use relieved or recessed flanges with threaded hole wheels, cones or plugs. Don’t mount more than one wheel on a single arbor. Grinding SAFETY

Dos 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 the date is over, do not accept the cylinder Always keep LPG and other liquefiable gas cylinder in an upright position and see that they cannot be knocked over Secure the cylinders used in horizontal position so that they cannot roll Store the cylinders in a cool, dry and well ventilated place under cover and away from open flames or any other potential source of heat Storage area for gas cylinders should be easily accessible Keep the cylinders containing flammable gases separated from other gas cylinders by an adequate distance Keep the empty cylinders segregated from the filled cylinders Caps used for valve protection must not be removed except when the cylinder is in use. A cylinders cap should be screwed all the way down on the cylinder neck and should fit securely Gas Cylinder Safety SAFETY

Dos If a cylinder containing flammable gas is leaking isolate the cylinder and switch off all the source of ignition nearby only if they are easily accessible otherwise leave the area immediately. Mark the area by warning signs. Notify the supplier immediately in case of a leak Use trolleys and cradles for transportation of cylinders Handle the cylinders carefully Secure the protective valve caps when the cylinder is to be transported Don’ts Do not slide or drop the cylinders Do not store the cylinders in direct sunlight Do not, in any condition, repair the cylinder yourself Do not lift the cylinder by its cap Do not use a lifting magnet for loading or unloading any cylinder Gas Cylinder Safety SAFETY

Take necessary safety instructions from your supervisor before you start work. See that the crane cannot move within a distance of at least 20feet from the place of your work when you want to work on or near ti the crane rails. Use Safety belt and anchor it properly before starting the work. Keep the safety belt in continuous use throughout the period of work. Keep the tools at proper height so that they will not fall down and cause injury to anyone working / passing below. Do not throw tools/materials from a height. Lower them with a rope in a proper and safe manner. After finish your work, see that no tool/material is left at height, before you leave your workplace. Working At Heights SAFETY

Do’s Scaffold should be provided for all work that cannot be safely performed from floor level Ensure that the scaffold material is of adequate strength Check scaffold components for damage and defects before use Avoid using combustible materials for scaffold For platforms , use planks of grade I quality at least 2” thick and 10” wide; free from all defects such as loose knots and splits Erect scaffold 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 Secure the platform firmly with the scaffold Minimum width of platforms 2 m above floor level should be 900 mm Scaffolding SAFETY

Provide guardrails 1.5m high, consisting of top rail and mid rail; for platforms higher than 2m above floor level Provide toe guards at the platform edges to eliminate hazard of tools or other objects falling from the platform Inspect the erected scaffold regularly, if the scaffolds are to be used for a long period of time Keep the platforms free from any unnecessary obstruction, material, rubbish and oil spillage Use safety belt properly anchored to a permanent structure while working on a platform higher than 2m from floor level Don’ts Do not allow persons to work from scaffold during storm or high winds 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 Do not overload the scaffolding Do not climb along the scaffolding if the scaffolding is more than 2 m. use a ladder. Scaffolding SAFETY

Do’s Use portable ladders for flights upto 4 m only Provide fixed ladders for flights above 4 m Place the ladder at an angle of 75o from the horizontal Extend ladder at least 1 m above the top landing Secure top and bottom of the ladder firmly to prevent displacement Ensure that the width of the ladder is not less than 300 mm and distance between the rungs is not more than 300 mm 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 Ensure that the areas around base and top of the ladders 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 Always face the ladder while climbing up or down Ladder Safety SAFETY

Do’s 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 Lift the tools, equipment and material with a rope Don’ts Do not use ladders of conducting materials near power lines Do not stand higher than the fourth rung from the top for carrying out any job standing on a ladder Do not climb up or down while carrying anything in hand Do not drop the ladder but it should be carried by two persons Ladder Safety SAFETY

Before entry by any person into a Confined space ensure that: No toxic/hazardous gas / fume / chemical inside the vessel / pit / sump. Proper ventilation should be provided. Oxygen percentage should be checked by oxygen meter. All personal protective equipment / standby are available e.g. Self Contained Breathing Apparatus Set etc. Person/s entering a confined space shall be provided with safety belt / life line. A trained person shall be kept standby at the entrance to the confined space to take care of any emergency. While working inside vessel / pit / sump 24v lamp should be used. Mobile / walkie talkie should be provided for communication purpose. Working In Confined Space SAFETY

Cranes Do’s Mark the equipment with the maximum working load in Kgs / tonnes. In case of mobile cranes safe load at various angles should also be indicated Crane should not be overloaded - crane operator should be the final authority on these matters Load should be raised and lowered smoothly, without any jerks no person, other than crane operator, should approach near the operating area irrespective of his work Cranes should never be used for lifting or lowering persons Only a qualified person should communicate to the crane operator by means of hand signals to undertake the lifting or lowering of load Before leaving an unloaded crane the hooks and slings should be raised to a height which will clear all fixed and moving object Driver of the crane should check all controls before commencing work Ensure all guards are in position Material Handling By using Cranes, Lifting Tackles and Chain Pulley Blocks SAFETY

Cranes Do’s All electrical and mechanical safety devices (limit switches) should be checked for proper functioning before commencing operation All controls should be in off position before switching the main switch off Shut off the engine when cleaning, adjusting or lubricating the machine Keep the crane boom length as short as possible for maximum lifting capacity and greater safety Always keep the boom at least 6 ft from overhead wires Don’ts Cranes should never be loaded beyond the certified safe limit of the crane Material hoist should never lift or lower persons Crane operator shall never take off his hands or feet from the controls while the crane or hoist is in operation Hoisting cable should not be slung around a load and used as a sling Nobody should work on the wheel track of an overhead crane while the crane is in operation No working should be done with the boom too close to the vertical Load should not be swung over ground crew Do not move the crane with boom at very high angle, especially on uneven terrain Do not leave the cabin with engine running or load in the air Never get on or off a machine in motion Material Handling By using Cranes, Lifting Tackles and Chain Pulley Blocks SAFETY

Chain Pulley Blocks Do’s Ensure proper maintenance and keep a record of the same Inspect daily, before start of work, and record in daily Inspection register Guard all the rotating parts of the machinery Maintain all the test certificates of all the lifting machinery Mark the safe working load on the lifting machinery Before lifting the load, ensure proper anchoring of the winch and the pulley Warn the persons in the vicinity before lifting the load Use of PPE must be mandatory Ensure proper illumination of the work area Only one person should give signals to the operator of the lifting machinery Material Handling By using Cranes, Lifting Tackles and Chain Pulley Blocks SAFETY

Chain Pulley Blocks Don’ts Do not attach lifting device to the floor grill, working platform or guard rail Do not allow anybody to stand under the load being lifted Never allow any person to ride on the load being lifted Never carry out welding in the boiler structure during drum lifting operation Ropes and Chains Do’s Tag chains with maximum working load and the date of last testing The factor of safety in case of chains should not be less than six Provide suitable thimbles for eye splices and hooks Visually inspect the wire ropes for any defects like kinks, snapped wires, rusting etc. before using them Material Handling By using Cranes, Lifting Tackles and Chain Pulley Blocks SAFETY

Ropes and Chains Do’s Regularly examine the fastening of the wire rope Apply fresh lubricant to the chain as and when required Store them away from corrosive atmosphere and moisture When using fiber ropes prefer the use of manila ropes For permanent rope connection employ splices and not knots When cutting a manila rope sizing the yarn should be applied on the side of intended cut Inspect the ropes before and after use Don’ts Do not drag manila or fiber ropes on ground or any rough surface. Employ a trolley or coil and lift by two persons Do not expose the fiber or manila ropes to corrosive atmosphere Do not use wet manila ropes. First dry them. Never leave the ropes outdoors Material Handling By using Cranes, Lifting Tackles and Chain Pulley Blocks SAFETY

All electric parts should confirm to IS specifications Installation of Earth trip device at main distribution board Earth all power equipment Ensure two independent earthing connection to all electrical construction equipment Ensure that all extension boards have proper earthing connection of suitable rating and only three pin metal clad industrial type sockets are mounted on the board Do not draw power by insertion of wires in the socket For electric hand tools metal clad three pin plug tops are used Never use earth as neutral Use of only three core flexible wire of proper rating for electrical hand tools Ensure that flexible wires and power cables are properly insulated and are laid in the marked corridor so that the same are not damaged due to construction activities and movement of machinery in the vicinity All cable terminations are properly tightened Junction box or plug and socket couplings only are used for joining cables Ensure installation of distribution boards in a covered place to avoid dust and rain water entry. Always put Warning signs at the location Electrical Safety SAFETY

Pressure testing is a hazardous operation, stresses are high in the item being tested. Persons in-charge of pressure testing should have a sound knowledge of pressurized system and be fully conversant with test procedures. The pressure should be lowered to zero before any leak repair is carried out. Use only calibrated test gauges mounted in the upright position. Pump discharge gauges must be visible to the pump operator for the duration of test. Hydro testing SAFETY

Only competent persons shall be employed for the use of radioactive source for inspection and testing. Dosimeter shall be used by such persons and radiation dose/ exposure shall be counted. Proper warning signs in the area of radio-active testing and shall take full care of employees by reducing / minimising the Time of exposure, by maintaining safe Distance, by providing proper concrete shielding. Radiation Hazard SAFETY

Do’s Ensure safe access to and means of escape from all site locations Construct temporary buildings like site offices and material stores without combustible materials as far as possible. Keep adequate safe distance between temporary buildings. Recommended safe distance of temporary sheds from main building is 15 m and 9 m from each other Provide free space between each section of the stored materials to allow access for fire fighting Store inflammable materials separately Remove combustible packing materials from the site periodically to avoid accumulation of fire load Clean site frequently at least once a week Display ‘no smoking’ posters in area where flammable materials are stored All electric parts should confirm to IS specifications Fire Protection SAFETY

Do’s Inspect the work place thoroughly where welding and gas cutting operations are to be carried out and remove any inflammable material around before starting work Ensure that welding and gas cutting sparks do not fall on combustible materials. In case it cannot be avoided cover the material with metal sheet In case, welding and gas cutting has to be done on a vessel, pipe or container which contains or earlier contained flammable liquids; ensure purging / inserting and issue work permit before starting work Ensure that there is no leakage of gases from hose connection fitted with the gas cylinders before starting gas cutting In case of electric welding, check that there are no loose connections in welding cables and earth connection Inspect the area for smoldering material after gas cutting / welding, if found extinguish them Fire Protection SAFETY

Do’s Remove gas cylinders to stores when not in use Ensure that the fire extinguishers are clearly visible and easily accessible Keep the fire extinguishers as near as possible to escape routes Conduct fire fighting drill at least once a month Don’ts Avoid using combustible material for formwork and scaffolding Do not light any fire in or around the storage areas for cooking or any other purpose Do not leave electric circuits on or gas cutting torches burning when not in use Fire Protection SAFETY

Fire Protection SAFETY

First Aid Boxes should be kept at site location. Make sure, items used are promptly replaced. The First Aider must always be calm and careful and quick. In case of serious injury or sudden illness, while help is being summoned, give immediate attention to the first aid priorities. Ensure that the victim has a clear airway and give mouth-to-mouth or artificial respiration, as necessary. Control Bleeding. Establishing casualties’ level of consciousness. Those talking, screaming or shouting are not immediately in so much risk of losing life as the unconscious person. Get urgent medical help as soon as you can. First Aid SAFETY

Provide suitable containers with lids where required. Paint mark/identify the containers for using them. Do not throw away / discard any items i.e. beverage cans, mineral water bottles, food items, rags, etc. at places other than that approved by the site. Do not empty acid/alkalis at places other than that approved by the site. Ensure that domestic and non hazardous waste is disposed off regularly. Ensure that scrap metals are disposed off regularly. Ensure that all hazardous / chemical wastes are disposed off in accordance with relevant site’s procedures. Waste Management SAFETY

Cordon off the area where the job is undergoing for stress relieving. Check the gas rubber hoses for leakage. Use calibrated pressure gauges used for gas pipeline. All combustible material should be removed from the area. Proper housekeeping should be maintained. In case of electrical heating proper earthing should be done. Board indicating hot job should be displayed. Adequate Personal Protective Equipment's such as handgloves,safety goggles should be provided. Electrical cables should be laid in proper manner. Stress Relieving SAFETY

Safety, Health & Environment At a glance