em -29 gen. safety(rev)

ORISSA POWER GENERATION CORPORATION LTD.IB THERMAL POWER STATION, BANHARPALI

STANDARD OPERATING PROCEDUREEHS GUIDELINE ON GENERAL SAFETY

Document No: EM 4 / 29(Revised)

Filed At: All Departments

Purpose:

This SOP is a document to provide best practices in Safety Management System.

The purpose of the Safety Management System is -

1. To establish and maintain procedures for identifying and reducing the occupational health and safety risks.

2. To achieve a vision of being the recognized leader, and one of the best among all the Power Plants in the country, by providing a remarkable Safety measure accomplishment.

Definitions:

Action Plans – Specific actions have to be undertaken to achieve the safety goals and objectives. Action plans must identify the detailed action(s) to be completed, person or department responsible for successful completion of the action, a target completion date and a means of measuring the outcome of the action.

Safety Coordinator – The person, who is designated by the safety committee, will be responsible in his department for the safety coordination.

Continual Improvement –To achieve an all time improvements in safety performance standard this is an ongoing process of enhancing the Safety Management System.

SOP – EHS Guideline on General Safety 1

Non-Conformance - Failure to comply with (elements of the Safety Management System, Safety Guidelines, results / findings of corporate or independent audits,) any identified safety issues, for corrective actions.

Occupation Health and Safety Hazard - Activities or services that can have an adverse effect or have the potential to cause injury or illness. Examples of health and safety hazards include, but are not limited to, harmful chemicals, electrical contact, falls from height, physical and/or biological agents or stressors in the workplace.

Risk - The combination of the probability and consequence of a specified hazardous event occurring. (Risk = Probability x Consequence)

Residual Risk – The risk level remaining after the implementation of risk controls

Significant Risk – Risks that, if uncontrolled, may result in employee illness or injury, property/equipment damage, or facility shut down.

Risk Significance Level – Level of risk as determined by the Risk Estimation Matrix

Safety Goals and Objectives - Something towards which effort is directed, to achieve a specific purpose or position, i.e. improve the quality of accident investigations, achieve 10% improvement on the safety audit. Goals must be program specific (ergonomics, accountability), measurable (improve 10%), attainable, as well as time based (by December 31, 2007).

Safety Management Plan - The component of the Safety Management System that defines the intentions in relation to its overall safety performance and provides a framework for action and setting safety goals and objectives.

Safety Records - Supporting documentation, data, documented programs or reports required to be demonstrated compliance with safety laws and regulations, or conformance with the Safety System Standards. Examples include but are not limited to training records, accident investigations, personal medical records, Material Safety Data Sheets (MSDS’s), Occupational Injury and Illness data, industrial hygiene survey data, etc

RESPONSIBILITY:Team Leader (All Department) is responsible for implementation of this SOP. The Management and Govt. Statutory authorities have designated Director (Operation), Safety Officer and Fire Officer as nodal officers for the policy implementation, internal audit and review etc.


Guiding Principles:

1. To achieve excellence in safety performance and to sustain it over a long term period is a matter of true perfection and commitment. It is the result of an effective implementation of safety management system, being supported by safety standards, policies, procedures, and being proactively managed the risks associated with work activities, rather than just reacting to accidents.

2. The Safety Management System must be implemented and managed as a continuous improvement cycle, and requires the leadership and active participation of every individual associate with the Plant.

3. A commitment that has to be complied with relevant safety legislation and regulations, and internal requirements.

4. A commitment to the continual improvement of occupational health and safety and reduction risk factor.

5. Provides a framework for setting and reviewing the annual safety goals and objectives.

Environment, Health and Safety Policy: This policy has to be developed and the Management will authorize the persons involved in it. Which will enhance the overall achievements in environment health and safety objectives, and a commitment for continual improvement in all these areas. Also the policy has to be well documented, implemented and maintained with regard to statutory and legal requirements. This will be reviewed periodically to ensure for total objective fulfillment by providing total awareness and involvement, to all the employees and associated persons in the Plant.

Health and Safety Hazard Identification, Risk Assessment and Risk Control: It has to be established and identify hazards, evaluate the occupational health and safety risks and implement effective control measures. The planning process should provide a framework for setting safety goals and objectives and implementing action plans. The planning process shall include:

a. Routine and non-routine activities, including maintenance.

b. Activities of all personnel having access to the workplace, including subcontractors and visitors;

c. Facilities at the workplace, whether being provided by the organization or others.


d. The OPGC Management / Director (Operation) /Plant Manager /TL (Environment) / Safety Officer /Fire Officer and the safety coordinators shall ensure that the results of risk assessments, and the effect of control measure being taken, are to be considered for developing safety goals and objectives.

Safety Goals, Objectives and Targets:

Annually a Safety review and coordination meeting has to be conducted, and this will establish, documented safety goals, objectives. Targets achieved, and action for future implementation plan will be the main objective. Some salient points are as bellow –

a. All quantifiable number of fatalities, lost time accidents, record able injuries, illnesses, and leading indicators, i.e. number of safety meetings, near miss reports, department/area of inspections, participation on safety committees, closure rates of action plans, risk reduction efforts etc. have to be meticulously reviewed and implemented.

b. Responsibilities for achieving the goals, objectives and targets, have to be assigned to the appropriate departments or individuals.

Management of Change: Management has to establish a management of change process to ensure that changes in activities, products, processes, tools, equipment, materials, services, operating conditions, and facilities are evaluated to determine the impact of the change on the safety program. Compliance with the Risk assessments, all related procedures, may have to be needed for modification / correction etc.

Responsibility and Resources:

The Management / Director (Operation) will provide the necessary resources, e.g., human resources, technology, financial, employee involvement, for the successful implementation and control of the Safety Management System. Responsibilities, authorities and accountability will be defined documented and communicated, in order to facilitate effective safety management program. Responsibilities and accountabilities toward achieving objectives and targets shall be integrated into the individual’s performance appraisal process. Achieving safety goals, objectives and targets will be integrated into the company’s overall business plan. Safety goals, objectives and targets shall be established for each relevant function and level of the Operation.


Awareness and Communication:

OPGC Management /Director (Operation) / Plant Manager /TL (Environment) / Safety Officer / Fire Officer and the Safety Coordinators will communicate regularly with staff and contractors to ensure that they are aware of safety policy. Some of the salient points are as bellow-

a. Safety Management System and all its elements, e.g., safety policy, safety programs, safety goals and objectives, safety standards, safety performance etc.

b. Individual’s role and responsibilities in achieving the Safety Management System.

c. The safety and health benefits and consequences associated with personal performance, i.e. performance appraisals, recognition, disciplinary action etc.

Consultation and Participation: Management and the authorized persons dealing with the policy will encourage for employees involvement and participations in day to day safety related issues and also for-

a. Involvement in the on going and future developmental activities and review of policies and procedures to reduce risks.

b. Consultation and sharing of information, when there is any change, which affects workplace health and safety.

c. Representation / Participation of all on environment, health and safety related matters.

Safety Management System Documentation:Director (Operation) / Plant Manager / TL (Environment) / Safety Officer / Fire Officer and Safety coordinators shall establish and maintain the Safety Management System in paper or in electronic format to describe the core elements, which is as follows -

a. The occupational health and safety policy statement.b. The system for health and safety hazard identification, risk assessment

and risk control.c. The system to identify and access all current applicable regulatory,

corporate, and business occupational health and safety requirements;d. The current safety goals, objectives and targets;e. Safety programs for achieving goals, objectives and targets;f. The structure and responsibility for development, implementation,


maintenance, and adherence to the Safety Management System;g. The processes for employee involvement, participation and consultation in

the Safety Management System;h. The processes for document control;i. The monitoring, measurement and corrective action process and activities

that can have a significant impact;j. Records required by the System; k. The annual review process of the Safety Management System, goals,

objectives and targets.

Document Control:

TL (Tech. Service) / TL (Environment) / Safety Officer / Fire Officer / Safety Coordinators shall establish and maintain procedures for creating, modifying and controlling all documents related to safety, fire and environment issues. Some of the salient points are as follows-

a. The required document can be located in a timely fashion;

b. The documents are to be periodically reviewed, revised as necessary and approved for adequacy by the competent authority.

c. The current versions of relevant documents are available at all locations where activities essential to the effective functioning of the System are performed;

d. Obsolete documents are to be removed from use.

e. Any obsolete document, which has been retained for legal or for knowledge preservation purposes, has to be suitably identified.

Operational Control:

TL (all departments) / TL (Environment) / Safety Officer / Safety Coordinators shall identify significant occupational health and inherent safety risks in work activities also existing facilities and equipments available to counter the same, and shall plan accordingly in order to ensure that risk control measures are being taken appropriately. Control measures should include the followings-

a. Establishing, maintaining and communicating documented safe working / operating procedures.

b. Establishing and maintaining procedures related to the identified occupational health and safety risks of goods, equipment and services purchased and/or used by the organization and communicating relevant procedures and requirements to suppliers and contractors.

c. Establishing and maintaining procedures along with concerned


Engineers for the design of workplace, process, tools, equipment, materials, installations, machinery and work organization etc.

Monitoring and Measurement: Director (Operation) /TL concerned / Safety Officer / Safety Coordinators will establish and maintain documented systems to monitor and measure, on a regular basis, identified processes and elements of the Safety Management System. This will include:

a. Regularly scheduled work observations of OPGC staff and contractors;

b. Regularly scheduled workplace inspections by Safety Walk.

c. Regular inspections and maintenance of critical tools, hoist and equipments.

d. Tracking progress, performance and conformance with the safety goals and objectives;

e. Reporting and analysis of accidents, illnesses and near misses, and conducting regularly scheduled safety audits and assessments.

Non-Conformance and Corrective and Preventive Action:Documented procedures will be established and implemented for identifying, reporting and investigating non-conformance as well as for, initiating, tracking and completing corrective and preventive actions. These procedures shall define the responsibility and authority for the bellow following points.

a. The report and investigation of accidents, near misses and non-conformances has to be generated.

b. Action has to be taken for mitigating any accident, near miss or non-conformance etc.

c. The administrative action for safety violations.

Safety Audits: An independent Corporate Audit has to be conducted in every three years, to assess the performance of the Safety Management System. Audit frequency may be increased based on audit results. The Corporate Audit shall determine -

a. The Safety Management System has been properly implemented and maintained;


b. Whether effectively meeting the organization's safety policy, safety goals, objectives and targets.

c. Non-conformance action plans are effectively being closed in a time frame.

Employee Training: Management shall provide awareness training, to ensure that the employee / contractors involved in implementation, of the Safety Management System have the adequate knowledge, skill as well as the dedication to fulfill their responsibilities.

General Safety Rules:

1. Before commencing any job take the time to look at the layout and condition of the work area to determine if you are able to do the job safely — if there is any doubt about safety, consult with your EIC / Head of the department before commencing.

2. All employees must observe all safety regulations and take adequate safety measures to ensure that there are no accidents at the work place.

3. Horseplay while on job shall be prohibited.4. Do not attempt to adjust or repair equipment while in motion.5. All rotating and dangerous parts of machines shall be guarded.6. Do not use the compressed air for cleaning of self and others personnel.7. No defective equipment of any kind shall be used.8. All lifting tackles and equipment shall be examined periodically by the

user and tested annually by a competent person. Do not misuse the lifting tackles by short cut methods.

9. Always report any accident/incident/near miss regardless of any injury/damage.

10.Wheel chocks shall be used for all stationary vehicles, trailers, carriers and automatic equipment to avoid their movement or tilting.

11.Any load to be carried by more than one person shall be lifted, carried and released from hold by unison of movement, under direction from the supervisor.

12.Get permits before starting any job, which requires Permit to work.13.Always keep it in your mind that adhering safety rules and regulations

can save you from dangers and ill health.14.Do not hesitate to ask the safe procedures (SOP/SMP) to carryout any

job, if you do not know.15.Always follow the Company’s EHS policy and procedures.16.Correct the unsafe situations at once, if not within your capability, report

the same to your supervisor/Safety officer/EIC.


17.Always use adequate & appropriate PPE for the task being executed.18.No child labor shall be employed and no children are permitted to enter

the plant premises.19.Unsafe condition or activities are reported through site safety walk and

forwarded to EIC/Head of the department for correction with a copy of the report to Safety officer and Safety officer shall follow up the report.

20.Report any accident or injury to your supervisor/EIC without delay and attend to getting the necessary first aid or medical treatment immediately.

21.All visitors entering the plant premises shall adhere to the safety rules and regulations and wear appropriate PPEs.

22.Health and safety manual is provided to contractor and all contract employees shall undergo EHS induction training prior to the entry to the plant premises.

23.All employees/visitors/contractors/transporters and others shall follow the emergency plan of the company

24.The speed limit of all vehicles is limited to 30 km / hr and all riders shall adhere to this speed limit. Over taking of vehicle is prohibited in plant premises.

25.Speed breakers shall be constructed as per BIS norm at strategic location.

26.Total plant area is declared as NON SMOKING ZONE. Person entering the plant premises shall deposit the matchbox & lighter if any at plant gate.

27. Intoxicated persons will not be allowed to enter the plant premises.

House Keeping:

1. Good housekeeping is an essential part of every job. Work areas, aisles, walkways and equipment shall be kept clear of loose materials, tools, refuse and scrap material.

2. Floors shall not slippery, wet, oily or worn out.3. No stumbling or protruding hazards.4. No loose material under foot or on gratings.5. No stairs, scaffolds and platforms without hand rails.6. No defective ladders or those not suited to the job are used.7. Keep the tools and equipment in a proper place.8. Proper lighting and ventilation is provided.9. Use container for oily/greasy rags and wastes.10.Protruding nails shall be either removed or bent over.11.Don’t keep your personal belongings in a haphazard manner.12.Compressed gases, chemical products, or other hazardous materials

shall not be left unattended in public areas. Gas cylinders, whether full or empty, should always be secured to a wall, bench, or rack with proper identification.


13.Spills such as oil, grease, acid, alkali or water shall be cleaned up as soon as possible as per the SOP- storage & handling of chemicals (EM 4 / 10). A delay could result in an accident to you or a fellow worker.

14.A safe access shall be maintained to work areas. Shortcuts, such as through construction areas shall be avoided. Never block aisles, traffic lanes, or fire exits with equipment or materials and make sure members of the public are kept out of hazardous and explosives work areas, by way of barricades and signage.

Safety precaution for out station work:

1. Basic safety guideline and traffic rule has to be followed during Journey. Persons riding two-wheeler must wear crash helmets. And persons driving four-wheeler must use the safety belt.

2. While on visit to some work site / factory / plant premises etc, everybody has to be very careful for his personal safety in that new place. He must use required PPE and without that he should not venture for any activity. Prior to start up any activity in that new area, he has to know the hazards associated with, emergency preparedness, congregation assembly points (if any) and their best practices for mitigation of hazards.

Procedure for working in and around moving parts:

The following procedure shall be followed while working in and around moving parts.

All the moving parts like belt drive, rotating gears, reciprocating shafts, couplings of motors, rollers of conveyors etc as far as reasonably practicable shall be guarded and in case of non provision of guards shall be made safe for any person by providing control mechanisms like provision of emergency stop buttons, limit switches, pull chord systems etc.

Procedure for preventing fall due to slips, trips and fall inside pits:

The following procedure shall be followed for cleaning and preventing slippery floor:

1. All the slippery floors shall be periodically cleaned. 2. The cleaning shall be carried out with displaying of proper signage.


3. The area to be cleaned shall be temporarily barricaded with caution tapes or safety cones preventing unauthorized entry.

4. To avoid slippery floor due to stagnation of water, it shall be ensured that proper grading of floor shall be maintained as far as reasonably practicable.

The following procedure shall be followed to prevent striking / trip hazards:

1. All pipes running across the floor as far reasonably practicable shall be avoided and taken overhead or

2. All pipes shall be covered with steps or humps to prevent trip hazard and humps shall be painted with yellow and black stripes. If steps or humps is not practicable caution board to be displayed.

3. All over head low lying pipes posing the hazard of striking against head of persons shall be painted in black against yellow background or caution board displayed to alert persons.

4. Any rise in surface posing trip hazard shall be provided with Caution board to alert persons or the rise in surface to be painted with yellow and black.

Fall into open pits/drains/trenches etc:

1. All open pits shall as far as reasonably practicable to be covered to prevent accidental falling of persons.

2. Open temporary pits / trenches excavated which are not covered due to the nature of work carried out shall be temporarily barricaded with caution tapes or suitable safety signs to be posted to alert persons moving in and around

3. All open drains in working areas (except storm water drains) shall wherever reasonably practicable to be covered with slabs or appropriate material to prevent accidental falling of persons moving in and around.

4. Permanent pits/sumps not covered due to the nature of activity carried on shall be provided with permanent barricading with toe guards.

Procedure for preventing the exposure of equipment related noise:

1. The operator(s) shall wear ear protection devices as per SOP- Personal protective equipment (EM 4/45) wherever signage for ear protection is displayed.

2. Operator(s) may make judicious use of cabins / rest rooms wherever provided to avoid continuous exposure to noise.


EHS Guideline for maintenance of Crane:

1. Proper access ladder to be provided.2. Safety belts to be used.3. Wearing helmets, safety shoes, safety glasses & gloves to be ensured.4. Tools shall be carried in special containers.5. PTW shall be obtained prior to commencement of maintenance activity,

which may require permit for working at height & hot work if need arises.6. The area around the crane shall be barricaded.7. Caution board to be displayed.8. Keep the fire extinguishers ready within reachable limit for any exigency.

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Revision No & Date

Prepared / Revised By Verified By

Technical CommitteeApproved By

Director (Operation)

00 M. G. Subudhi

Rev. 01

P.K.Mishra Tech. Cell

Approved


em -29 gen. safety(rev)

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