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Secti-on

Subject Page no.

1. Safety Policy of Company2. Purpose and Scope3. Fundamentals of Safety

G. GENERAL INSTRUCTIONS FOR SAFETY

G 1. Responsibilities of SupervisorsG 2. Responsibilities of IndividualsG 3. Personal ConductG 4. Personal Caution and Self

AwarenessG 5. Physical FitnessG 6. Reporting Hazardous

Conditions or PracticesG 7. Accident Reports, Records and

InvestigationsG 8. House keepingG 9. Storing and Piling MaterialG 10. Lifting, Carrying and Hoisting G 11. LaddersG 12. Hand ToolsG 13. Metal Scaffolds & TowersG 14. Suspended ScaffoldsG 15. Fall Arresting EquipmentG 16. Metal WorkingG 17. Grinding OperationsG 18 Welding & CuttingG 19 Safeguarding the PublicG 20. Use of Personal Protective

Equipment (PPE)G 21. Cleaning of PartsG 22 Preventing Fires & ExplosionsG 23 Fire Fighting

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G 24. Work on Tunnels, Penstocks, Valves,Dams and Ductlines.

G 25. Work on Transmission lines during inclement weather conditions:

G 26 Safety Guidelines for Thermal Units

G 27 Office Work

E ELECTRICAL OPERATIONSE 1. General Safety PrecautionsE 2. Authorisation for doing workE 3. Protective Equipment

E 4. Working on electrical lines E 5 Working on Dead Lines and

Equipment. Grounding of lines and equipment

E 6 Work on Double/four circuit overhead lines with one circuit/one side live

E 7. Inspection of equipment on live lines

E 8. Line work on poles and towers E 9. Tree trimming E 10. Right of way clearing and

trimmingE 11. Patrolling linesE 12. Switching OperationsE 13. Receiving Stations and Sub

stationsE 14. Pumped Storage UnitsE 15. GIS Switchgear and SF6 Circuit

breakers

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E 16. Storage BatteriesE 17. TransformersE 18. GeneratorsE 19. Work on generator windingsE 20 Static CapacitorsE 21 Lightning ArrestersE 22 Underground systems

E 23. Ring Main Units (RMU)E 24. Air Blast Circuit BreakersE 25. SCADA E 26. Communication system

equipment/FOP/Microwave/PLCC/Broadband

E 27. Testing of Electrical Equipment

28 Work Permit System

ST SAFETY TAGGING SYSTEMST 1. Fundamental Tagging RuleST 2. Requirements of Tagging

SystemST 3. Desirable Characteristics of

Tagging SystemST 4. TagsST 4A. Responsibilities involved

under the Tagging SystemST 5. Release OrderST 6. Caution OrderST 7. Operating PermitST 8. Construction OrderST 9. Release

Tags :Tagging Rules and Procedure for Equipment and Lines

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Subject Page no.

10. Rules Pertaining to use of Operating Permit (Green Tag)

12. Safety Tagging (illustrative)Case 1 Outage of 220/132/110

KV Interconnecting Buses

Case 2 Outage of Interconnecting Tie lines

Case 3 Outage of Thermal Units

Case 4 Outage of equipment/Auxiliary System at Thermal Power Stations

Case 5. Outage of Hydro Generating Units

Case 6. Outage of a Distribution Feeder fed from a Receiving Station

Case 7 Outage of an overhead 33/22/11 KV Distribution Feeder

Case 8 Megger or High Potential test on a feeder cable:Use of a Release order and Operating Permit

Case 9 Protective Relay testing

Case 10 Clearing of protection schemes only after equipment are taken in load service

ST 12 Discussion on usage of safety tags in day to day operations

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W Work Permit System

C CONSTRUCTIONC 1 ScaffoldsC 2 Rigging and HoistingC 3 Welding, Burning &

Cutting(General)C 4 Handling & Storing Compressed

GasesC 5 Explosives: Storage &

TransportationC 6 Handling & Use of ExplosivesC 7 ExcavationsC 8 Concreting & CementingT TRANSPORTATIONT 1 General PrecautionsT 2 DrivingT 3 ParkingT 4 Operation of Trucks & TrailarsT 5 Procedure in Traffic AccidentsF First Aid

F1 Principles of First AidF2 Restoration of Breathing by

artificial respirationF3 External Cardiac MassageF4 Cardio Pulmonary ResuscitationF5 External bleedingF6 BurnsF7 ShockF8 General rules for Treating an

Unconscious caseF9 General rules for Treatment of

FracturesF10 Treatment for Chemical BurnsF11 Foreign body in the EyeF12 Snake bite

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F13 Heat ExhaustionF14 Heat Stroke

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SAFETY POLICY OF COMPANY

The safety policy of the company includes the following objectives:

i. To integrate safety practices completely with production maintenance and all related operation requirements.

ii. To provide safe working conditions, proper and adequate tools, equipment and protective devices.

iii. To see that employees are at all times kept familiar with the general and special practices for the safe conduct of their work.

iv. To see that those safety measures and recommendations that apply are in all cases carried out by the employees.

2. PURPOSE AND SCOPE

This Safety Manual is for the guidance of employees in prevention of accidents to themselves, the public and the damage of the company property. Accidents can be practically eliminated with forethought, carefulness and planned protection on the part of supervisor and workmen. This manual also outlines First-Aid methods as applicable to work processes, environment and practices. These are to be used at the time of accidents before medical aid becomes available.

The safety instructions are divided into six parts:

1) General (applicable to all situations)2) Electrical Operations3) Safety Tagging and Work Permit System4) Construction5) Transportation6) First Aid

OMISSION OF ANY SAFE PRACTICE HEREIN DOES NOT REDUCE INDIVIDUAL RESPONSIBILITY FOR ALERTNESS AND GOOD JUDGEMENT IN THE PERFORMANCE FOR WORK.

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3. FUNDAMENTALS OF SAFETY

(1) Prevention of accidents requires the wholehearted co-operation of all members of the organisation. A capable, mentally alert employee will avoid accidents.

(2) An unsafe person is a liability to the company. Such person is danger to self, fellow workers, the public and to the general environment.

(3) Accidents Do Not “Just Happen” – Accidents are the result of unsafe acts or unsafe conditions or a combination of both.

(4) Unsafe Acts, which cause majority of accidents, include the following :-

(a) Operating without Authority or Warning such as closing switches, operating valves without authority and proper line up, operating hoists and cranes without warning, failure to block or guard equipment against unexpected movement, failure to place caution boards or signal persons where needed.

(b) Operating or Working Unsafely such as driving too fast, throwing material or tools to another worker, jumping from vehicles or platforms, or unnecessary haste.

(c) Making Safety Devices Inoperative such as using oversize fuses, blocking safety valves, defeating or bypassing interlocks.

(d) Using Unsafe Equipment or Using Equipment Improperly such as using dull cutting tools or mushroom-head chisels, pipe extensions on wrenches not designed for them, using excess leverage instead of hand force where required, wrong tool for the job, using hands instead of hand tools. Tools without proper insulation or defective tools.

(e) Unsafe Loading, Placing or Mixing such as overloading cranes and winches, carrying too heavy a load,

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leaving objects where they are likely to fall, improper packing, combining chemicals to form a dangerous mixture.

(f) Acquiring unsafe position or Posture such as walking under suspended loads or too close to openings, lifting while in awkward position, riding on running boards or other unsafe places on vehicles.

(g) Working on Dangerous Equipment such as cleaning, oiling or adjusting moving machinery and working on live electrical equipment that could conveniently be de-energised.

(h) Distracting, Teasing, Startling such as practical joking, horse play, quarrelling or annoying.

(i) Failure to Use Personal Protective Equipment (PPE) or Safe Clothing such as failure to use rubber gloves on energised equipment, and failure to use goggles, helmet, safety shoes, gas mask, respirator or gloves when necessary and wearing loose sleeves, neckties or jewellery near moving machinery,

(j) Use of rings in fingers, carrying metallic pen, wristwatch, coins, keys in the pocket while working inside any panel, open tank, exposed equipment, etc.

(k) Use of jhoola while working at height.

(5) Unsafe conditions that may result in accident include the following: -

(a) Unguarded Equipment such as unshielded moving parts of machines, saws, compressor belts, etc., un-barricaded floor opening and excavations, and high voltage circuits which are un-isolated, live, unguarded and without caution notice plates.

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(b) Defective Material or Equipment such as mushroomed chisels, split handles, poorly constructed scaffolding, damaged tools, electrical hand tools without proper insulation.

(c) Improper Illumination such as insufficient light or unsuitable location of lamps producing glare or objectionable shadows.

(d) Unsafe Design and Construction. Structures like platforms, scaffoldings should have large safety factors and their construction and design in general should incorporate safety features. All anticipated hazards should be pointed out to workers.

G. GENERAL INSTRUCTIONS FOR SAFETY

G-1 RESPONSIBILITIES OF SUPERVISORS

Divisional Heads Departmental heads, Line Engineers and other Supervisors have the definite responsibility of ensuring the following: -

(a) Safe working conditions.

(b) Necessary protective equipment and its use.

(c) Properly maintained tools and equipment.

(d) Properly planned work performed in a safe manner.

(e) Application of the general and special safety instructions by their workmen.

(f) Assignment of employees to jobs which they are capable of doing safely.

(g) Immediate steps to correct any violation of safety rules observed or reported to them.

Supervisors will be held responsible for seeing that work under them is done in a safe manner. Each Supervisor shall make certain that his men understand the following: -

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(a) Work to be done(b) Hazards that may be encountered(c) Proper procedure for doing the work safely.

Frequent periodic inspections of construction, operation and maintenance equipment, materials, work areas, conditions and methods should be made by supervisors as a part of their routine duty. Such inspections are essential to prevent fires and accidents.

G-2 RESPONSIBILITIES OF INDIVIDUALS

(1) Your definite responsibility is to act so as to provide

(a) Safety to yourself(b) Safety to your fellow employees(c) Protection to the public(d) Protection to the company property.(e) Protection to the general

environment.

(2) Every employee is expected to study the Safety Manual, familiarise with its contents and apply them. Ignorance of Rules and Regulations will result in accidents to self and co-workers.

(3) Whenever in doubt regarding any rules and regulations, employees should consult their Engineer or Supervisor.

(4) Before attempting any work under conditions that is considered to be unsafe, employees are required to call these conditions to the attention of the person-in-charge of work and seek his/her advice.

(5) It will be the duty of every employee to report promptly to his/her Engineer or Supervisor any dangerous or improper condition of company apparatus or equipment, which comes to his/her notice.

G-3 PERSONAL CONDUCT

(1) Use of intoxicating liquor and drugs while on job is strictly prohibited. No employee shall report for work while under the influence of liquor, and no Engineer or other Supervisor and Security on duty shall knowingly permit a person to go to work while under the influence of liquor/drugs.

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(2) Practical joking and horseplay or gossiping while on the job is strictly prohibited.

(3) No employee shall distract the attention of another worker from his job unless he thinks that the worker is doing something, which is dangerous or risky either to self or equipment.

(4) Any employee who endangers own or others’ safety and lives by violating the foregoing requirements of personal conduct shall render liable to disciplinary action.

(5) Security on duty should not allow any person under the effect of liquor/drugs to enter the company premises.

G-4 PERSONAL CAUTION AND SELF AWARENESS

It is in workman’s own interest to exercise utmost personal caution as indicated below so as to prevent accidents and injury.

(1) Every employee should consider the result of each act and no chances should be taken that will endanger either workman’s own or other employees’ lives.

(2) Always Be Careful (ABC); the work-man should place himself in a safe position while working to avoid falling, stumbling, slipping or moving backwards against live parts.

(3) The workman should satisfy regarding the safe working conditions before starting the work. The care exercised by others should be checked.

G-5 PHYSICAL FITNESS

(1) Before and during employment, every employee will be given a physical examination and must be certified by the company’s Medical Officer as being physically qualified for the work he/she will be expected to do.

(2) Any employee who is unable to perform duties due to illness or other disability shall promptly report the condition to immediate supervisor.

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(3) After absence from work due to illness or injury, an employee may be required to pass a physical examination to determine fitness for duty.

G-6 REPORTING HAZARDOUS CONDITIONS OR PRACTICES.

(1) All hazardous conditions should be reported to the Supervisor and engineer on duty.

(2) Hazardous conditions should be eliminated as soon as they are discovered. Where a hazard cannot be removed, taking reasonable and proper precautions can prevent accidents.

G-7 ACCIDENT REPORTS, RECORDS AND INVESTIGATION

(1) Accident records are essential to the prevention of accidents. They show the type of accidents most frequently encountered where they occur and their relatives severity. A study of these records will emphasise common hazards, and prompt a better understanding of the causes of accidents and most effective methods of preventing them.

(2) All accidents which result in injury or not or however small the accident may be shall be promptly reported to Engineer or Supervisor and operation Engineer on duty. Many near misses / near accidents, which are not reported, recur with serious injuries.

(3) All accidents to the public involving company personnel, equipment or property shall be reported promptly.

(4) Accidents should be investigated to determine the cause and what steps are needed to prevent a recurrence. It shall be the responsibility of the person-in-charge of the job to get a complete, detailed story of the accident as soon as possible after it occurs.

(5) Accidents, whether they result in personal injury or not, shall be promptly investigated by the Divisional Head.

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Definitions :

Accident :

Accident is any event, which has or could have caused injury. Such an event may also involve damage to machinery / property.

Work Injury :

Work injury is an injury arising from the event during the course of employment.

Reportable Accident :

Reportable Accident is an accident which causes bodily injury as prevents or will probably prevent the injured person from working for a period of 48 hours immediately following the accident

Handling of Accidents / Injuries :

Role of TATA Power Supervisor

After notifying the Medical Officer / Retainer / Specialist, the TATA Power Supervisor must ensure the removal of the injured to Occupational Health Centre / Dispensary / external hospital either using the ambulance / vehicle or with the help of co-workers of the injured employee. He should send a note regarding the injury immediately to Medical Officer / Retainer / Specialist.

In case of damage to facilities, he must immediately get suitable steps taken as per requirement. If, in doubt, he must await Dept. Manager / Divisional Head's advice.

Role of Medical Officer / Retainer / Specialist

The Medical Officer / Retainer / Specialist must immediately reach the Occupational Health Centre / Dispensary / Hospital on receipt of the information. He shall then decide on the course of treatment and need for hospitalisation and inform administrative needs. After initial handling of the injured, he should inform Divisional Head, the status of the injured. In case of hospitalisation, the Medical Officer / Retainer / Specialist should

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liaison with the hospital and advise by way of remarks on internal report form. The second copy of the internal report form should be sent to Safety Officer / Steward and the third retained in Occupational Health Centre / Dispensary / Office for the records.

Role of Safety Officer / Safety Steward

The Safety Officer / Safety Steward / Supervisor nominated by Station Head must rush to the scene of accident, establish first information on how the accident occurred and provide any assistance that may be necessary. Subsequently, he should proceed to the Occupational Health Centre / Medical Dispensary / Hospital and interview the injured with the consent of Medical Officer / Retainer / Specialist.

Role of Department Head

He should immediately visit the scene of accident and enable his supervisor to take effective steps. He should keep Station / Divisional Head informed of the developments.

Role of Station / Divisional Head

He should render all administrative assistance sought by Medical Officer / Retainer / Specialist. These could include providing vehicles for transporting Injured / Relatives (if need be), to the hospital. Administrative Officer will co-ordinate with Division, if any outside assistance is to be sought.

Role of Visitors

No visitors or onlookers are permitted near the scene of accident. Co-workers of the injured can visit the Occupational Health Centre / Dispensary / Hospital only within specified visiting hours with prior permission of Medical Officer / Retainer / Specialist.

Role of Injured

The injured person should report the accident immediately to his supervisor / to the Department Head (in the absence of supervisor). He is expected to co-operate

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with Medical Officer / Retainer / Specialist in treatment, hospitalisation, discharge and re-instatement. The advice of Medical Officer / Retainer / Specialist is binding on all concerned personnel.

Statutory Reporting

Under the provisions of Factories Act, 1948, and Maharashtra Factories Rules 1963, framed within the Act, there are certain statutory information that needs to be sent to the various Government authorities in case of reportable accident or dangerous occurrence as defined by the Act.

As per Factories Act, following locations are Factories

Thermal – Trombay

Hydro – Bhira, Bhivpuri, Khopoli.

Transmision and Distribution – Andhra Workshop, Mahalaxmi.

Statutory reporting to the Directorate of Industrial Safety and Health (Factory Inspection Office) is applicable to accidents occurring at above locations.

Briefly, the notices have to be sent as prescribed under –- Section 88 "Notice of Certain accidents"

and - Section 88-A "Notice of Certain Dangerous

Occurrences" of the Act, - “Form 24” for accidents as prescribed in

Rule 115 of the Factories Rules. - “Form 24-A” for dangerous occurrences.

Form 24 / 24-A is to be sent to the Deputy Director of Industrial Safety and Health (Formerly known as Factory Inspector).

It is also necessary to maintain a "Register of Accidents and Dangerous Occurrences" in Form 30 as prescribed in Rule 123.

Safety Officer / Steward, in consultation with Station / Divisional Head, will take care of above statutory communication.

Task Force members are covered under Employee’s State Insurance (ESI) Act.

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ESI scheme is applicable to Mumbai region (including Kalyan and Ambernath) and Lonavla.

Bhira, Bhivpuri and Khopoli are not covered under ESI scheme.

Form no. 16, as per ESI Act, is to be sent to the Administrative Medical Officer, Employees’ State Insurance (ESI) Scheme, Mumbai.

In case of fatal accident, information shall be sent by the factory manager by telephone, special messenger or telegram within 24 hours of occurrence to:

a. Factory Inspector (Directorate of Industrial Safety and Health).

b. Administrative Medical Officer, Employees’ State Insurance Scheme, Mumbai.

c. District Magistrate or Sub-Divisional Magistrate.

d. Officer-in-charge of the nearest Police Station.

G-8 HOUSEKEEPING

Workmen are frequently injured by tripping, stumbling, stepping on, or bumping into tools, material and other objects left lying around, or by carelessly placed objects falling from above.

To ensure good housekeeping following precautions should be observed: -

(a) Walkways, aisles, stairways, fire escapes and all other passageways shall be kept clear of all obstructions.

(b) Tools and materials should not be placed where they may cause tripping or stumbling hazards or where they may fall and strike anyone below.

(c) Puddles of oil and water create a slipping hazard and should be cleaned up promptly.

(d) Nails in boards, such as those removed from scaffolds, forms and packing boxes, constitute a hazard and should be removed. The boards

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should be carefully stacked or stored.

(e) Dirty and oily waste rags should be deposited in approved containers and disposed off as soon as practicable to avoid fire hazard.

(f) Broken light bulbs, glass metal and scrap and other sharp objects should be dumped in places or containers provided specially for them.

(g) Discarded fluorescent and other gas filled tubes shall be disposed off safely.

G-9 STORING AND PILING MATERIAL

(1) Material stored in quantity should be arranged so that the weight is evenly distributed and not top heavy.

(2) All stacks and piles should be protected against overturning or other movement.

(3) Sand, gravel, lime, cement and other heavy material require supports of unusual strength and shall not be stored in buildings unless the supports are designed for additional weight.

(4) Barrels, drums and kegs should be stored on end or securely blocked to prevent rolling.

G-10 LIFTING, CARRYING AND HOISTING

(1) Most lifting accidents are due to improper lifting methods rather than to lifting too heavy loads. When manually lifting heavy objects, person should keep his back close to vertical and the lifting done with leg and arm thigh muscles rather than with back muscles.

(2) Bulky loads should be carried in such a way as to permit unobstructed view ahead.

(3) Pipes, conduits, reinforcing rods and other conducting materials should not be carried on / above shoulders near exposed live electrical equipment or conductors in switchyards.

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(4) Rope tackle and slings, wherever required, should be checked to ascertain that they have sufficient strength to perform the work in hand.

(5) Chain hoists will not be used until their condition is known to be satisfactory. Care should be taken to avoid overstraining hoisting equipment. Chains should be inspected before use and at intervals during extended operations to avoid failure of worn or weakened links, hooks or other parts.

(6) No one shall stand or pass under any suspended load being handled by a crane, derrick or other hoisting equipment.

(7) Safe loads that can be lifted with various sizes of Nylon Manila and Sisal ropes under different hitches are given in the attached chart. The values given are valid for undamaged ropes and when the loads are lifted without jerk.

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Specifications of Manila, Polypropylene and Nylon Ropes as per IS-1084, IS-5175 and IS-4572

Manila Ropes

Circum-ference in MM

Diameter in MM

Breaking Strength (Kg.) Weight(Per coil of 220 Mtrs)

Grade 2

Grade 3

Commer-cial

25 8 483 419 210 12

32 10 635 559 280 15

38 12 955 838 419 23

44 14 1285 1118 561 31

51 16 1805 1576 788 42

57 18 2135 1880 940 49

64 20 2845 2215 1108 81

70 22 3405 2972 1136 73

76 24 4085 3558 1750 88

83 26 4725 4140 2070 103

89 28 5325 4725 2363 118

95 30 6055 5385 2693 138

102 32 8860 6071 3051 155

114 36 8635 7570 3786 197

127 40 10415 9703 4850 244

140 44 12700 11024 5500 298

152 48 14735 12955 6478 352

165 52 17275 15088 7500 414

178 56 19815 17425 8713 479

190 60 22805 19813 9908 549

203 64 25700 22800 11300 639

216 88 28500 24700 12350 707

229 72 32700 27600 13800 792

241 76 35000 30000 15000 881

254 80 38700 32600 16300 988

279 88 46800 39200 20500 1177

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Polypropylene Ropes


Diameter in MM

Breaking strength(Kg.)

Weight(Per coil of 220 Mtrs)

4 214 1.63

6 602 3.67

25 8 1060 6.6

32 10 1560 10

38 12 2210 14.5

44 14 3050 20

51 16 3770 25.5

57 18 4810 32.5

64 20 5800 40

70 22 6960 48.5

76 24 8130 57

83 26 9410 67.6

89 28 10700 78

95 30 12220 89

102 32 13500 101

114 36 16930 129

127 40 20510 158

140 44 24640 194

152 48 28610 229

165 52 33110 268

178 56 37850 312

190 60 43280 359

203 64 48980 407

216 88 -- --

229 72 61500 515

241 76 -- --

254 80 75640 638

279 88 90760 772

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Nylon Ropes


Diameter in MM

Breaking strength(Kg.)

Weight(Per coil of 220 Mtrs.)

4 320 2.3

6 750 4.95

25 8 1345 8.8

32 10 2088 13.6

38 12 2995 19.6

44 14 4095 26.8

51 16 5300 35

57 18 6695 44

64 20 8300 54

70 22 10000 66

76 24 12000 78

83 26 13950 92.4

89 28 15800 107

95 30 17755 122.1

102 32 20000 139

114 36 24900 176

127 40 30000 218

140 44 35800 264

152 48 42000 312

165 52

178 56

190 60

203 64

216 88

229 72

241 76

254 80

279 88

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(8) Some of the dependable rope knots and hitches are shown in the attached sketches indicating their special purpose and advantages.

(9) In switchyards No material should be lifted/carried above shoulder level.

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G-11 LADDERS

(1) All ladders shall be inspected at regular intervals and maintained properly.

(2) When a ladder has fallen or been struck, it should be carefully inspected for possible damage before use.

(3) Split, broken or otherwise defective ladders should be destroyed or cut to smaller lengths.

(4) A ladder shall never be placed on slanting, oily, slippery or on vibrating footings, unless the ladder is held by another person or securely fastened to prevent it from slipping or twisting.

(5) The base of a ladder should not be placed more than 1/4th the length of the ladder from a wall or supporting surface.

(6) The overlap of sections for extension ladders should be sufficient to prevent collapse of extensions.

(7) Ladders placed near doors or in passageways should be protected against being struck by doors or traffic.

(8) While going up or down a ladder, always face the ladder and use both hands for climbing.

(9) All ladders for outdoor use should be given a suitable coating such as clear varnish or linseed oil. Metallic paint shall not be used on wood ladders.

(10) Portable metal ladders shall not be used unless specifically authorised.

(11) The use of ladders for other than their intended use and the use of defective ladders is prohibited.

(12) The most likely type of accident to occur at a power plant that could result in severe injuries is a fall.

(13) When you select a portable ladder, choose the proper type and size and inspect it for defects. Whenever possible, make sure the top of the

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straight or extension ladder will be long enough to extend at least three feet above the step-off level.

(14) Never climb an extension or straight ladder that is not adequately tied off unless someone is holding the ladder to prevent it from moving.

(15) Straight ladders and extension ladders, except for job made ladders, are not to be used unless they have safety feet. Job-made ladders should only be used for a specific purpose intended. If possible, they should also be provided with slip resistant feet.

(16) Be sure the horizontal distance from the foot of a straight or extension ladder to the base of the vertical support it rests against is equal to one-fourth the working length of the ladder.

(17) Do not work higher than the second step from the top of a stepladder or the third rung from the top of a straight ladder.

(18) If it is necessary to place a ladder in the swing of travel of a doorway, barricade the door and post warning signs or post a watchman.

(19) Use a ladder-climbing safety device when it is provided.

(20) Do not use stepladders as straight ladders.

(21) Straight or extension ladders are to be provided with safety feet and must be tied off or held when in use.

(22) Face the ladder and use both hands when ascending or descending ladders.

(23) Carry tools up and down a ladder in a tool holder or raise them with a hand line or hoist.

(24) Clean mud or grease from shoes before climbing ladders. Ladder steps should also be kept cleaned of oil and grease.

(25) Only one person at a time is permitted to work from a ladder.

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(26) Metal ladders are not to be used in locations where they may come in contact with electrical conductors except for special jobs performed in switchyard that must be approved by the supervisor prior to beginning the job.

(27) Do not use general-purpose metal ladders for electrical work.

(28) Do not use boxes, chairs, barrels etc., as a base for a ladder.

(29) Ladders are to be inspected before each use and defective ladders are to be tagged for the defect.

(30) Do not use a fixed ladder from which there is a fall

potential of over 6 meters unless it is equipped with an approved cage or a ladder safety climbing device.

(31) Do not use a fixed ladder that is greater than 10 meters in length unless the ladder is provided with a cage, offsets, and rest platforms at least every 10 meter or is equipped with a ladder safety climbing device.

(32) Fixed ladders must have at least 17-18 cms clearance from the centreline of the grab bars to the nearest permanent object behind the grab bars.

(33) While climbing the ladder the foot should be at right angles to the step of the ladder.

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G-12 HAND TOOLS

(1) Many accidents result from improper use of tools and use of defective tools and equipment. Employees should use only those tools and equipment, which are in good condition and should use only for the purpose for which they were designed. Where proper and safe tools are not available for the work at hand, the employee shall report the fact to the Supervisor.

(2) Tools, which develop defects while in use, should be removed from service, tagged and not used again until placed in good condition.

(3) Impact tools such as chisels, drill, hammers and wedges with mushroomed heads should not be used until they have been reconditioned.

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(4) Hammers, axes, shovels and similar tools should not be used if handles are loose, cracked or splintered.

(5) Defective wrenches such as open-end and adjustable wrenches with spread jaws, or pipe wrenches with dull teeth, should not be used, as they are likely to slip.

(6) Pipe or other extensions should not be used on a wrench handle to increase the leverage unless the wrench is specifically designed for such an extension.

(7) Portable electric tools with metal body should be equipped with 3-wire cord having the ground wire permanently connected to the tool frame and means for grounding the other end.

(8) Use of multimeter should be done for checking of presence of electric supply/voltage instead of tester.

G-13 METAL SCAFFOLDS AND TOWERS

(1) Ensure that metal scaffolds and towers are erected in accordance with the manufacturer’s specifications and that the recommended load limits are not exceeded.

(2) Position metal scaffolds so that they will not come in contact with energised electrical conductors.

(3) Plumb and level all scaffolds and towers. Use rolling scaffolds only on firm, level and clean surfaces.

(4) Securely fasten all braces used in metal scaffolds.

(5) Cleat or secure scaffolds planking at both ends to prevent movement.

(6) Use a positive wheel-locking device to prevent all rolling scaffolds from accidentally moving while the scaffold is in use.

(7) Move all rolling scaffolds by applying force to the base only.

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(8) Riding on rolling scaffolds while they are being moved is prohibited. Remove or secure all tools, materials, and equipment on the deck before moving the scaffold.

(9) Do not allow the height of the work platform of free standing scaffold towers to exceed four times the smallest base dimension.

(10) Work only from scaffolds that have been approved and display a current signed scaffold permit.

(11) Use an approved means of access to and from all elevated work areas, i.e. ladders, stairs, or approved personnel hoists.

G-14 SUSPENDED SCAFFOLDS

(1) Before getting on a suspended scaffold, attach a lanyard from your full-body harness to an independent lifeline secured to a firm anchorage above. The anchorage for the lifeline or lanyard must withstand at least a 5,000-pound load.

(2) Ensure that wire or fibre rope used to support scaffolds is capable of supporting at least six times the intended load.

G-15 FALL ARRESTING EQUIPMENT

(1) The use of full-body harnesses and lanyards, either tied off to a life line or to an anchorage, is required under the following circumstances:

a. When the scaffold permit requires their use.b. When required by your supervisor.c. When working from any suspended scaffold when

the fall potential exceeds four feet.d. When working from any work surface that is not

protected by guardrails and all potential exceeds four feet.

e. When working from an aerial lift bucket. (Tie off to bucket or boom.)

(2) Lifelines and lanyards are to be tied off to anchorage capable of supporting at least 5,000 pounds. All tie-offs shall made as high as possible above waist height level.

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(3) Lanyards shall have as little slack as possible and limit any fall to six feet or less with a harness.

(4) Lifelines, harnesses, and lanyards are to be removed from service and destroyed if they have been used to arrest a fall.

(5) Metal rules, metal tape lines, or tape lines containing wires shall not be used around electric conductors or equipment.

(6) All tools carried on trucks should be inspected each month and defective tools repaired or replaced.

G-16 METAL WORKING:

GENERAL

(1) Operating machinery without authorisation by supervision is prohibited.

(2) The floor area around machines is to be maintained clear and free from grease, oil, scrap and trash.

(3) Keep machinery free of tools, rags and scrap.

(4) Know the operating capabilities of the machines used and never exceed those limits.

(5) Before tripping shears, make certain that everyone is in the clear.

(6) Keep fingers out of the area of cutting edges and other exposed moving parts.

(7) Use a brush or other suitable means to remove chips, dust, or other material from machines.

(8) Where the work must be held in position, it must be securely bolted or clamped to the table or held in a vice or jig. Do not try to hold it by hand.

(9) Shut off the power before setting up work on equipment, such as shears, lathes, drill presses etc.

(10) After using the chuck key, immediately remove it from the chuck of a lathe or drill press.

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(11) Calipering or gauging is not to be attempted while the lathe or milling machine is in operation unless the device is designed for such use.

G-17 GRINDING OPERATIONS:

GENERAL

(1) Do not use a bench or floor stand grinder when any of the following conditions exist:

a) Guard(s) are not installed.

b) Grinder not securely anchored.

c) Work rest exceeds 1/8 inch distance from the wheel.

d) Adjustable tongue exceeds ¼ inch distance from the wheel.

e) Excess wear is evident on the grinding wheel.

f) Wheel is chipped, cracked, out of round, or otherwise defective.

(2) Do not use potable grinders without guards.

(3) Before mounting a grinding wheel on a grinder, check the operating speed marked on the grinder and the rated safe speed of the grinder wheel. Grinding wheels are not to be mounted on grinders that operate in excess of the rated safe speed of the grinding wheel.

(4) Adjusting the work rest or tongue guard while the grinding wheel is in motion is prohibited.

(5) Inspect grinding wheel and discs on portable grinders before use for any cracks, damage, or wheels out of round or balance. Where any defect is evident, the wheel or disc must be removed from service immediately.

(6) Check the grinding wheel mounting flanges for equal sizes and correct diameters. Flanges are to

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be at least one-fourth diameter of the wheel diameter.

(7) Do not stand directly in front of any grinder when first starting it up.

(8) Allow the wheel to develop its full speed before beginning work.

(9) Never force the stock into the wheel of a fixed grinder or a portable grinder into the work to the point where the motor slows noticeably or the work becomes excessively hot.

(10) Ensure that the wheel is properly dressed at all times.

(11) Do not grind on the side of the wheel unless the wheel is specifically designed for this purpose.

(12) Store grinding wheels in a safe place designated for that purpose.

(13) Machines must be shut off when unattended.

G-18 WELDING AND CUTTING :

A. GENERAL:

1. Only authorised employees are to perform welding and cutting operations. Prior to starting a job, check with your supervisor to see if a cutting and welding permit is required.

2. Do not perform welding, cutting, or hot work on used drums, barrels, tanks, containers, or inside confined spaces prior to venting and testing the atmosphere. Purge, inert, and clean, as necessary, to ensure that the work can be done safely.

3. Inspect all welding and cutting equipment before use. Remove defective equipment from service and tag it.

4. Protect or remove combustible material from any welding and cutting area.

5. A fire watch must be maintained for at least 30 minutes after completing cutting or welding in coal handling areas.

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6. Use non-combustible material to cover openings when cutting or welding over grated flooring.

7. Suspend welding cables and hoses overhead or arrange them so they will not cause a hazard.

8. When welding or cutting, shirt collars must be fastened and sleeves rolled down and fastened. Wear trousers without cuffs, along with footwear designed for industrial work exposures.

9. Approved eye protection must be worn in conjunction with industrial safety glasses when performing welding and cutting operations.

B. ELECTRIC ARC WELDING AND CUTTING:

1. Ground the non-current carrying metal parts of electrically driven welding machines.

2. Neither terminal of the welding generator is to be bonded / grounded to the frame of the welding machine.

3. Do not use pipelines, which are pressurised or contain flammable gases / liquid, or conduits carrying electrical conductors for a welding ground return circuit.

4. Welders are not to handle the electrode holders from two different machines at the same time.

5. Do not coil or loop welding cable around parts of your body while it is energised.

6. Electrode holders must not be dipped in liquids to cool them.

7. Wearing rings, metal wristbands or other jewellery while welding is prohibited.

8. Special precautions must be taken when welding on wet or damp surfaces. See your supervisor for protective requirements.

9. Do not use welding leads that have a splice within 10 feet of the electrode holder.

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C. GAS WELDING & CUTTING:

1. Keep compressed gas cylinders beyond the range of sparks, hot slag, or flame. Keep two buckets of water or a running water hose at the job site.

2. Close the torch valves and shut off the gas supply whenever work is suspended. Bleed the torch before disconnecting gauges.

3. Remove the torch and hose from confined spaces whenever work is suspended during lunch breaks and at the end of the shift. When torch and hose removal is no practical, the cylinder valves must be closed, the regulators backed off, and the torch turned off to prevent any gas flow.

4. Use only appropriate tools to ignite torches. Do not use open flames or matches.

5. Do not take compressed gas cylinders into confined spaces.

6. Both the oxygen and fuel gas lines must be equipped with flash back preventers (reverse flow check valves / non-return valves) at their connections to the torch.

7. A fire watch must be maintained for at least 30 minutes after completing cutting or welding operations in the coal handling area.

D. PRESSURISED SYSTEMS AND CYLINDERS:

GENERAL:

1. Inspect pressurised equipment and systems for damage before they are placed in service and after major repairs or modifications.

2. Do not pressurise a non-pressure-rated vessel with plant air, a compressed gas cylinder, or other sources. Use liquid at atmospheric pressure to test for leaks.

3. Atmospheric tanks, low-pressure tanks, and pressure vessels are designed and manufactured in accordance with acceptable standards and therefore may not be pressurised above the designed pressure of the vessel.

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E. COMPRESSED GAS CYLINDERS:

1. All compressed gas cylinders are to be labelled as to their contents. Do not use cylinders if a label does not identify their contents. Colour code for gas cylinders is to be followed.

2. Store cylinders in well-ventilated locations.

3. Smoking within 15 meters of designated flammable gas or oxygen storage facilities is not allowed.

4. Protect cylinders from extreme temperature, physical damage and electric current.

5. Close cylinder valves and place valve caps on the cylinders when they are in storage, in transit, or not connected for use.

6. Secure all compressed gas cylinders to a fixed structure or in portable racks or hand trucks.

7. Compressed gas cylinders transported by crane, hoist, or derrick shall be transported in hoist racks, cradles, nets, or skip pans, and never by silings, chains or magnets.

8. Always store oxygen, acetylene and other fuel gas cylinders in an upright position. Keep acetylene cylinders upright at all times, except for short periods of time. I.e. if necessary, during transportation to a job.

9. Have a valve wrench or wheel ready to operate when a cylinder is in use.

10. Leaking cylinders must be moved, using appropriate precautions, to an isolated location out of doors.

11. Using oxygen as a substitute for compressed air is not allowed. Compressed gases of any kind are not to be used as a substitute for compressed air unless used in a system designed for such use.

12. Keep oil or grease away from oxygen cylinders and fittings.

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F. COMPRESSED AIR:

1. Wear approved eye and face protection when using compressed air for cleaning. Ensure that all persons are adequately protected from flying chips and particles. Do not direct compressed air toward any part of your body or toward anyone else.

2. Do not use air pressure in excess of 30 psi (when dead-ended) for cleaning operations.

Note 1 The down stream pressure of air at the discharge end of a nozzle, cleaning lance, or opening of a pipe shall remain at a pressure below 30 psi for all operating conditions. This requirement is necessary in order to prevent a backpressure build-up if the nozzle is obstructed or dead-ended.

Note 2 To modify an air lance to meet the above requirement, drill a series of small holes in the pipe or lance directly behind the nozzle to relieve the pressure in case the nozzles is obstructed. There is no intent to restrict the diameter of the nozzle orifice or the volume (CFM) flowing from it.

3. Using compressed air to pressurise or force the contents out of a drum or a non-pressure-rated vessel is prohibited.

G. EXCAVATIONS:

GENERAL:

1. Before starting any excavation, determine if there are any underground utilities in the area that could be damaged.

2. Excavations of one meter deep or more, unless in solid rock, must be shored, sheeted and braced, or sloped to such an angle that the soil is at rest (angle of repose) as determined by a competent person.

3. Use ladders, steps, or ramps as a means of entrance and egress in excavations more than one meter deep. Ladders must extend at least one meter above the top landing for mounting and dismounting.

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4. No more than 8 meters of lateral travel in an excavation 4 feet deep or more is allowed without an adequate means of egress.

5. Vibrations from machinery and equipment shall be considered when determining the angle at which the soil will be at rest.

6. Store and retain all excavated materials at least half meter or more away from the edge of the excavation. Keep equipment at least half meter away from the edge of the excavation.

7. A competent person must make daily inspection of excavations. If evidence of possible cave-ins or slides is apparent, all work in the excavation is to cease until the necessary precautions have been taken to safeguard the employees.

8. Warning devices such as signs, lights, and adequate barricades must be installed around unattended excavations.

H. ABRASIVE BLASTING:

GENERAL:

1. Employees transferring abrasive blasting materials or working near where any material may be flying must wear approved goggles and respiratory protection. The area of blasting should be enclosed to avoid nuisance.

2 Use adequate ventilation in enclosed areas.

3. Unauthorised personnel are not to enter an abrasive blasting area.

I. LABORATORIES :

GENERAL:

1. Know the exact locations and operation of emergency showers, eye wash fountains, fire extinguishers, etc.

2. Should acids or caustics come in contact with eyes or skin, flush with large amounts of water for a minimum of 15 minutes. DO NOT RUB YOUR

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EYES. Seek medical attention immediately after flushing eyes or skin.

3. Do not use broken, chipped, scarred, or badly scratched laboratory glassware.

4. Use only substances from properly labelled containers.

5. Ensure that incompatible chemicals are properly separated in storage, such as oxidisers separated from flammables.

6. Do not transport acids or caustics outside the laboratory in exposed glassware. The glassware is to be carried in sealed, padded containers.

7. Oxygen and fuel gas cylinders shall not be stored in the laboratory.

8. All compressed gas cylinders must be properly secured to prevent tipping.

9. Never use temporary tubing (i.e. Tygon, PVC., etc.) for the piping of oxygen or fuel gas.

10. Ventilation in laboratory hoods must be verified as adequate by flow measurement on an annual basis.

J. COAL HANDLING :

GENERAL :

1. Smoking is not permitted anywhere in the coal handling system, conveyors, bunkers etc.

2. Employees shall not step on a conveyer nor attempt to repair the equipment unless proper clearance has been obtained.

3. Do not ride on conveyors or cross over or under operating conveyors except where designated passageways are provided.

4. Before maintenance may begin on a conveyor, proper release on respective system must be obtained. Any adjustments made while it is running must be under supervisory control.

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5. Safe access to conveyors shall be maintained to permit safe inspection, lubrication, repair, and maintenance operations.

6. Before entering a coalbunker or silo, the air within the space shall be tested for oxygen content, flammable and toxic gases, and vapours.

7. When cleaning down coal in a bunker, employees

should use a lance with a non-sparking tip and should work from a position above the lodged coal.

8. Employees shall not work inside pulverised fuel equipment until it has been thoroughly purged or the coal dust has been wet down with water.

9. Employees shall not place hands on moving conveyors, rollers, or pulleys.

K. ASH HANDLING:

GENERAL:

1. Persons who enter or clean areas contaminated with ash shall wear all necessary personal protective clothing and equipment.

2. If an employee becomes dizzy or drowsy while working around ash-handling equipment, or in other gaseous areas, he/she should immediately go to an area of fresh air and notify someone of his/her condition and location.

3. When inserting or using a rod in a furnace, the operator shall keep the rod away from his /her body so that he/she will not be struck if falling ash or slag causes the rod to kick upward. A pipe shall never be used for de-slagging operation unless the pipe is sealed or connected to an air or water supply.

4. All rods in the vicinity of the area in which they are used shall be treated as being hot.

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G-19 SAFEGUARDING THE PUBLIC

(1) Every effort should be made to protect the public at all time where company’s work is in progress by the use of signs, barricades or personal warning.

(2) When working on customer’s premises or public property, every effort should be made to avoid hazards to persons or unnecessary property damage.

(3) When work is conducted along public streets or highways, pedestrian and vehicular traffic shall be warned by signs and flags by day and red lights or flares by night. Whenever necessary, signalmen should be provided.

(4) Barriers shall be placed around all open manholes, exposed open ditches and excavations.

G-20 USE OF PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal Protective Equipment (PPE)

Protection for PPE to be used PPE protecting from ------- PPE to be used during ------ / in -------

Body Cotton Uniform Exposure to Steam, Hot Oils, Chemicals, Alkalis.

Constant use in designated places.

Rubber Apron Splashes of Acids, Alkalis, Solvents.

Sampling, transferring, Filling, Drumming.

Head Helmet Falling objects and materials Constant use in designated places.Eyes Safety goggles Flying objects, Splashes,

Sprays

Breaking of flanges, Chipping concrete / metals, Gas Cutting, Uncoupling of hoses, De-pressurising, Venting, Sucking, Sampling.

Welding Goggles

Ultraviolet rays from welding arc

Arc welding, Gas welding.

Face 1. Face-shield Chemical Splashes Grinding, Furnace burner lighting, Chemical handling, Metal shaving.

2. Blue Face- shield

Hot rays, Ultraviolet rays, Grinding sparks

Arc welding, Gas welding.

Hands 1. Electrical Shock proof Gloves

Electric shock Working on high voltage electrical equipment / lines.

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2. Leather Gloves

Abrasion Pulling ropes / chains, Using tools like spanners, Operating hard valves, Welding.

3. Asbestos Gloves

Hot burns Handling hot materials, Tightening steam leak.

4. PVCGloves

Acids, Alkalis, Chemical handling

5. Rubber Gloves

Oils, Aromatic solvents, Alcohols.

Chemical handling

Foot 1. Safety Shoes

Falling object, Striking against object

Constant use in designated areas

2. Gum Boots

Muddy Land, Water, Chemical Spill,

Use under specific condition

Respiratory System

1. CanisterMask

Toxic Gas, Vapours, Use for specific jobs.

2. Self Contained

Breathing Apparatus Set

Toxic gas leaks, Smoke, Emergencies.

Use for specific conditions.

3. Dust Mask

Air containing dust / solid particles

Coal / Fly Ash handling, Grit blasting.

Ears Ear Plugs / Ear Muffs

Noise Constant use in designated areas

Falls Safety Harness Belt

Fall from height 1. Working above 4 metres for erecting scaffolding.2 Transmission line jobs.3. Jobs at elevated locations where adequate protection against falling is not available.4. Working on elevated platforms

above 4 met. without hand railing.

5. Working on Cooling Tower tops where wood is likely to cave in.6. Entry in confined spaces,

Inspecting vessels.

Job / Operation Additional PPEWelding Welding Screen, Chrome Leather Gloves.Gas cutting, chipping Safety Goggles, Chrome Leather Gloves.Manual hoist / tackle chain running Leather Gloves.Shifting weights, equipment Leather Gloves.Bench / pedestal grinding Safety Goggles / Face-shield.Pneumatic tools Ear Plugs, Leather Gloves, Face-shield.Power saw cutting Face-shield / Safety Goggles, Leather Gloves.Tightening glands, Dismantling of equipment Safety Goggles / Face-shield.Breaking flanges on pipelines / equipment Safety Goggles / Face-shield.

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Sweeping, Mopping up saw dust Dust Mask, Safety Goggles.Concrete chipping, cold metal chipping Safety Goggles.Painting Safety Goggles, Safety Harness Belt for the job

to be done at heights.Acid / Caustic handling, filling toxic chemicals Rubber Apron.Spading / de-spading, Connecting / disconnecting hoses

Safety Goggles / Face-shield.

Erecting scaffolding Safety Harness Belt, Leather Gloves.Working on scaffolding Safety Harness Belt, Gloves (as per job).HdPE pipe welding Safety Goggles, Leather Gloves.Chlorine tonner connection / disconnection Canister maskLead Acid Battery maintenance jobs Safety Goggles / Face-shield.Drawing samples Safety Goggles / Face-shield.Transferring chemicals Safety Goggles / Face-shield.Emptying / filling carboys / drums Safety Goggles / Face-shield.Opening draining / de-pressurising valves Safety Goggles / Face-shield.De-choking lines Safety Goggles / Face-shield.Air blowing operations Safety Goggles / Face-shield.Steaming operations Safety Goggles / Face-shield.

G-21 CLEANING OF PARTS

With flammable solvents

(1) Adequate ventilation must be available to avoid fire, explosion and health hazards.

(2) Avoid breathing solvent vapours.

(3) Keep open flames and sparks away from flammable liquids and their vapours.

(4) Metal nozzle of a hose for spraying flammable solvents shall be grounded.

With compressed air

(5) Goggles shall be used when blowing out dust with compressed air.

G-22 PREVENTING FIRES AND EXPLOSIONS

(1) Waste paper, rags and other combustible material should not be allowed to accumulate.

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(2) Flammable liquids shall be kept in approved safety cans and identified by proper labels.

(3) Varnish, paints, lacquers and thinners are highly flammable and should be stored away from all-open flames or possible sources of ignition. Matches and open flames should not be used where varnish, paint or lacquer is being applied with a spray gun.

(4) Open flames and smoking are prohibited in all areas where flammable liquids or gases are stored or being used. Such areas shall be posted with appropriate warning signs.

(5) All employees should be familiar with the location and proper use of fire extinguishers in their work area.

(6) No employee should smoke or use matches or open flames on customer’s premises

G-23 FIRE FIGHTING:

ELECTRICAL FIRES

Any fire started by electrical equipment must be a class A, B, C or D fire. Normal procedure is to cut off the supply of electricity and use an extinguishing method appropriate to burning material.

Special agents which are non-conductors of electricity and non-damaging to equipment should be used in case of any doubt about positive isolation of electric supply.

FIRE- ITS ANATOMY & CLASSIFICATION

Nature of Fire

Fire is as old as human civilisation. Fire of controlled nature has been part and parcel of day to day life. As the proverb goes “FIRE IS A GOOD SERVANT BUT BAD MASTER”, fire plays only constructive role in generating electricity.

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What is Fire

Fire is an exothermic chemical reaction resulting from combination fuel, heat and oxygen.

CLASSIFICATION OF FIRES and EXTINGUISHING MEDIA FOR PARTICULAR CLASS

CLASSIFICATION OF FIRES

Fires are classified on the basis of type of fuel involved.

Method of extinguishment & type of extinguishing media depends upon the class of fire.

As per Indian Standards : IS : 2190 - 1979, fires are classified as follows :

Class of

Fire

Type of fuel / material involved

Method of extinguishment

Extinguishing Media to be

usedA Ordinary Solid

Combustibles e.g. Wood, Paper, Grass, Plastics

Cooling fuel below its ignition point.

Water

B Flammable Liquids,Liquefiable solidse.g. Fuel Oil, LSHS, Diesel, Gasoline (Petrol), Paints, Petrochemicals.

Blanketing fuel surface in the bulk fire.

Protein Foam AFFF, Alcohol Resistant Foam

Flame Suppression in the spillage fire.

CO2, D.C.P., Halon

C Flammable Gases e.g. Acetylene, Hydrogen, LPG, Associated Gas, Natural Gas

Starvation by the control of fuel supply.

No medium is required

Inhibition of the burning fuel at fast rate with an inert gas.

CO2, D.C.P., Halon

D Combustible Metalse.g. Magnesium, Aluminium, Zinc, Sodium, Potassium, etc.

Inhibition of the chain reactions of combustion process

Special D.C.P.

II. Smothering :

In very simple word it can be understand as cutting of O2 (air) supply.

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This method can be accomplished by covering a burning surface with blanket, sand, DCP, foam, etc.

III. Cooling :

If heat generated during combustion can be dissipated at footer rate than generation by some means, the combustion can not sustained by proper cooling, the heat lost will be more than the production and fire will die down.

IV. Chain Inhibition :

Fire Triangle Fuel O2

OxygenHeatFuel Heat

Basic need of fire is these three elements in proper proportion without which fire can not involve.

With removing any of the side of fire triangle, we can extinguish fire. Depending upon these three parts of fire triangle, there are three extinguishing methods.

V. Chemical chain inhibition combustion consists of repaid chain reactions involving hydrogen atom and other active species and free oxygen atom. By applying proper chemicals, these chain reactions can be arrested e.g. D.C.P.

FIRE PREVENTION

Fire safety has four legs as shown below :

1. Fire Protection : Elimination of contribution2. Fire Prevention : Elimination of causes3. Quality control4. Preventive maintenance

The best way of fire safety is to eliminate the cause of fire i.e. fire prevention.

I) Good HousekeepingII) No smoking (or separate preparation of smoking

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III) Use of fire resistant paintIV) Electrical safetyV) Fire check doorsVI) CompartmentalisationVII) Separate storage of Hazardous chemicalsVIII) Naked Flame safetyIX) Use of earth leakage and current balance relays

and thermostat, fireproof chokes.

Do’s and Don’ts for Prevention of Electrical Fire

1) Ensure that current ratings of wires, cables and accessories are equal to or higher than maximum possible loads.

2) Ensure that all electrical wires and cables are protected by fuses.

3) Use of MCBs or cartridge fuses instead of wire fuses.

4) Ensure switch boards, terminal boards, joints etc. are not fixed close to combustible material.

Use only those electrical equipment, cables/wires and accessories which comply with relevant I.S.

NOTE: All portable fire extinguishers should be wall mounted (1000 mm above ground/floor level).

G-24 WORK ON TUNNELS, PENSTOCKS, VALVES, DAMS AND DUCT LINES

(1) Isolate the tunnel, pipeline, aqua-duct or associated turbine from all sources of water.

Open the switches or fuses controlling supply to motors for operating all valves, intake, gates etc. Lock all hand operating mechanism.

Work or inspection parties shall consist of not less than two persons.

(2) Use Safety shoes always. Use Gum boots when inside Duct-line

Confirm that Caution order or Release is taken.

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Carry out head counting before starting and after closing the days work.

Be cautious about ups and downs, slippery conditions during monsoon etc.

Use Helmet and Safety belt while working on heights.

(3) Read the Operating Instructions or consult the supervisor before touching the equipment or opening or closing valves.

Confirm that no one is in the path of waterfall while opening the scour valves.

(4) For grass removals on Dams use Rope ladder, Safety belts and helmets.

(5) All earth moving equipment movement in the tunnel should be slow while de-mucking in the tunnel.

Wear safety helmet and safety shoes inside tunnels.

The cable used for providing light should not have any joint in between.

Carry a whistle for giving out warning of dangerous situations when inside the tunnel.

Keep first aid box ready inside the tunnel.

(6) Ensure sufficient ventilation and light while working inside penstocks.

Ropes and trolleys should be tested before use inside the penstocks.

Carry out head count before entering and after coming out of penstocks.

(7) While lowering or lifting of stop log gates, take the help of Divers who are fully equipped with all the diving accessories. Confirm still water condition is maintained before entering into water.

While lowering and lifting of the stoplogs in approach channels and dams, the weather

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condition usually remains windy. Approach the job with utmost care and maintain clear & proper communication during this operation.

Physical fitness is a must for work inside the penstocks and tunnels.

Use 24 Volts hand lamps for lighting inside.

G-25 WORK ON TRANSMISSION LINES DURING INCLEMENT WEATHER CONDITIONS:

Fasten to the tower before starting any work and wear safety belts.

Do not work on overhead lines during thunder storms or lightning

G-26 SAFETY GUIDELINES FOR THERMAL UNITS

1. Common Guide Lines for Various Thermal Station Systems

2. General Safety Guide Lines for High Pressure Air System

3. General Safety Guide Lines for Control Fluid System4. General Safety Guide Lines for Fuel Oil LSHS

system

5. General Safety Guide Lines for High Pressure and Temperature Feed Water / Steam System

6. General Safety Guide Lines for Pumps in Thermal Station

7. General Safety Guide Lines for High Speed Rotary Equipment

8. General Safety Guide Lines for Hydrogen Gas System

9. General Safety Guide Lines for Various valves in Thermal Station

10. General Safety Guide Lines for Handling Fuel Gas System

11. General Safety Guide Lines for Lube Oil System12. General Safety Guide lines for handling chlorine

leaks.

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1. Common Guide Lines for Various Systemsin Thermal Stations

1. Persons handling the system should use safety apparel such as safety shoes, helmet, safety goggles, hand gloves, earplugs etc.

2. Ensure all fire-fighting equipment is in working condition.

3. Ensure adequate lighting in area of operation and its vicinity.

4. Communication source i.e., phone or page-party, should be available near the area of operation or in the vicinity. VHF sets can be used as an alternative.

5. Spanners of proper size should be available for operation.

6. Persons doing the operation should have complete knowledge of the system.

7. Before draining the system its isolation is to be re-confirmed from parameters such as pressure, flow, temperature etc.

8. After confirming the isolation, system should be drained in controlled manner. Drain valve should be opened such that there should not be heavy steaming which would affect other systems.

9. In case of leakage in the system, utmost care to be taken if it is a superheated steam as it is not visible. The only indication is from the noise and visual inspection.

10. Leaky system should be isolated at its earliest. If immediate isolation is not possible then the area should be cordoned off and should be properly tagged and it should be attended at the earliest.

G-26-2

2. General Safety Guide Lines for High Pressure Air Systems

1. Follow all Common Guide Lines of safety.2. Before charging the system close all drains.3. During initial charging the rate of pressure rise should

be minimum, so that air leakage in the system can be traced out.

4. For releasing the system, after confirming isolation, system should be depressurised in controlled manner. Drains should be opened such that there

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should not be any hindrance to other working equipment.

5. In case of any leakage in the system, utmost care to be taken as air is not visible. The only indication is from noise.

6. No direct contact to be made with the rotating/moving part of the compressor.

7. There should not be any loose or hanging clothes worn by the person inspecting the compressor.

8. The compressor should not run with any abnormal noise.

9. Monitor oil pressure and temperature to ensure that they are within the range recommended by manufacturer.

10. Check bearing metal temperature for confirming normal operation as specified by the manufacturer.

11. Record vibration measurements on all bearings while the compressor is rotating / running.

G-26-3

3. General Safety Guide Lines for Control Fluid Systems

1. Follow all Common Guide Lines of safety.2. Store control fluid in dry places only.3. Do not use pure copper any where in the control fluid

system due to catalytic effect in the decomposition of the phosphoric ester

4. Do not use Butyl rubber 11R is not compatible with control fluid. Silicon rubber since it severely impairs the air release capability of control fluid.

5. Biological decomposition of control fluid is difficult; control fluid is heavier than water and affects it adversely and therefore it should not be passed into the sewage system.

6. Avoid inhaling control fluid spray clouds or decomposition products.

7. Do not eat, smoke or drink when working with control fluid or parts in contact with control fluid.

8. Keep control fluid away from foodstuffs9. Keep control fluid away from skin, eyes and clothes.10. After handling control fluid, wash hands immediately11. If control fluid gets into eyes, sponge carefully and

rinse with large quantities of water. Obtain medical attention if irritation persists.

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12. If skin contact occurs, flush areas with water and wash with soap. Obtain medical attention if irritation persists.

13. If control fluid is swallowed, give large amounts of salty water to cause vomiting. If unsuccessful, tickle back of patient's throat with finger. Obtain medical attention if stomach discomfort persists.

14. All moisture should be eliminated from control fluid system otherwise; the control fluid forms acid components when in contact with water.

15. Chlorine presence in control fluid clauses erosion-corrosion at the edges of control components. Therefore all traces of solvents containing chlorine should be removed.

16. Before charging of control fluid system, confirm that all drains are closed.

17. In case of control fluid leakage it should be absorbed by using saw dust or oil binding granules and should be removed quickly.

18. For disposal control fluid may be mixed with saw dust and burned in incinerating plant or mixed in small quantities of used oil for burning.

19. In case of any major control fluid leakage, FIRE PROTECTION should be activated to give a complete shutdown to the control fluid system.

G-26-4

4. General Safety Guide Lines for Fuel Oil LSHS systems

1. Follow all Common Guide Lines as Per Chapter 1.2. Vents and drains of the system should be diverted to

the proper drains / sumps after checking sufficient space availability. If not then alternative arrangement should be made.

3. Open vents or drains (during charging or draining operation) in controlled manner to avoid any overflowing.

4. Confirm safe tank filling heights and reference heights before filling the tanks.

5. Do not charge the steam to the tank heating coils until the coils are fully submerged in the oil. The condensate from the coils should be monitored for oil content.

6. For first charging pumping rate should be maintained to minimum so that line can be thoroughly checked for

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any leaks. Subsequently the rate can be increased.

7. Maintain oil tank temperature well below its flash point.8. Rate of pumping should be within the maximum line

carrying capacity.9. Start the pump always with re-circulation valve full

open. throttle re-circulation valve after confirming flow & no oil leak.

10. All heat tracing circuits should be ON so that no part of the LSHS line becomes cold. This is to avoid solidification of the LSHS within the line.

11. While draining the LSHS tank care should be taken to monitor the tank temperature.

12. Transfer oil to other tanks as fast as possible to avoid wastage when a tank leak occurs.

G-26-5

5. General Safety Guide Lines for High Pressure and Temperature Feed Water / Steam Systems

1. Follow all Common Guide Lines as Per Chapter 12. During charging operation, drains (which are kept

open for warming up of the line) should be throttled so as to avoid heavy steaming in the area. Also it will help in closing the valve after the operation.

3. Take systems in service after thorough warming up so as to avoid hammering of the line.

4. Before draining the system confirm isolation from parameters such as pressure, flow, temperature etc.

5. In case of leakage in the system, utmost care to be taken if it is superheated steam as it is not visible. The only indication is from the noise.

G-26-6

6. General Safety Guide Lines for Pumps in Thermal Stations

1. Follow all Common Guide Lines as Per Chapter 1

2. Safety precautions to be taken before starting and isolating pump

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Take following precautions before starting pump.

All releases are cleared and area is cleaned/ cleared by all working parties (No oil drum, cotton waste, spanner etc are lying in the vicinity).

Protocol has been filled/ signed by the respective departments.

All fire-fighting equipment is in working condition.

Page party, Telephones and other modes of communication are available near the equipment to be started.

Nearby emergency exit door in operable condition.

Persons should be technically qualified and authorised to do the operations.

Safety apparels should be worn by the person starting/ inspecting the pump.

Pre Starting Guidelines

Check Pump and Prime mover alignment in uncoupled condition

Check suction / discharge piping to ensure no strain coming on the pump

Check direction of rotation of prime mover Check all piping connections Ensure all instruments are calibrated Tighten Foundation bolts and re-check

alignment. Couple the pump to the prime mover. Ensure replacement of lubricants/

lubricating oil (after flushing as necessary). Fix coupling guard. Check suction strainer for correct size. Prime the pump gradually. Attend leaks from joints/fittings (after the

pump attaining suction pressure). After completing all the above checks and

the pump housing attaining temperature close to that of the fluid, the pump shall be rotated to ensure free rotation.

Ensure that the discharge valve is fully closed and suction is fully opened.

Post Start Checks - The following shall be checked/observed:

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Check all instruments, observe readings at regular intervals and compare the performance of equipment with manufacturer’s data.

Check vibration readings for any abnormality and take necessary corrective actions.

Check temperature rise and pay attention to any abnormal sound from bearings.

3. Safety precautions to be taken for isolating the pump.

Pump should be in stopped condition. Prime mover of pump is in de-energised condition. Prime mover breaker of pump is in off /racked out

condition. (Pump auto standby is off while its breaker is being racked out).

cool down the pump as per manufacturer recommendations. (If required).

Isolate pump from suction and discharge sides by using right size of spanners if suction and discharge valves are manually operated.

Place releases tags at all the isolating points and respective breakers. Place release tags only after breaker is made off / valve is in closed condition).

Hand over the equipment to the working party.

G-26-7

7. General Safety Guide Lines for High Speed Rotary Equipment

1. Follow all Common Guide Lines of safety.2. Carry out Overhaul/preventive maintenance as per

the schedule given by the manufacturer.3. Carry out steam blowing of piping and flushing of

lubricating oil system for removal of foreign materials as per requirement.

4. Provide proper foundation as per the specifications.5. Fix couplings and coupling guards properly.6. Fix all instruments for alarms and trip and ensure they

are functional.7. Concerned departments should sign protocol before

the equipment is lined up and taken in service.

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8. Maintain proper housekeeping around the equipment so that there is no hindrance for operation and monitoring the equipment.

9. All safety devices and protections should be available.10. Local/remote stopping of the equipment should be

available, wherever applicable.11. All motor protection relays should be available for

alarms and trip service for motor driven equipment.12. All commissioning / decommissioning checks should

be completed and the required procedures should be followed.

13. All simulations should be removed and protections that were bypassed (eg: for uncoupled run of the motor) should be normalised before taking the equipment in normal service.

14. Ensure proper line up, normal lug. oil levels, correct lubrication oil, cooling water line up before taking equipment in service.

15. For steam turbines ensure that the steam quality (temperature, purity etc.) is matching the specified values before admitting steam to the turbine.

16. For steam turbine driven equipment, ensure that over-speed tests and other tests such as testing of safety devices and steam valves is carried out at regular and specified intervals.

17. When the equipment is in service it should be continuously monitored for any abnormality. Special attention is required to be paid to critical parameters such as vibrations, bearing temperatures, speed of the equipment, casing and shaft expansions etc. Equipment should trip automatically on protection or it should be manually taken out of service if any of the parameters reach values, beyond which operation of the equipment is detrimental to the safety of the personnel/equipment.

18. Maintain history of operation & maintenance and of tests and trials.

19. The operation/maintenance personnel should wear safety apparels (including earplugs when working in the high noise level zone in the vicinity of the equipment).

20. Only authorised persons should be allowed to operate and carry out maintenance jobs on the equipment.

21. No direct contact should be made with the rotating parts of the equipment.

22. Direction of rotation of the prime mover should be checked (by carrying out motor uncoupled run) wherever possible.

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23. Communication and fire fighting equipment should always be available in the vicinity of the equipment.

24. Carrying of matches, lighters and smoking should be prohibited in the vicinity of the Turbo-Generator. No hot work should be allowed in the vicinity of the Turbo-Generator.

25. All electrical and mechanical protections should be available for the Turbo-Generator. As Generator is filled with Hydrogen, special safety precautions need to be taken in this regard.

26. Emergency stopping/tripping should be available for all high-speed rotary equipment.

27. Whenever the equipment is to be given for maintenance it should be de-energised and properly isolated from all sources and should be properly tagged.

G 26-8

8. General Safety Guide Lines for Hydrogen Gas Systems

1. Follow all Common Guide Lines as Per Chapter 1.2. Operation personnel should be well acquainted with

hydrogen handling system, as hydrogen gas is highly explosive. Check gas purity cylinder wise before use.

3. Detailed operation procedure and checklist of the hydrogen filling and purging should be followed.

4. Proper instrumentation should be available in hydrogen gas system.

5. Purity of gas should be continuously monitored.6. Adequate ventilation should be available for gas

escape in case of leakage.7. Gas leak detection system should be available.8. Fire fighting equipment should be available nearby.9. No welding should be permitted without proper

approved permit.

G 26-99. General Safety Guide Lines for

Various valves in Thermal Stations1. Follow all Common Guide Lines of safety.2. Check mode of operation of valve i.e. motor operated,

pneumatically operated, hydraulically operated manually operated etc.

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3. Check the position of valve i.e. close/open/in between and confirm with remote and local feed back/ check back. If the positions are not matching inform respective maintenance department.

4. After or during the operation of any valve if any abnormality like gland leak etc. is observed then restore the original position of valve or keep the valve in position where the abnormal behaviour is minimised and inform respective maintenance department.

5. Check the housing of the area in the vicinity of valve to be operated, if not proper then inform respective maintenance department or Main Control Room.

6. Check the type of valve i.e. isolating, control etc.7. Confirm valve is easy to operate.8. Gate valves are always to be operated in full open or

full close condition.9. Avoid frequent operation of high-pressure valves as

for as possible to avoid any gland leak.10. For Motor Operated Valve Confirm from working party or Main Control Room

whether valve operation is to be done electrically or manually.

For electrical operation check the direction of operation by giving an impulse command if possible and if direction is ok then operate it fully.

If manual operation is to be done then first confirm that motor breaker is off and then valve can be operated in the similar way as that of manual valve as given below for manual valves.

11. For Pneumatically Operated Valves Check instrument air supply isolating valve is open and

thus air is available for valve operation. Reset pneumatic air lock, if any and check the direction

of valve by giving small command from remote or local and then valve can be further operated from remote or local as per requirement.

If valve operation is not possible pneumatically then it can be done manually in the same as given for manual operating valves by isolating its instrument air supply.

12. For Hydraulically Operated Valves Check hydraulic circuit is properly lined up and enough

hydraulic pressure is available for valve operation. Check for any leakage during or after the operation of

valve in hydraulic circuit.13. For Manually Operated Valves Arrange right size of spanner as per size and location

of valve and also arrange hand gloves and other of 147

safety accessories as per specific requirement of the valve to be operated.

Fix the spanner in such a way so that enough space is available for spanner movement and also confirm that spanner grip is proper and there is no slipping or sliding of spanner. This can be confirmed by applying smaller force initially. Change the spanner if required.

Gradually start operating the valve (close/open as per requirement).

G 26-10

10. General Safety Guide Lines for Handling Fuel Gas Systems

1. Follow all Common Guide Lines of safety.2. Gas line filters, separators and line vents and drains

should diverted to vent stack or at higher elevation.3. Smoking, welding or cutting job should not be carried

out in vicinity of gas pipeline, without chemist’s confirmation that explosive test is nil. Also fire cell personnel should be present at site with necessary fire fighting equipment.

4. If welding or cutting job is required to be done in the vicinity of gas pipeline, gas line should be covered with asbestos sheet or other non-inflammable material.If welding or cutting job is to be done on gas line, it must be properly purged with Nitrogen.

5. Inflammable material like wooden plates, plastic sheets, cotton waste and sawdust should not be stored near gas pipeline.

6. Healthiness of gas leak detection system should be checked periodically.

7. ‘No Smoking, welding or cutting’ sign board and ‘Emergency telephone number of fire department and control room’ should be displayed in vicinity of gas pipeline.

8. Do not allow diesel engine without silencer to run in the vicinity of gas pipeline before confirming that explosivity is nil.

G 26-11

11. General Safety Guide Lines for Lub. Oil Systems

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1. Follow all Common Guide Lines of safety.2. Do not store inflammable material like wooden plates,

plastic sheets, cotton waste and sawdust near lubrication oil system.

3. Check healthiness of fire fighting system for lub. oil system periodically.

4. ‘No Smoking, welding or cutting’ sign board and ‘Emergency telephone number of fire department and control room’ should be displayed in vicinity of lubrication oil system.

5. Leakage or spillage of oil should be cleaned and attended immediately.

6. Leaked oil should be prevented from coming in contact with any high temperature system or electrical equipment.

7. Sudden rise of oil temperature or any drop in lubricating oil tank level should be checked immediately.

G 26-12

12. General safety guidelines for handling chlorine leaks.

Chlorine is a toxic gas. It is of dense greenish yellow colour and pungent odour. It is 2.45 times heavier than air. It is a strong oxidising agent and is soluble in water. In case of gas leak, the presence of gas can be marked with liquid ammonia (NH4OH) with which it will form a thick white mist.

The persons trained in handling chlorine gas leakage should only attend such operation by using SCBA (self-contained Breathing Apparatus sets) and equipment from chlorine emergency kit.

GENERAL INSTRUCTIONS -

At following events checks should be carried out for chlorine gas leakage with ammonia solution.1. After unloading the chlorine gas cylinder.2. Before removing cylinder bonnet cap.3. Before opening cylinder valve cap nut.4. While opening cylinder valve after connecting cylinder on

header.5. Before disconnecting cylinder from header after cylinder is

empty.

IN CASE OF CHLORINE GAS LEAKAGE – of 147

1. Alert persons working in the vicinity of Chlorination plant.2. Sound Emergency alarm.3. Try to close chlorine cylinder valve only after wearing air

mask/air canister.4. Take out the person affected by Chlorine gas to open air.5. Request for medical attention.6. Always ensure all chlorine gas leak detectors are available

and their supply is on. follow the proper operation procedures while connecting /

disconnecting the cylinders. after closing the cylinder valve, ensure proper flushing of

chlorine in the pipeline before disconnecting the cylinder. do not pour water on liquid chlorine. windsock should be in proper condition. in the event of a chlorine gas leak, try to remain away from

the wind direction. do not allow any gas welding without

explosivity test. Provide chlorine scrubber system where applicable.

G-27 OFFICE WORK

(1) Lifting and carrying

(i) Serious strains often result from improper handling of boxes and bundles of office supplies, ledgers, portable filling cases and office machines. Lifting should be done with the back erect by using the more powerful leg muscles.

(ii) Large boxes or bundles of supplies should be moved by a hand truck, or unpacked and delivered in smaller parcels.

(iii) Bulky objects should not be carried in such a way as to obstruct the view ahead or interfere with free use of handrails on stairways.

(2) Slipping, Tripping and Falling

(i) Water, oil or other liquid spilled on floors presents a dangerous slipping hazard and should be cleaned up at once.

(ii) Where floor surface is treated, it should be done with a slip-resistant preparation. Waxing of floors should be avoided.

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(iii) Loose objects such as matches and pencils should not be left on stairs or floors as they may cause slipping and bad falls.

(iv) Extension cords should not be strung across aisles or walk ways where people may trip or fall over them.

(v) Open desk or file drawers and desk slides constitute a serious hazard as persons may strike or fall over them.

(vi) Avoid standing on boxes,chairs or other makeshift supports to reach objects overhead. Use a safe ladder.

(vii) Open doors slowly to avoid striking anyone on the other side.

(viii) Avoid running in aisles and corridors. Use the handrail when going up or down stairways.

(ix) In walking, particularly at blind corners, always keep to the right.

(3) Office Equipment

(i) Serious injury may be caused by filing cabinets that are not properly balanced or anchored. Opening of overloaded upper drawers, particularly more than one at a time, may tip over the cabinet.

(ii) All exposed moving parts of power-driven office machines should be covered with suitable guards. Operators should be instructed in the safe use of these machines.

(iii) While using power-operated office machines, avoid touching any grounded metal object such as a radiator or water pipe since short circuits sometimes develop in such machines. Apparent defects in the cords should be reported and promptly repaired. Power Operated machine should

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be disconnected each evening or before the office is closed.

(4) Sharp or pointed Objects

(i) Do not use pins to fasten papers together. Use paper clips or stapling machine.

(ii) Do not carry pointed objects such as uncapped fountain pens and pencils with the point exposed in the pockets, attached to the clothing or through congested aisles or working areas. This warning includes knives and scissors also.

(iii) Paper cuts on fingers, hands or lips frequently occur when handling paper or sealing envelopes. Gummed strips of envelopes should be moistened with suitable device and not with the tongue. Avoid opening envelopes with fingers and sliding hands along edges of paper.

(iv) Do not use safety-razor blades for cutting paper, sharpening pencils or other cutting operations unless secured in a holder into which the blade may be drawn out of sight when not in use.

(v) Do not keep razor blades or other sharp instruments loose in desk drawers/ pockets.

(vi) Broken glass or other sharp objects should never be placed in wastebaskets but safely wrapped, plainly marked and left beside the wastebasket for removal.

(vii) Keep fingers of your free hand away from cutting edge of paper cutters. The cutting knife should never be left raised while unsupported and should always be closed when not in use.

(viii) Each employee should know nearest first-aid kit and its proper use. Every injury, no matter how trivial it may seem, should receive prompt first-aid treatment.

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(5) Personal computers – The wiring for the PCs should be neatly arranged and tied properly so as not to have overheating at the backside of computer and prevent fall due to tripping over them or pulling.

(6) Press Pins for velvet notice boards should not be allowed to fall on floor as they may be stepped on by any person.

(7) Glass top kept on the tables should be fixed with proper locking corners so that it will not fall due to sliding.

(8) Ensure no object is left behind on tabletop before lifting the glass.

(9) While opening drawers of the tables it should be pulled out slowly as the latch for the drawer may not be properly engaged and the drawer may fall down on feet.

(10) Discard old and scrap stationary papers, card board boxes etc immediately as they are potential fire hazards and presents possibility of termite growth.

G-28 ELEVATORS:

1) Before operating the lift for going down or up ensure proper working of the telephone in the lift.

2) Train all personnel about emergency lifting of the elevator cabin manually and opening of the door at proper floor level for rescuing of persons inside.

3) Wherever traffic through lifts is heavy, the stand by arrangement of staircase must always be made obstruction free for use particularly during major maintenance work at the station.

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E ELECTRICAL OPERATIONS

E-1 GENERAL SAFETY PRECAUTIONS

(1) ALL VOLTAGES SHALL BE CONSIDERED DANGEROUS EVEN THOUGH VOLTAGE MAY NOT BE HIGH ENOUGH TO PRODUCE SERIOUS SHOCK.

(2) ALL ELECTRICAL CIRCUITS ARE TO BE TREATED AS LIVE AND NO WORK (MAINTENANCE, REPAIRS, CLEANING) IS TO BE CARRIED OUT ON ANY PART OF

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ELECTRICAL APPARATUS OR CIRCUIT UNLESS SUCH PARTS ARE

(a) Dead

(b) Isolated and all practicable steps taken to lock off from live conductors.

(c) Efficiently connected to earth at all points of disconnection of supply to such apparatus, or between such points and points of work.

(d) Released for work by issue of release or other tags.

(e) Checked for de-energisation.

E-2 AUTHORISATION FOR DOING WORK

(1) Maintenance, repair and construction work on electric circuit or apparatus shall not be done until after making sure that working conditions are safe and obtaining proper authorisation for doing the work.

(2) “Proper authorisation” means notification by the person in charge that a particular job is to be done and also the approval by the person or persons responsible for the equipment to be worked on.

(3) No person shall begin work on any circuit or equipment until clear and complete instructions are issued by the supervisor to do so.

E-3 PROTECTIVE EQUIPMENT -

USE AND CARE OF RUBBER PROTECTIVE EQUIPMENT

(1) Rubber goods such as gloves, mats etc. may be used for protection on electrical circuits.

(2) All rubber goods shall be of high-grade material, bearing ISI mark and carefully inspected, stored and cared for.

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(3) When not in use rubber should be shielded from sunlight, heat, ozone and oil.

(4) Rubber will age or oxidise quickly at points of distortion. Rubber gloves should not be worn wrong-side out. Blankets should be rolled rather than folded.

(5) Rubber gloves shall not be continued in use more than specified number of days without an approved electrical test.

(6) Rubber gloves shall be worn during the following operations or conditions.

(a) Working on 220 to 5000 volts circuits and also on lower voltage circuits where safety requires gloves because of presence of moisture, grounds and other conditions.

(b) Working on street lighting circuits.

(c) Stringing wire near live 220 to 5000 volts circuits.

(d) Raising or lowering poles near 220 to 5000 volts circuits.

(e) Connecting, disconnecting or replacing energised fuses with tongs and switch sticks.

(f) Working on circuits within reaching distance of 220 to 5000 volts circuits.

(g) Operating GODs or disconnects by handles.

E-4 WORKING ON ELECTRICAL LINES:

(1) Work close to energised H.T. equipment shall be carried out only with explicit permission from the Head of the Department and under his/her direct supervision with adequate safety precaution. Whenever practicable de-energise the HT equipment for facilitating work in the vicinity.

(2) When working near live lines or apparatus, each person should plan moves and take extreme care in moving from one position to another.

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(3) Where impractical to erect barriers between personnel at work and live parts within reach of their hands and objects being handled, continuous watch shall be kept by the Supervisor or someone specifically designated for that purpose.

(4) When a truck-winch line or derrick is used near live parts, all workmen except the driver should stay away from the truck. Driver should see that the truck is clear from live lines before leaving and entering the truck.

(5) Whenever it is required to inspect an energised equipment or work close to it, the following minimum safe clearances must be maintained.

Voltage Range V Minimum Safe Distance mm750 – 3,500 307

3,501 – 10,000 61410,001 – 50,000 921

50,001 – 100,000 1535100,001 – 250,000 3070

All inspection or work must be carried out without approaching live parts nearer than the above safe distances. All parts of an insulator like arcing horns, grading rings etc. shall be treated as fully live when the conductor is live.

(6) Outdoor work in the proximity of live H.T. equipment shall be discontinued if signs of adverse weather conditions like high humidity, thunder, lightning or rainfall are encountered.

(7) Take a caution order when carrying out inspection or work adjacent to an energised equipment or line, so that such an equipment is not auto re-closed or charged by the operating party subsequent to tripping without obtaining clearance from the working party.

E-5 WORKING ON DEAD LINES AND EQUIPMENT; GROUNDING OF LINES AND EQUIPMENT

(1) Before starting any work on dead lines or equipment where there is a possibility of their becoming energised from any source, such line or

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equipment should be short circuited and grounded between the locations of work and all possible sources of energisation.

(2) Conductors to be grounded should be checked for potential by an approved method before the ground is installed.

(3) Temporary grounding cables shall be flexible standard copper not less than No. 1/0 SWG (0.1 sq. inch) and shall be equipped with approved clamps at each end.

(4) Grounding cables should be inspected before each use.

(5) When grounding lines or equipment, the connection to the ground shall be made first and that to the circuit or equipment last. In removing grounds, first remove the connection to the circuit or apparatus.

(6) Ground shall be placed on all phases even if work is to be carried out on one phase only.

(7) For work on lines, grounds shall be placed at nearest tower on each side of the point of work but in no case should be more than six spans apart. As an additional safety measure, line should also be grounded on the tower where the work is to be carried out.

(8) When work is to be carried out on lines of all insulated construction and grounding point is not provided at the point of work, temporary grounds shall be connected at point of work to an efficient portable earth stake driven into the ground. The line shall also be grounded at the nearest line grounding point on either side of the point of work.

(9) Where two or more crews are working independently on the same line or equipment, each crew shall properly protect themselves placing their own temporary grounds.

(10) Conductors used for temporary grounding shall be kept clear of the working area and the workmen should be warned not to handled those conductors without adequate safety precautions while they are connected to H.T. equipment or lines.

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(11) The use of chains and defective grounding devices is prohibited.

E-6 WORK ON DOUBLE/FOUR CIRCUIT OVERHEAD LINES WITH ONE CIRCUIT/ONE SIDE LIVE

(1) To distinguish dead circuits from live ones, green flags will be fitted on the towers on the side of the dead circuit in case of double/four circuit towers. Flags of any other colour shall not be used for indicating a dead circuit.

(2) Flags will be removed only after work is finished and temporary grounds have been removed.

(3) Procedure to be followed for working on Multi- Circuit towers.

(a) Work planned on multi-circuit towers should be discussed with line staff before commencement of work for methodology and safety aspects.

(b) Walkie-talkie sets or Mobile phones shall be available with ground as well as tower crew for effective communication between them. While carrying out the work, ensure proper communication between staff at ground level and on the tower.

(c) While carrying out any work on ‘Bottom Circuit” of multi-circuit towers, obtain ‘Caution Order’ for the ‘Top Circuit’ (working in the vicinity of the top circuit) and Release Order for the Bottom circuit.

(d) While carrying out any work on ‘Top Circuit’ of multi-circuit towers, ‘Release Order’ for both the ‘Top and Bottom Circuits’ shall be obtained and both the circuits shall be effectively grounded on either sides of working place with flexible line grounds before commencing the work.

(e) All line crew shall ensure use of ‘Fall Safe equipment’. Utmost care shall be taken by the first person climbing the multi- circuit tower by carrying rope with him as he shall not have advantage of ‘Fall Safe equipment’.

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(f) Line crew shall use ‘Full Body Harness’ while carrying out any work on multi-circuit towers and anchor themselves firmly as soon as they reach the required height of work.

(g) Line crew shall be instructed to climb slowly with a steady speed and should rest for couple of minutes at rest platform wherever provided.

(h) After completing the work, working party shall ensure removal of flexible grounds and also ensure that all men and material are away from the line. Subsequently necessary Release/Caution Order can be cleared.

(i) The Engineer, who is holding the release/caution order, shall remain available till completion of work at work site of the multi- circuit tower with vehicle wherever possible.

E-7 INSPECTION OF EQUIPMENT ON LIVE LINES

(1) Inspection will be carried out from within the body of tower.

(2) No tool shall be taken up the tower.

(3) No person shall climb above the anti-climbing device unless under observation by another at ground level.

E-8 LINE WORK ON POLES AND TOWERS

(1) Before climbing any elevated structure, every employee shall first assure that the structure is strong enough to sustain his/her weight safely.

(2) If poles or cross arms are apparently unsafe because of decay or unbalanced tensions of wires on them, they shall be properly braced or guyed.

(3) Linemen shall wear their safety harness while working on the poles and towers.

(4) Wire hooks shall not be attached to linemen’s belts or safety straps.

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(5) Safety straps should not be placed above the top cross arm when he is at the top of the pole.

(6) No tools above 0.3 meter in length shall be taken up the tower when both the lines are alive.

(7) All light equipment and tools to be used aloft should be raised and lowered by means of hand-line and canvas bucket or other suitable container. Men on the ground should stay clear of overhead work to prevent being stuck by falling objects.

(8) Tools and materials should not be thrown from the ground to a lineman working aloft nor should lineman throw tools and materials from above to the ground.

(9) No person shall work in such a manner that his arms or any tools extend beyond the body of tower when working on the live side.

(10) Broken insulators or other sharp-edged material shall not be left in vacant lots, along the right of way or in the location where the hazard of cutting feet could be caused for people or animals.

(11) When stringing wires across streets and highways, avoid interfering with traffic or causing injury to workmen or pedestrians. Danger signs should be erected on both sides of the work location and where conditions warrant, flagmen should be stationed.

(12) Hand lines, materials, tools or equipment must not be scattered round streets, sidewalks, highways, etc. but must be kept in a neat, orderly manner, where they will not be liable to cause accident.

(13) A lineman working on live wires should, wherever possible, work from below the wires.

(14) In handling wires on a pole, they should be raised or lowered with a dry hand line and extreme care exercised to prevent them from coming in contact with a live line or equipment.

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E-9 TREE TRIMMING

(1) The public shall be protected against hazards of tree trimming along public streets and highways by placing danger signs and signals.

(2) Before climbing a tree, the trimmer should look it over carefully to decide how best to climb it, the best locations from which to work, and the ground area where bush and limbs may be safely dropped.

(3) Before climbing, the limbs should be carefully inspected to make sure that they will hold the trimmer’s weight. Dead or decayed limbs are not safe to support any weight.

(4) Axes shall not be used aloft; always use saws or bill hooks.

(5) Avoid dropping tools from a loft to the ground. All tools should be raised and lowered by hand lines in such a way as to avoid touching hot conductors.

(6) Parts of trees in contact with live wires should be handled as live wires.

(7) Before cutting down a tree, all limbs should be cut off for a sufficient height to avoid striking electric lines. Where there is danger that the tree may strike and damage property, block and tackle should be used to control the direction of fall.

(8) Felling operation, once started, should be finished before the crew leaves for the night or for lunch hour.

E-10 RIGHT-OF-WAY CLEARING AND TRIMMING

(1) A number of hazards to be guarded against for these jobs are

(a) When walking through slush, use ankle high canvas boosts to prevent injury to feet from broken insulators, thorny undergrowth, shells, etc.

(b) Take extreme care while handling axes, brushing hooks and other sharp cutting tolls.

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(c) Trees should be carefully felled to prevent their falling on transmission lines or adjacent buildings.

(d) Be careful of grass or forest fires and avoid starting a fire.

E-11 PATROLLING LINES

(1) Emergency line patrol, trouble shooting on transmission lines and similar work should always be done with the greatest caution. Patrolmen should be particularly alert at night to avoid walking into fallen wires or metal fences, which may be energised by fallen conductors.

(2) Be careful with lighted cigarettes and matches that may cause a fire along transmission rights-of-way. Break matches and crush cigarette stubs into earth on discarding.

(3) Patrolmen should be alert of poisonous snakes and stumbling hazards.

E-12 SWITCHING OPERATIONS

(1) A record of switching operations will be entered in station logs.

(2) All switches and disconnects should have lettering or sign boards to indicate the circuit they control.

(3) When releasing electric circuits, breakers or equipment for work on them, the associated breaker and disconnecting switches shall be opened in the following order.

(a) The circuit breaker will be opened first.

(b) Then the disconnecting switches will be opened, but before operating the disconnects it shall be made sure that the breaker is open.

(4) After opening disconnects and air break switches, checks carefully to see that all blades are in full open position.

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(5) If the circuit is controlled by an automatic re-closing breaker, the re-closing mechanism shall be made inoperative.

(6) Disconnects shall be closed in firm positive manner, using sufficient force to make full contact of blades.

(7) Before removing fuses, switches should be opened, if provided. Removing fuses from an inductive circuit carrying current without opening the switch is hazardous.

(8) Removal of fuses from circuits, where no switches are provided should be done with approved fuse-pullers.

(9) Interlock system should not be made inoperative unless authorised by the Station In-charge.

E-13 RECEIVING STATIONS/SUB-STATIONS:

(1) Danger signs should be placed on all enclosures of high-voltage equipment and wherever necessary to warn persons of the presence of high-voltage equipment.

(2) Gates in switchyard fences and doors to bus compartments and other enclosures containing live equipment or other hazards should be kept locked at all times except when people are working inside.

(3) When carrying ladders, pipes, conduits, reinforcing rods and other long material into stations, switchyards, bus compartment rooms and other places, where there is danger of touching live parts, the material should be held by two men, one at each end, and carried in the hands and not on the shoulders.

(4) When working in the vicinity of fuses, circuit breakers or buses use every precaution to avoid injury from arcing.

(5) Before doing any work on rotating equipment it should be shut down and properly disconnected from power source, except when necessary to

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change commutator brushes, clean with compressed air or add oil.

(6) Care should be taken to prevent clothing, wiping cloths, waste dusters, oil cans or tools from catching in the moving parts of machinery.

(7) When using compressed air on live electrical machinery, an insulating hose and nozzle should be used. Dust-proof goggles should always be used when cleaning with compressed air. Compressed air should never be used for cleaning or dusting clothes or any part of body.

(8) If personnel are working on H.T. (voltages above 600 V) equipment the area safeguarded for work shall be cordoned off by tying red buntings of 9” to 12” width all round and danger boards shall be fixed within the safeguard area at various locations with the inscription facing the safe working area to warn personnel not to cross over to the area with live equipment during the progress of work.

(9) The metal bodies of portable equipment or hand tools shall never be grounded by connecting them to the main station ground to which the neutrals of H.T. equipment are connected. Separate ground should be provided for such equipment.

E-14 PUMPED STORAGE UNITS

1. Operation of pumped storage units, although fully automatic through PLC, may need manual interface.

2. Manual operation is also possible for checking each step in PLC sequence.

3. While in manual mode or local auto mode machine need not be kept in hot standby mode for more than half a minute due to high vibration problem in penstock.

4. Before draining of draft tube and penstock of pumped storage units, it is necessary to have maximum number of drainage and de-watering pumps in working condition since these drains are located below ground level.

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E-15 GIS SWITCHGEAR AND SF6 CIRCUIT BREAKERS

SF6 gas, commonly used in GIS Switch gears & SF6 breakers, is considered to be an inert gas inhalation of very high gas content can cause headache, giddiness, unconsciousness and suffocation due to lack of oxygen. Degraded products may cause irritation at high temperatures. The gas is approximately five times heavier than air, colourless and odourless. Presence of SF6 gas, while being filled in the tank, is difficult to identify.

The following precautions are normally observed.

i) Have good ventilation at work place.ii) Substitute air for the gas before entering the tank.iii) Donot touch the decomposed by-products.iv) Use rubber hand gloves.v) Clean the by-products with a vacuum cleaner.

E-16 STORAGE BATTERIES

(1) When making electrolyte for storage batteries always pour acid into water. The reverse method (i.e. pouring acid in water) may cause an explosion. Suitable goggles or face shields should always be worn when making electrolyte.

(2) Smoking and use of matches or other open flames are not permitted in battery rooms or while inspecting, filling testing or handling batteries. Vents in covers of battery should be clear.

E-17 TRANSFORMERS

(1) Before starting work on any transformer, ensure both electrical and physical isolation. Take care to prevent any possibility of transformer being made live through synchronising or voltmeter plug.

(2) Before commencing any work on a transformer, the transformer winding should be discharged to ground. In case the transformer is isolated from the supply by a single point of disconnection e.g.

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fuse disconnects or disconnects only, the transformer shall be safeguarded by shorting the phase terminals together and connecting them to ground before commencing any work.

(3) Whenever transformers are replaced the new transformer should be checked carefully for voltage, polarity and phase rotation before taking into service.

E-18 INSTRUMENT TRANSFORMERS.

(1) The cases of all instrument transformers should be grounded.

(2) Current transformer secondary should never be open circuited when current is flowing in the primary.

(3) The secondary circuit of current transformers should be connected to ground at all times when the transformer is in service.

(4) Potential transformer secondary should never be shorted.

(5) The low voltage winding of potential transformers should always have one side permanently and effectively grounded.

E-19 GENERATORS

1) Generators in the system have different specifications and accessories as per the station conditions.

2) When work is to be carried out on a generator, the generator must be at standstill and disconnected from the grid and isolated properly. Similarly before working on connected PT / CT circuits, proper isolation on primary and secondary side must be insured.

3) For working on generator auxiliaries, separate release orders as per station equipment list are issued.

4) The generators should be released as per station operating procedures. Whenever particular

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isolations are required such as draining of inlet bends, stopping of auxiliary pumps, making emergency stop activated & keeping the machine control on local etc. These should be done in consultation with working party.

5) Before working on slip rings for cleaning or brush replacement, rotor earth fault protection needs to be made inoperative.

6) Before bypassing any protection, proper authorisation from station in-charge is to be obtained and informed at the time of normalising.

7) Make CO2 protection inoperative before opening the generator door.

G-20 WORK ON GENERATOR WINDINGS

(1) The generator shall be at rest.

(2) The field circuit will be opened and isolated.

(3) The valve or valves controlling the supply to the turbine shall be locked in closed position.

(4) Before commencing any work on a generator with an ungrounded neutral, the windings shall be discharged to ground.

E-21 STATIC CAPACITORS

(1) Every capacitor shall be treated as hot until proved otherwise. Capacitors store energy and are not necessarily dead when disconnected from the power source. Once charged, a capacitor may retain this charge for several hours after it has been disconnected.

(2) Before starting work on capacitor banks, open all cut-outs or disconnecting devices to the capacitors.

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Wait for a least five minutes for the internal resistor to reduce the voltage. Next using a hot stick, short circuit and ground all terminals of the capacitor. The short-circuiting grounding jumpers should be left attached while work is being done on the capacitor.

(3) To place the capacitor banks in service, first remove the jumpers with hot sticks, then close the cut-outs.

(4) The capacitor container acts as one terminal and as it is insulated from earth through bus support. It is live unless the bank is isolated and safeguarded.

E-22 LIGHTNING ARRESTERS

No work shall be done on a lightning arrester unless it is disconnected from the live circuit discharged and grounded at both the line and ground terminals.

E-23 UNDERGROUND SYSTEMS

(1) When manhole cover is removed, properly constructed railings and warning signs must guard the hole. Warning flags by day and red lights by night should be placed at all open manholes, excavations and on tool carts located on public right-of-way or where exposed to traffic of any kind. The warnings should be placed in such a manner as to be visible from a distance and give persons or vehicles ample time to avoid the obstructions.

(2) If the Supervisor considers that manhole working conditions warrant additional precautions, a person should remain within easy calling distance of occupant to render assistance in case of emergency and also to warn traffic of existing danger.

(3) Before any one enters a manhole, ascertain that the air is safe enough. If harmful gases are present, they should be expelled and frequent checks made during work progress to determine the condition of the air.

About 10% of carbon-di-oxide will extinguish most flames. Before entering the manhole, it should be

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kept open at least 10 minutes even if air is expected to be safe. Look out for the smell of Hydrogen sulphide gas. Tie a rope round the worker entering the manhole.

(4) Never step on live cables even though they are enclosed in lead sheath. Tools and materials should not be allowed to rest against the sheath of live cables.

(5) Open flames and smoking should be avoided in manholes.

(6) Solder and compound pot should be kept where they will not spill into the manhole if the pot is upset.

(7) Before any work is started on a cable in a manhole, the cable should be checked by the Engineer for duct number, location identifying tag and by other approved methods to make sure that work is started on the appropriate cable only.

(8) After completing cable work in a manhole, the cable should be properly tagged and identified for exact location by a sketch, and this information be kept in cable identification cards.

(9) A person in a manhole shall carry out no work, where space is restricted, unless someone else is present nearby.

E-24 RING MAIN UNITS (RMU):

1. All earth switches in a Ring Main Unit can be closed only after opening respective line switch disconnector.

2. Cable back charge indicators are provided to draw attention to avoid accidentally grounding a charged cable. Also cable back charge indicator voltage is used for checking phasing of both incomers safely.

3. SF6 gas indicator shows safe operating pressure.

4. The sheet metal cover of incomer cable compartment and fuse compartment can be removed only after the respective earth switch is

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closed, and vice versa i.e. ground switch cannot be opened unless the covers are in place and locked.

E-25 AIR BLAST CIRCUIT BREAKERS

High voltage air blast circuit breakers close back automatically when the air pressure drops to a pre-set value. The breaker should be isolated whenever the equipment connected to this breaker or the breaker itself is given out for maintenance. The isolation should be effected without time delay after the breaker is opened out.

E-26 SCADA

1. SCADA systems are used for monitoring and control of switchyard equipment at Generating and Receiving Stations. They also provide a user interface for the purpose of monitoring and controlling Generating Units.Every SCADA System has the following essential components.

Master Computers along-with peripherals Front End Processors RTU along-with Input/output modules

2. All the above components are located in the Control Rooms, Switchyards or in Turbine / Generator rooms. General safety precautions as outlined in safety manual should be followed while working on this equipment.

3. As the system uses electronic circuits, it is essential that proper safety strap is wrapped on the hand (with other end connected to ground) of the personnel while working on these circuits.

4. The Master Computers and Front End Processors use an auxiliary supply of 230 V AC.

5. The peripherals of the Master Computer, RTU and the input/output modules use an auxiliary supply of 48 Volts DC. This voltage is also used for contact wetting purpose for digital inputs. The

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transducers/energy meters use an auxiliary supply of 48/110/220 Volts DC.

6. Positive terminal of Station DC Voltage(230/110 /48 Volts) is routed through the contacts of output relays connected to Digital Output Cards of SCADA for Trip and close commands.

7. CT inputs (1 Amp or 5 Amp) and PT inputs (415 / 110 Volts) are wired to the transducers/energy meters for the purpose of providing analogue parameters on SCADA.

8 It is essential that proper drawings of the panels, circuits and Interconnecting cable schedule to identify source and destinations of the cables are available with the personnel before starting any work. A written step by step procedure for the job to be done on SCADA equipment, approved by the concerned authorities, should also be available with the working personnel.

9 The safety tagging rules are applicable for any work on SCADA equipment. Maintenance Engineer of the Division/Station will request for appropriate safety tag and obtain it from the concerned authority before actual work is started.

10 The personnel carrying out the work will inform the Maintenance Engineer of the division at least two days in advance providing following details:

The name/ number of the equipment Time duration of work Specific jobs to be performed

(a) Maintenance Engineer in turn will request the operating authority to issue the appropriate safety tag.

(b) Personnel carrying out the task will record above details in SCADA register kept in the Control Room.

(c) If the task involves testing of control outputs, relevant control output links will be dropped prior to the testing.

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(d) Record the results of the tests carried out, if any. Confirm in presence of maintenance engineer that the system is functioning normal.

(e) Make the relevant output links through after confirming that there are no pending commands and there are no “Command Fail” messages in the alarm list indicating that an unwarranted Command was issued.

E-27 COMMUNICATION

1. All the communication equipment are located in the Carrier room, Relay room or in Control room. General safety precautions of this safety manual should be followed while working on this equipment.

2. As the system uses electronic circuits, it is essential that proper safety strap is wrapped on the hand (with other end connected to ground) of the personnel while working on these circuits.

3. The 48 V battery chargers for the above equipment use an auxiliary supply of 230 V AC.

4. The peripherals of the Fibre Optics system, Microwave system and PLCC and Broad Band system use an auxiliary supply of 48 V DC. This voltage is also used for contact wetting purpose for digital inputs. The 4 Wire E and M circuits use an auxiliary supply of 12/24/48 Volts and the protection coupler modules use an auxiliary supply of 110/220 Volts DC.

5. CT and PT inputs and switchyard conditions are wired for the purpose of providing analogue and digital parameters on SCADA and SMS RTU. These parameters are in turn wired with the data module of FOP/MW/PLCC/Broad Band system.

6 It is essential that proper drawings of the panels, circuits and Interconnecting cable schedule to identify source and destinations of the cables are available with the personnel before starting any work. A written step by step procedure for the job to be done on communication equipment, approved by the concerned authorities, should also be available with the working personnel.

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7 The safety tagging rules are applicable for any work on communication equipment. Maintenance Engineer of the Division/Station will request for appropriate safety tag and obtain it from the concerned authority before actual work is started.

8. The personnel carrying out the work will inform the maintenance engineer of the division at least two days in advance providing following details:

The name/ number of the equipment Time duration of work Specific jobs to be performed

(a) Maintenance engineer in turn will request the operating authority to issue the appropriate safety tag.

(b) Personnel carrying out the task will record above details in communication register kept in the Control Room.

(c) If the task involves testing of control outputs, relevant control output links will be dropped prior to the testing.

(d) Record the results of the tests carried out, if any. Confirm in presence of maintenance engineer that the system is functioning normal.

(e) Make the relevant output links through after confirming that there are no pending commands and there are no “Command Fail” messages in the alarm list indicating that an unwarranted Command was issued.

9 Working on transmission tower joint boxes may require outage of 220/110/33/22 KV line. The working parties will co-ordinate the outage requirements with the concerned departments after providing details of work.

10 No person should go near any equipment or inspect or do any kind of check or test without

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taking proper permission from the operating authority however small the work may be.

W Work Permit System :

1. All activities such as working at heights fragile roof tops, confined spaces or any other work in operational area that involves generation of hot work, open flame, spark etc. are considered as critical & safety officers clearance will be sought.

2. Format for work permit will have a specific checklist to indicate various criticalities against each work.

3. These formats may vary from division to division according to the nature and scope of work without diluting the safety precautions to be taken for each type of work.

ST-1 FUNDAMENTAL SAFETY TAGGING RULE

All lines and equipment must be considered energised unless tags are placed to designate other conditions.

ST-2 REQUIREMENTS OF SAFETY TAGGING SYSTEM

(1) The Safety Tagging System is intended to meet three principal requirements of safety.

(a) Protect personnel at work under all conditions.

(b) Protect equipment from damage.

(c) Designate abnormal conditions.

ST-3 DESIRABLE CHARACTERISTICS OF TAGGING SYSTEM

(1) The tagging system should apply with equal force to both electrical and mechanical equipment, broad enough to cover every condition that can arise and applicable throughout the entire organisation.

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(2) The system should be easily understood and reasonably simple in application. A system that is too elaborate becomes burdensome and encourages unsafe short cuts. Simplicity, however, should not be obtained at the expense of safety.

(3) It should be workable from viewpoints of both the issuing authority and workmen.

(4) Maximum protection will be obtained by the use of more than one type of tag, each of which has a single purpose. The name of each tag should indicate its general use. Each tag should be of different colour.

(5) In order to obtain uniformity in safety and tagging practices, each station should incorporate in its station rules, the step by step operations to safeguard every station equipment for maintenance work and should list the locations where tags are to be located. In case of abnormal switching operations or conditions of work regarding special tagging system, a scheme will be prepared in advance in consultation with Load Despatch Department/Division head.

(6) To ensure correct functioning of the tagging system, the placement and removal of tags will be the sole responsibility of the operating organisation in charge. Similarly, tags issued to a working party should be handled by the person concerned only. Any person delegating the authority to handle the tags to an unauthorised person as well as the unauthorised person himself would be liable for disciplinary action.

ST-4 TAGS

(1) The tags designed to meet requirement outlined in Section ST-3 are as follows :

RELEASE : Pink tag, withORDER blue printing.

:RELEASE RELEASE : Red tag, withTAGS PERMIT black printing

RELEASE : Thin yellowPERMIT paper with of 147

Black printing.

CAUTION : White tag withORDER red printing

OPERATING ; Green tag withPERMIT black printing

CONSTRUC- : Blue tag withTION ORDER black printing

The first three tags listed function as one tag and the last being used for construction or reconstruction leaves only three types of tags for system operation purpose.

(2) The tags are of shipping tag style, about seven by 15 Cms. Each tag has a string for attaching it to equipment. The tags shall never be attached to

Energise equipment or to locations where they can get energised. Similarly a tag should not be placed close to an energised equipment in crowded locations, such that the person removing or placing the tag is required to approach the energised equipment closer than the safe distances. Special arrangements may be made so that they can be placed and removed safely.

(3) Transparent plastic envelopes will protect tags that are to be placed outdoors during wet weather.

(4) Space is provided on each tag for recording a tag number, the station name, date, time, line or equipment covered, person to whom issued, person placing, person ordering and reason for placing. A brief summary of the rules covering its use is printed on the back of each tag. All tags must be completely filled out before being placed.

(5) Placement and removal of the tags must be done

by authorised personnel of operating organisation in-charge. Persons on probation or under training apprentices, trainees, shift mazdoors, etc. are not authorised to place, remove or fill up safety tags.

ST-4 RESPONSIBILITIES INVOLVED UNDER THE TAGGING SYSTEM

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Three parties are generally required for the correct functioning of the tagging system. The names of these parties appear on the tags and they are as follows:

i) The party authorising operations and the commencement of outage, whose name appears under “Ordered by”

(ii) The party carrying out the actual operations and placing the tags, whose name appears under “Placed by”

(iii) The party who would be taking over the equipment for work or tests etc., whose name appears under “Issued to”

The functions and responsibilities of these parties are defined below:

(i) The Authorising Party:

Party authorising operations and the outage will be the party under whose charge or jurisdiction the equipment concerned is placed e.g. the party may be the Load Despatcher, Station In-charge, Divisional In-charge,In-charge-Transmission/Distribution, or their qualified representatives. The names of the authorising parties should always appear in the Station Rules or operating instructions. This party will be responsible for the following functions:

(a) Pre-planning of the outage.

He/she will ensure that due to the outage there shall be no interruption in supply or process or lowering of standard of service or security of power supply. If any of these factors are involved, he/she will obtain prior concurrence of the consumers or parties concerned. He/she will also inform all concerned parties of the outage soon after it is arranged preferably one or two days in advance.

(b) Planning of operations.

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He/she will check if operating instructions for the outage are available to the operating organisation. If not, he/she will issue such instructions in advance of the outage.

(c) Checking the Working Party

He/she will check that the party taking over the equipment is included in the tagging list. If not, and if in his opinion the working party is capable of undertaking the work, he/she will arrange with the concurrence of the Station In-charge to have the party’s name included in the tagging list before handing over the equipment to him/her.

He/she will also check that the working party is familiar with all operations that are to be carried out for isolating and safeguarding the equipment.

(d) Issuing of the Release Permit

He/she will normally hand over the equipment to the working party. Before handing over, he/she will call the party taking over the equipment in person or on phone and advise him/her of the isolation and safeguarding of the equipment that is carried out. He/She will ask the working party to confirm that he/she is satisfied with the safety precautions taken on the equipment and inform the working party of the conditions under which the outage has been sanctioned viz. Duration, time to clear in emergency, etc. He/she would appraise him/her of abnormal conditions, if any, that may exist on the equipment being handed over.

In case the working party is close to the operating party, then the ordering party may authorise the operating party to hand over the equipment, e.g. Load Despatcher may authorise the control room engineer on duty to hand over a turbo-generator to a working party. In such a case the operating party should follow the above-mentioned procedure of handing over.

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(e) Cancellation of an outage.

The ordering party is empowered to cancel the outage at any time either before its commencement or during the outage period, if system or station conditions so require. In the event of such cancellation, the working party will be asked to clear the equipment within the period prescribed for clearing the equipment in emergency. It will therefore be necessary for the ordering party to be vigilant and watch carefully the progress of work on the equipment in relation to the system or station operating condition.

(f) Obtaining Clear

When the working party gives clear, the ordering party will check that the switching conditions of the equipment are normal for taking equipment back in service. If any abnormal conditions still exist, he/she will issue the necessary caution order indicating the restrictions and ensure that adequate tagging is carried out by the operating party.

(ii) The Operating Party

The operating party is normally the control room engineer on duty of the operations. The operating party will be responsible for the following :

(a) Cross check the outage.

To study the conditions under which the outage is authorised by the ordering party and ensure that the system or station operation is not affected by the outage. The operating party will keep a vigilant watch on the system or station conditions prior to and during the course of the outage and in case the outage is likely to affect the system or the station he will advise the ordering or authorising party of the same without delay.

(b) Planning of Operations.

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The operating party will ensure that clear operating and switching instructions are available for the planned outage. If not, he/she will request the ordering party to issue them in advance.

The operating party will carry out all operations as per operating instructions issued and the tagging as per Station rules. He/She will bring to the attention of the ordering party if any amendment is required in the operating instructions and the Station rules due to changed operating conditions.

(c) Verifying the Working party.

The operating party will ensure that the equipment is never handed over to any party not included in the tagging list.

He/She will appraise the working party of all the switching operations carried out to isolate and safeguard the equipment and obtain confirmation from him/her that the safety precautions taken are adequate and satisfactory.

He/She will study the scope of the work to be carried out by the working party, and if required he/she may ask the working party to carry out additional safety precautions like cordoning off the working area, placing danger boards, additional grounds etc.

(d) Cancellation of Outages.

In case of severe system or station emergency during which no delay is permissible in cancelling the outage, the operating party may cancel the outage and advise the ordering party as soon as possible thereafter of the cancellation under emergency conditions.

(e) Obtaining Clear.

When the working party gives clear, the operating party will check that the electrical and mechanical condition of the equipment

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under his/her charge is normal i.e. as it was at the time of handing over and that all grounds and safeguards placed by the working party are removed. He/She will also find out from the working party if any abnormal operating conditions exist and if so he/she will prepare suitable caution orders for them under instructions from the ordering party.

If everything is clear, the operating party will take the equipment into service as per station rules and operating instructions, grounds and safeguards placed by the working party are cleared. He/she will also find out from the working party if any abnormal operating conditions exist and if so he/she will prepare suitable caution orders for them under instructions from the ordering party.

If everything is clear, the operating party will take the equipment into service as per station rules and operating instructions, after obtaining authorisation from the ordering party.

(iii) The Working Party :

The working party will be a person whose name is included in the tagging list of the station or division concerned and who is familiar with all operations that are to be carried out for isolating and safeguarding the equipment.

The working party will have the following responsibilities:

(a) Preplanning of the Outage and Operations.

The working party will fully familiarise with the operations that are planned in connection with the outage. He/she will be responsible for checking that the isolation and safeguarding that is proposed to be carried out would be adequate and sufficient for the work planned. If any special safeguarding or tagging is required

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he/she should advise it to the operating party.

(b) Taking Over the equipment.

Before taking over the equipment, the working party will visually inspect all points of isolation, safeguarding and tagging of the equipment. If the working party is away from the operating party and is taking over the equipment on telephone, he/she should ask the operating party of all details of isolation, safeguarding and tagging to satisfy himself/herself of the safety precautions taken and should also obtain a third party confirmation of the same. If he/she finds that the operations carried out do not provide adequate safety, he/she should ask the operating party to carry out further isolation and tagging as per his/her requirements.

He/she will be fully responsible for ensuring that safe conditions of working exist for all personnel working under him/her & will take all necessary precautions like placing grounds at the location of work, placing danger boards at necessary locations and cordoning off safe area etc.

Before taking over he/she will carefully note the conditions under which the outage is arranged and will work within those restrictions. He/she will advise the crew working under him/her of the exact location, nature and scope of the work and the safety precautions to be taken. The crew should not be authorised to work unless this briefing is adequately carried out at the location of work.

(c) Giving Clear.

On completion of the work and before clearing the equipment, he/she will restore the equipment to the same operating condition electrically and mechanically in which he/she had taken it over, by removing

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grounds placed, reconnecting jumpers that may have been removed etc.

If any abnormal conditions exist on the equipment, the operating party will be advised and will have the necessary caution order issued. He/she should advise the crew working under him to clear away from the work location prior to giving clear to the operating party.

The above mechanics of the safety tagging provides that each phase of the outage is double checked viz. Preplanning, switching operations, safety measures, clearing etc. Thus if one party omits a particular detail of an outage, it is detected and corrected by the other party.

ST-5 RELEASE ORDER

(1) PURPOSE

This tag is used to protect personnel at work on de-energised lines or equipment. The word ‘’release’’ was adopted from the thought “a line or equipment is released from service”. The line or equipment covered by this tag is said to be released from service and the persons working under it are said to have obtained a Release.

(2) ISSUING OF RELEASE

THE RELEASE SHALL NEVER BE IN FORCE ON ANY ENERGISED LINE OR EQUIPMENT. LINES OR EQUIPMENT UPON WHICH RELEASE TAGS ALONE ARE ISSUED SHALL NEVER BE ENERGISED OR OPERATED BY ANY PERSON UNTIL ALL PERSONS HOLDING RELEASES HAVE REPORTED CLEAR.

Note: The word ALONE signifies that the equipment under release should not be energised by internal or external source of energy. However, it can be energised under operating permit issued along with the release order to one party only for trial operations.

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The word energised as used in tagging system refers to any electrical or mechanical force including steam, air, water, fluids, gas that might be dangerous to persons coming into contact with it. It is not permissible to energise the equipment released under “Release Order” tag from any source of power whether normal or external like mechanical or electrical charging.

Whenever the meggering of an electrical equipment does not require the removal of all safety precautions taken under the “Release Order” and when the equipment being meggered is not likely to build up dangerous electric charge, megger tests upto a voltage of 1000 volts are permitted under the “Release Order”, without the need for an “Operating Permit”.

A “Release“ on any equipment shall not be issued until (I) a visible isolation has been provided to each possible source of energy, (ii) all such isolations have been properly checked and tagged regardless of their position during normal operation (iii) it is safeguarded and (iv) all safety precautions are taken.

(3) REPORTING CLEAR

A Release Order is issued to protect personnel at work. The supervisor to whom the Release is issued, when not working or proceeding away from the scene of work, must clear his personnel and report the same even though the work is not completed and the equipment is not available for service. This is to forbid the men from working without supervision or authority during the absence of their supervisor. When an equipment is handed over to the working party for the work, it is to be treated as a continuous one and no reporting of clear for temporary short stopping of work is necessary.

No equipment that has been cleared should be energised unless all release notices are collected and cross checked against the entries on the “Release Order or Orders”.

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The working party while giving clear for a released equipment shall restore it to the same conditions as it was when the equipment was handed over for work. Any difference in conditions should be brought to the attention of the operating party at the time of giving clear and should request for necessary Caution Order.

(4) MULTIPLE RELEASES

A Release is issued to only one person who is responsible for the safety of all personnel working under him/her on the job until he/she reports clear. If a second person wants to work on the same equipment and cannot work under the first person, he/she must obtain an entirely separate Release in his/her own name.

No person may delegate any other person to obtain a Release for him/her or report clear for him/her. A Release is non-transferable. If the holder of a Release desires to leave the work and have it continued by another person, he/she must have a new Release issued to him/her. If the working party is not available and equipment is to be cleared in emergency, the divisional head/department in charge is authorised to give clear on behalf of working party after thorough checking.

Multiple releases shall not be issued for an equipment whenever the equipment is released to one working party along with an operating permit.

When multiple releases are issued on an equipment it will be the responsibility of the Supervisor of working party to ensure that the work of one party does not interfere with or endanger the crew of the other party.

Whenever multiple outages at a station are planned it will be the duty of the operating party and the working parties concerned to plan and arrange the timing of the operations in such a manner that the operating party can carry out the sequence of the switching operations for the outages without undue interruptions.

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RELEASE NOTICE

(1) PURPOSE AND FILLING OF TAG

Switching operations for release of an equipment usually require placing several tags. If Release Orders only were issued, the amount of writing required would become burdensome and placing of these tags cumbersome. To eliminate these difficulties, an auxiliary miniature tag known as Release Notice is used at all points except the master control of equipment in a station. The tag requires only the recording of the number of Release, the name of line or equipment and the person to whom the release is issued with the dateline. When an outage is required at short notice for a short duration, the Release Notice tags need bear only the Release number and date.

(2) CROSS-CHECK

Space is provided on the back of the ‘Release Order’ in which the operating party indicates each point to which a ‘Release Notice’ is attached. The number of Release Notices entered on the Release Order must tally with the number of Release Notices removed before the equipment is returned to service.

(3) WEATHERPROOF ENVELOPES.

Miniature Release notice tags are inserted in fully covered plastic envelopes to make them water proof for outdoor use and removable. The same weatherproof Release Notice tag can be used with different miniature tags for different outages.

Miniature Release Notice tags alone can be used in crowded locations like control boards, test links or terminal boxes where the shipping size Release Notice tags prove too large and unwieldy and have the same significance as the full sized release notice tag.

(4) “MEN AT WORK” NOTICE

At consumer substations, where tagging system as laid down in this manual cannot be fully

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implemented and where operations are carried out by consumer operators only, Notices 18” x 12” in size with the following inscriptions shall be used instead of the “Release Notice” Tags.

TATA POWER

RELEASE NOTICE MEN AT WORKDO NOT CLOSE THIS SWITCH

The board will be pink in colour with black lettering.

“Men at Work” and “Caution” Notices are printed on either side of the same board. Working party should ensure that the correct side of the tag is displayed on the operating handle of the switch.

RELEASE PERMIT

(1) PURPOSE

When a release is issued on equipment at attended stations, a replica in the form of a Release Permit is issued to the person obtaining the Release. It is desirable for the person receiving the Release Permit to accompany the operating party performing the switching operations and check each operation or check the switchings done and tags placed before taking over the equipment.

The Release Permit must be signed and turned over to the operation personnel when reporting clear with appropriate remarks.

(2) FILLING OF PERMIT

The front of the ‘Release Permit’ tag is a duplicate of the front of the Release Order tag and is printed on a thin paper with a gummed edge by which it is attached to the Release Order Tag. The two Tags can be filled out at the same time with carbon paper.

ST-6 CAUTION ORDER

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(1) PURPOSE

Caution Order tag is used to indicate abnormal conditions such as failure, hazards, relay inoperative, equipment not in service, temporary changes in operating rules etc. This tag can be placed on either energised or de-energised equipment. This Caution Order tag may be issued either to a person or placed on equipment to designate a particular operating condition.

(2) DESIGNATING EQUIPMENT FAILURE/DEFECT.

Equipment failures/defects are designated by placing Caution Order tags on control switches, valves etc. until the equipment is taken out for inspection and repairs.

(3) DESIGNATING HAZARDS, CAUTIONING AGAINST OPERATION OF SWITCHES, DISCONNECTS, VALVES AND PUMPS (WHICH PROHIBITS THE OPERATION OF EQUIPMENT)

EXAMPLE (WHEREVER APPLICABLE)

At the Generating and Receiving stations, where the operating personnel has to leave the control room and go to the switchyard to open or close disconnects after opening or before closing circuit breaker, a blank Caution Order tag is placed on switchboard control of the breaker. This way, the tag not only protects the operating party from operation of the breaker by another person but also directs the attention to the proper control switch upon his/her return.

(4) ISSUING TO A PERSON

The Caution Order may be issued to a person when he/she is working near energised lines or equipment and might accidentally contact or foul the equipment.

While getting a caution order issued, the working party should indicate to the operating party the possible hazards by way of nature of caution and by way of nature of work.

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For transmission lines with auto-re-closing facility, when a Caution Order of this nature is issued, the re-closing gear is made inoperative.

It should be clearly understood that A CAUTION ORDER ISSUED TO A PERSON NEITHER AUTHORISES HIM/HER TO OPERATE THE EQUIPMENT NOR DOES IT PROTECT HIM/HER FROM OPERATION OR ENERGISING OF THE EQUIPMENT EXCEPT WHEN AN AUTOMATIC TRIP OUT OCCURS.

(5) “Caution Notices” at Consumer Substations.

At consumer Substations, where tagging system as laid down in this manual is not in force and where operations are carried out by consumer operators, “Caution” Notice boards 18 x 12 cms in size with the following inscription are to be used in place of “Caution Order” tags :

TATA POWER

CAUTION NOTICE DO NOT CLOSE THIS SWITCH

The notice board will be with white background and red lettering.

These caution notices will be placed on the operating handles of disconnects or switches which are open under normal and abnormal operating conditions to remind consumer operators that the switches are to be operated only under instructions from Tata Control room operation engineers.

ST-7 OPERATING PERMIT

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(1) PURPOSE

One of the fundamental requirements of operation is that no equipment be operated by any person other than the operating personnel authorised to do so. The operating personnel or any other person is prohibited from operating any equipment upon which persons are working. Both the Release Order and Caution Order forbid this.

Under certain conditions such as relay testing and checking breaker operations etc, the equipment needs to be operated. This tag authorises such an operation.

An operating permit is also issued to carry out hot line work, meggering above 1 kV, hi-pot-test, current injection or any other test, which is likely to inject or induce high voltage and dangerous electric charge, relay testing, trial tripping of live equipment, machine slip ring grinding, valve operation, trial run of machine and its adjustments after maintenance, operation of valves / gates, test charging of equipment when requested by working party, changing machine brushes in running condition etc.

(2) ISSUING RULE

The Operating Permit may be placed on either energised or de-energised equipment. If used on de-energised equipment, it can be placed either alone or with a Release Order. When used in conjunction with a Release Order, the Operating Permit may authorise operations, which would energise the equipment or a line from a source of power which is normal or external for trials only.

Equipment to which an Operating Permit is attached may be operated only by or under personal direction of the person to whom it is issued. But this person is restricted by the rules that no person except the operation personnel may operate the equipment from a switchboard.

Only one operating permit will be issued at a time for an equipment. If an equipment is released to more than one person under separate Release Orders, Operating Permit cannot be issued.

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When used in conjunction with a ‘Release order’, the operating permit authorises trial operations of certain equipment, especially in thermal plants, where the equipment is energised from a source of power which is normal or external.

ST-8 CONSTRUCTION ORDER

(1) PURPOSE

During construction work, there are times when work is being performed on new or removed equipment that is in the vicinity of equipment in operation. Although normal operating rules cannot be applied to such work, it is necessary to designate the equipment under construction in order to prevent accidental work on the wrong equipment. The tag used for this purpose, known as the Construction Order, is not really an operating tag but is intended for use by the construction organisation that may not be familiar with the operating safety rules. A Construction Order will not be issued unless the equipment involved is isolated from all possible sources of power by an opening other than normal isolating equipment viz. removing jumpers etc. Also all control and protection circuits are isolated and links dropped. This means, for example, that when the final leads are to be connected to a circuit breaker or set of disconnects to a bus, the Construction Order will no longer be valid and a Release Order must be obtained for any further work. The placing of a Construction Order removes the equipment from normal jurisdiction of operating organisation and permits the construction personnel to work on, move, operate, or energise the equipment at will with the restriction that they may not energise it from the existing system or operate it from a switchboard in service which is likely to lead to undesirable trippings.Operating Permit during Construction Work :

When an equipment is under construction order, there are occasions when hipoting is required. In such cases an operating permit shall be issued for the high potential testing activity to the same party to whom construction order is issued. The hipot activity is permitted only if it does not adversly

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affect other equipment/task in the proximity. Only one such operating permit for a particular hipot can be issued at a time.

ST-9 RELEASE TAGS: TAGGING RULES AND PROCEDURE FOR EQUIPMENT AND LINES.

(1) As a general rule, all equipment which affect overall power supply reliability in case of Mumbai licensed area are within jurisdiction of the Load Despatch Department.

(2) The Divisions are equipped with lists of equipment conforming to the above operational philosophy.

(3) No work shall be done on lines or equipment where release is required for safe conduct of the work until release has been applied for and lines and equipment released in accordance with Rules and Procedure outlined.

(4) During emergencies, the equipment may be taken out by the concerned operating party. Once the equipment is out under emergency and isolated, tags should be prepared and placed before handing over the equipment to the Maintenance Engineer for repairs, inspection etc.

(5) The personnel in tagging list should be thoroughly familiar with the tagging system and plant layout.

(6) It is the duty of the Authorising Party to interpret and rigidly enforce rules to keep an accurate record of all orders, checks and circumstances of all work carried on under the rules and to assist employees and others to interpret and comply with the rules.

(7) It is the duty of the operation personnel to assist authorising party in rigidly enforcing rules and to keep an accurate record of all orders, checks and circumstances of work carried out.

(8) All circuits and equipment shall be considered ‘live’ until released by the proper authority.

The Authorising Party shall require the following information of the outage:

(i) Equipment to be released.

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(ii) Nature of work.(iii) Time and date of commencement of

outage.(iv) Duration of outage.(v) Names of the person taking over the

equipment.(vi) Time to clear the equipment in emergency.(vii) Any special safety precautions necessary.

(9) The Authorising party shall investigate conditions and have those consumers notified whose service will be interfered with and also arrange, wherever possible, alternative feeds to consumers affected. If in his/her judgement the time and date asked for are suitable, Release will be arranged as required. Otherwise, considering the system operating conditions, alternative time and date will be advised. As soon as the outage programme is decided, all the parties concerned will be informed by a Telephone/E-mail message at least one day in advance. The Telepnone/E-mail message will contain the relevant details when an outage is arranged at short notice, the information to all the concerned parties will be conveyed on phone.

(10) All instructions and messages relating to the operation and switching given over the telephone shall be repeated in full to the sender to ensure that the message has been accurately understood.

(11) In order to obtain uniformity in safety and tagging procedures, each station will incorporate in its Station Rules, the step by step operation to safeguard every station equipment to maintenance work and the tagging scheme to be followed. In abnormal switching operations requiring special tagging, a scheme will be prepared in advance in consultation with the authorising party.

(12) To ensure correct functioning of the tagging system, the placement and removal of tags will remain sole responsibility of the Operation in charge/representatives. Tags issued to a working party should be handled only by the person for whom it is issued. If any person from the Operating party or from the tagging list for whom equipment is tagged, is observed delegating such authority to others he/she will be liable for disciplinary action. Any unauthorised person, who is observed

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handling, tampering or making entries on safety tags, will render himself/herself liable for disciplinary action. In emergency, if an exception has been made, the Local Authorising party should be advised without delay.

(13) At the scheduled time, the station operating party will carry out the necessary switching operations in proper sequence to de-energise the line or equipment as per operating instructions.

(14) After opening out the circuit breaker and before operating any disconnects, the operator shall attach a blank Caution Order tag to breaker switchboard control switch. The operator will then proceed to circuit breaker and after making visually sure that it is open, will open the disconnects to isolate the equipment and place Release Notices on each of the disconnects (including Transfer Bus disconnects, if any) and other sources of energising the line or equipment and check by approved methods that the equipment or line is de-energised.

(15) If the apparatus or line is de-energised, the operator will proceed to ground the apparatus. If a grounding disconnect is provided he shall close the disconnect and attach a Release Notice to its operating lever. If no grounding disconnect is provided, the operator shall request working party to ground the equipment by means of an approved 3-wire grounding device. The connection to the ground will be made first and that to the line or equipment last. All the three phases will be grounded.

The use of chains and defective grounding devices is prohibited.

(16) Returning to the control room, the operator will remove the Caution Order and attach a Release Order to the control switch. He will then report to the authorising party in detail all the operations that he performed and the tags he placed.

(17) After receiving reports from all the operators about having placed “Release Order Number’’ the authorising party will call the person for whom the equipment is tagged for and hand over the line or equipment to him/her.

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(18) In case work is to be carried within an attended station, a ‘Release Permit’; will be issued to the person for whom the equipment or line is tagged.

(19) Before starting work, the person for whom the line or equipment is tagged shall check in the presence of another person whether the line or equipment is de-energised and effectively grounded by one or more of the following methods:

(a) Electrically for electrical apparatus such as glow detectors, neon testers voltage indicating devices etc.

(b) Visually such as open disconnects, grounds closed and locked whenever applicable, main valves head on the drained out penstocks etc.

(c) By Inspection of Release Order and Release Notice tags.

(d) By checking with operator directly. Further, the person in charge of work will be cautious regarding any close clearances, hazards or unusual conditions known or suspected to exist. The working party, if necessary, may provide own additional temporary grounds on the line or equipment, which is released. On placing temporary grounds, care should be taken to make the ground connections first and then the connections to the line or equipment afterwards.

(20) GIVING CLEAR

Before giving clear, the person in charge of work shall make certain that all personnel are clear from the work site, that equipment is in good condition, that all temporary grounds placed by them have been removed and all tools used on the job accounted for. In removing temporary grounds, care should be taken to remove the connection to the line or equipment first and remove the ground connection last. At the time of giving clear he will specify his Release Number, name of line or equipment and his own name.

In case a Release Permit has been issued to the person in charge of work, the reverse side of the

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permit will be filled and returned to the operating party. If there is any difference in condition it should be brought to the attention of the operating party at the time of giving clear and necessary ‘caution order’ issued.

(21) On receiving clearance, the authority as specified in the operating instructions, will have the grounds removed and ask the station to remove Release Number for which the clearance is received After removing the Release Notices, the Release Order will be removed from the main control point.

(22) If there is more than one Release Notice attached to any control point, only that Release Notice will be removed which corresponds to the Release Number and person from whom clearance has been received.

(23) After removing the Release Order, the Operator shall enter thereupon the name of the person who removed the tag and the authority that ordered it to be removed alongwith date and time.

(24) After all Release Orders attached to the main control point have been removed, the equipment will be taken into service as specified in the operating instructions.

ST-10 RULES PERTAINING TO THE USE OF

OPERATING PERMIT (GREEN TAG)

(1) Whenever any person wants to carry out tests on any equipment, like meggering, hipot test, current injection test, or any other test which is likely to inject or induce high voltage and dangerous electric charge, relay testing or trial tripping of energised or de-energised equipment like circuit breakers, valve operations, trial run of machine and its adjustments, operation of valves/gates etc he/she shall apply for an operating Permit for the equipment to the authorising party under whose control the equipment may be situated.

(2) The person requiring to carry out the tests shall furnish the following information when making an application :

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(a) Name of the equipment(b) Exact nature of tests proposed to be carried

out(c) Whether equipment is required to be de-

coupled,made dead and grounded before carrying out the tests

(d) Time at which tests are proposed to be carried out and duration.

(3) Authorisng party shall investigate conditions, and if, in his/her judgement, such tests may be carried out, permission will be granted.

(4) If the apparatus is required to be made dead and grounded while carrying out the tests, it will be necessary to obtain Release Order also in addition to the Operating Permit.

(5) When the Operating Permit alone is issued to the person, the equipment shall be considered live equipment & no work except testing/trial operation shall be done or allowed to be done on the equipment.

(6) The person to whom the Operating Permit is issued shall be responsible for safety of the personnel working under him/her.

(7) Equipment, issued under an Operating Permit, is under orders of the person for whom it is tagged and may be energised or de-energised as per his/her directives only.

An operating Permit shall never be issued to a party if a release for the same equipment is already issued to another party or vice versa.

(8) After the testing is completed, the person to whom Operating Permit has been issued shall report clear to the operating party. The tags will be removed then and the equipment returned to normal service. If the equipment is de-energised grounded and covered by a Release Order, grounds will be removed and necessary switching operations carried out to take the equipment in service as per operating instructions.

ST-11 SAFETY TAGGING: (ILLUSTRATIVE)

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Case 1:

OUTAGE OF 220/132/110 KV INTERCONNECTING BUSES:

There are instances in the system wherein electrical equipment controlled by two or more control rooms are connected to a common bus. Proper co-ordination and utmost care are called for when the outages are planned & executed on these buses. Approved step by step operating instructions must be available in the associated control rooms for carrying out all switching operations sequentially.

Case 2:

OUTAGE OF INTERCONNECTING TIE LINES:

There are 220/110 KV interconnections with MSEB/BSES in service in Mumbai area. A system of issuing cross permit numbers is prevalent for the safe conduct of these outages.

Case 3: Outages of thermal units

a. For Mechanical Works.

1. The outage of Thermal units will be arranged in consultation with the authorising party/parties.

2. The machine will be taken out of service as per written down procedure. Boiler may be remain on HP / LP bypass (wherever applicable) or fire may be killed as per the requirement of the outage jobs. Machine will be on turning gear.

3. A Release order on the Unit will be issued to Manager (Operation) on duty.

4. Release notices will be placed at the following locations :

Generator breaker and isolators. Unit Auxiliary Transformer breakers racked out

and tagged. On Unit Control Board.

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5. Operation personnel in unit control room will arrange to issue releases for various associated outage jobs after confirming isolations.

6. When work on various outage jobs gets completed, the working party will return Release permit duly signed. Unit control room engineers will check for any abnormal remarks and arrange to remove all Release notices from various locations.

7. Manger (Operation) on duty will give clear the Release order on the Unit.

8. Normal unit start-up procedure will be followed to take the unit back in service.

b. For Work on Generator.

1. Release order on the unit will be issued to Manager (Operation) on duty.

2. Generator shall be at standstill condition.3. The field circuit will be opened and isolated.4. The generator winding is disconnected at the

generator terminals.5. The unit control room engineers will arrange to

issue releases to various associated outage jobs after confirming isolations.

6. The generator winding shall be discharged to ground before commencing any work on the generator.

7. Generator hydrogen will be purged by CO2 and further purged by Instrument air. Generator shell will be depressurised.

8. Generator seal oil system will be taken out of service.

9. Main turbine lub. oil system will be taken out of service.

10. Exciter rotor / stator connection will be disconnected and dismantled.

11. Generator primary water system may be kept in service.

12. When work on various outage jobs gets completed, the working party will return Release permit duly signed. Unit control room engineers will check for any abnormal remarks and arrange to remove all Release notices from various locations.

13 The unit control room engineers will ensure that the protocol is duly filled and signed by all working parties. The system will then be charged in concurrence with the re-commissioning group. If no abnormalities are found and all tests / trials / re-

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commissioning checks carried are out, the system will be taken back in service.

14 Manger (Operation) on duty will clear the Release order on the Unit.

15 Normal unit start-up procedure will be followed to take the unit back in service.

NOTE – Normally, for all the generator/UAT/GT side jobs, the machine should be standstill i.e. off the turning gear. However, when machine is on turning gear, some of the jobs can be carried out under caution tags with proper precautions taken such as grounding at proper location (s), use of specified standard safety gloves and insulated tools. Working party is responsible for taking safety precautions while carrying out above jobs. The authority concerned should thoroughly look into all safety aspects before allowing personnel on the job. Following are some of the jobs that may be carried out when the machine is on turning gear with safety precautions mentioned above: -1. Cold line washing of GT bushings, coolers, gantry

insulators, isolators of GT breakers, CVTs & LAs.2. CVT of GT replacement.3. Attending to GT oil leaks.4. GT /UAT oil topping up.5. Investigations of GT / UAT primary protection tripping.6. Generator Transformer HT clamp tightness checking.7. GT breaker CT replacement.8. GT breaker replacement.9. GT unit replacement.10. GT breaker gantry insulator replacement.11. Work on GT isolators.12. Generator jumper disconnection work before long

duration outage jobs.

c. For long duration outages

The outage of the thermal unit will be arranged in consultation with the authorising party/parties. The long duration outage will be generally for Main Turbine overhaul / Generator overhaul / Boiler re-certification.

1. The machine will be taken out of service as per written down procedure. Boiler fire will be killed. The Machine will be on turning gear to bring down Main Turbine metal temperatures less than 100C. Machine will be taken off turning gear thereafter.

2. A Release order on the Unit to Manager (Operation) on duty will be issued.

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3. Generator leads will be disconnected at the terminals and exciter leads will be disconnected from main exciter. Control and protection circuit will be isolated and links will be dropped.

4. Once the release is issued to various working parties, Lub oil, Seal oil and Hydrogen systems will be taken out of service. Various other systems will also be shut down and isolated as per requirement. Release order and Release notices will be placed at proper locations and then released equipment will be handed over to working parties.

5. When work on various systems gets completed, the working party will return Release permit duly signed. Unit control room engineers will check for any abnormal remarks and will arrange to remove all Release notices from various locations.

6. The unit control room engineers will ensure that the protocol is duly filled and signed by all working parties. The system will then be charged in concurrence with the re-commissioning group. If no abnormalities are found and all tests / trials / re-commissioning checks are carried out, the system will be taken back in service.

7. Manger (Operation) on duty will clear the Release order on the Unit.

8. Normal unit start-up procedure will be followed to take the unit back in service.

Case-4 OUTAGE OF EQUIPMENT/AUXILIARY SYSTEM AT THERMAL POWER STATIONS

(1) When any equipment/auxiliary system is to be released for maintenance, the impact on generation on the unit and chances of a trip out need to be assessed.

(2) The plant conditions should be brought to a level suitable for taking the equipment/system out of service causing minimum disturbance on the unit system.

(3) The equipment concerned should be first isolated from the electrical side, if it is electrical power operated.

(4) Subsequent isolations on steam/water/gas/air / hydraulic, lubricating oil or fuel, should be carried

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out as per station rules and as per requirements of the working party.

(5) While isolating the equipment system, the following should be considered.

(a) Possible effect on other associated equipment.

(b) Changes it may cause in plant operating conditions.

(c) Urgency of the nature of job and adverse effects if the equipment is left out of service.

(6) Safety Tagging: Depending on the nature of maintenance work, the tagging should be done for all necessary switches and valves as per the procedure described in the Safety Manual.

Case 5: Outage of Hydro generating units:

For annual overhaul:

1 The outage is arranged in consultation with the authorising party/parties.

2 ‘On load draining’ of penstock is carried out as per specified draining rate normally before disconnecting the unit from the grid. In some cases the unit is first cut out, shut down and then the penstock is drained.

3 Isolate the generator by opening its main bus side isolator. (or rack out generator LT breaker) and shut down the turbine on hydraulic side.

4 Control room engineer on duty will obtain a release order for annual overhaul of the generator unit from the authorising party, place proper safety tags as per station operating instructions and hand over the Turbine Generator unit to working party(s).

1. On receiving clear from the working party/parties, check that all the releases on the unit are cleared.

2. Fill up the penstock as per station operation procedure and synchronise the unit.

3. A heat run test under operating permit is carried out when stator winding resistance is found low (especially during rainy/winter seasons.)

Note: For the outage of a pumped storage unit,

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the outage procedure is similar to outage of any hydro unit. In addition, spherical valve and draft tube will have to be drained as per operating instructions and filled up before taking the generator in service.

Case 6:

Outage of hydro units for longer duration:

1. The outage may be required for stator rewinding and turbine major overhaul.

2. The penstock of the unit will be drained as stated above.

3. The generator will be placed under a Release Order for disconnecting the generator leads from the circuit breaker and the field leads from the generator field switch. Also control and protection circuits are isolated or links dropped.

4. After item 3 are completed and release permit is duly returned, the operating party obtains construction order for further works on the generator

5. When the construction work is over and the generator leads and field leads are required to be reconnected, the Construction Order is cleared and a Release is obtained for reconnection of generator leads.

6. Commissioning test are carried out under an operating permit before clearing the set for service.

Case-7 OUTAGE OF A DISTRIBUTION FEEDER FED FROM A RECEIVING STATION

(a) Outage of a Distribution feeder will be arranged through the Distribution Division.

(b) Outage will be given as per the station operating instructions for distribution feeders/system.

Case-8 OUTAGE OF AN OVERHEAD 33/22/11KV DISTRIBUTION FEEDER

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The concerned stations prepare detailed outage procedures. These procedures will be strictly followed.

Case-9 MEGGER OR HIGH POTENTIAL TEST ON A FEEDER CABLE: USE OF “RELEASE ORDER” AND “OPERATING PERMIT”

(a) The work connected with the testing of a cable can be divided into three parts:

(i) Isolating and safeguarding the cable and connecting up testing equipment.

(ii) Energising the cable from the testing set for testing.

(iii) Discharging the static charge from the cable and disconnecting the testing equipment after the tests are over.

The work stages (I) and (iii) will be carried out under a ‘Release Order’ and the work of stage (ii) shall be carried out under an ‘Operating Permit’. The procedure will be followed as per operating instructions provided in station operating instructions.

Case-10 PROTECTIVE RELAY TESTING :

“Caution Order” is necessary for keeping the inoperative. In addition an “Operating Permit” is necessary, if tests are to be carried out on the relay. “Release Order” is taken for disconnected and shifting the relay. Operating permit is taken for carrying out trial trippings of circuit breakers through relays.

Case-11 CLEARING OF PROTECTION SCHEMES ONLY AFTER EQUIPMENT ARE TAKEN IN LOAD SERVICE :

Working party should mention on the “Release Permit”, while giving clear for the equipment that the specific

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protection scheme has to be taken into service only after the equipment has been taken in service and the tests / checks on the protection equipment are completed. However no primary protection will remain inoperative while taking back any equipment in service. A “Caution Order” will be issued stating the reason as above. The “Caution Order” will be cleared only after all protection schemes are tested and cleared.

ST-12 DISCUSSION ON USAGES OF SAFETY TAGS IN DAY TO DAY OPERATIONS

(1) Use of “Release Order” and “Operating Permit”:

After particular maintenance job is completed, the working party may wish to check the performance by operating the equipment for few times and make some adjustments, if necessary (e.g. decoupled trial run of pump-motor unit). An Operating Permit can therefore, be issued to the working party along with the existing Release Order provided that all other Release orders are cleared except the one in the name of the working party, who is also the operating party.

(2) Use of “Construction Order” and “Caution Order”:

Electric supply and compressed air supply of the station may be provided to the equipment under construction without adversely affecting the station working condition. Equipment being erected by construction party under “Construction Order” may required to be pressurised, charged or trial operations and adjustments carried out before the final jumpers are connected. E.g. the air pipeline with isolating valve is installed and is ready for pressurising the new Air Blast Circuit Breaker from the Station compressed Air System. A Caution Order was placed on this isolating valve since the time the station compressed air supply was connected to this breaker under construction. The construction party will request the station/department for compressed air supply requirement for trial operations of the breaker. The concerned head will arrange to monitor the air supply & pressure during the trial

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operations of the breaker and then request the operation department to issue a Caution Order to construction party with instructions, that the station air supply will not be allowed to drop below a certain pressure during the trial operation of the breaker. This will be then co-ordinated with engineer on duty. The Operation Engineer will then open air valve for the breaker under direction of Construction Supervisor to pressurise the breaker.

The Construction Supervisor will take precautions while operating the breaker that the station compressed airs supply pressure is maintained at the required safe value.

(3) Work on Bus Fault Relay/ Current Injection Tests – Use of “Caution Order and Operating Permit”

Caution order is necessary for keeping it on the bus fault relay as it is made inoperative for Testing work. In addition an Operating Permit is also issued to the working party, if the tests are to be carried out on the relay. Instead of Operating Permit, a Release Order may be required to be issued if the relay is to be disconnected for shifting etc. The Operating Permit or Release Order will depend upon the nature of the work.

(4) Equipment in Service – Use of Caution Order :

A Caution order is issued to the control room engineer on duty when certain jobs are done on an equipment so that he does not commission the equipment, if it trips out unless clearance is obtained from the concerned working party. A caution order is also issued to the working party so that he works at a safe distance from the line/bus/equipment.

(5) Hot Line Changing of an Insulator – Use of a Caution Order & Operating Permit :

Under Caution Order, the control room engineer on duty will make the auto-reclosure of the line inoperative. He is prohibited from charging the line/equipment in case it trips out unless clearance is obtained from the concerned working party. Operating Permit is issued to the working party for

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changing the insulators etc. under hot line conditions with hot line tools.

(6) Starting a hydro unit after Routine Maintenance or Overhaul – Use of Operating Permit & Release Order” :

If the unit has to be started for trial operations, adjustments etc. the Release Order should be cleared since the penstocks, turbines are hydraulically energised. Operating Permit should be issued for starting the set for trial purposes, adjustments, observation, etc.

(7) Still Water condition in Headworks – Use of Caution Order, Operating Permit and Release Order :

Under Caution Order, the control room engineer on duty will maintain still water condition by cutting out sets/exciters etc. or locking the sets at no loads. An Operating Permit should be issued to the working party for lowering or lifting the stop logs, gates, etc. Release order should be issued to the working party for working in still water condition.

(8) Cleaning of Slip rings/Replacement of Exciter brushes, Grinding of slip rings of a Generator – Use of Caution Order :

Under the caution order, protections such as rotor earth fault will be made inoperative for cleaning slip rings, replacement of exciter brushes or slip ring grinding.

CONSTRUCTION:

C-1 SCAFFOLDS

(1) Scaffolds shall be built of sound material, securely fastened, and be capable of supporting four times the combined weight of men and materials which may be placed on them.

(2) Wood planks used in scaffolds should be not less than ten (10) inches wide and two (2) inches thick, and shall not extend beyond the outer supports

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more than twelve (12) inches nor less than six (6) inches and the planks should be securely fastened down. Wooden planks without any nails projecting should be used; similarly planks or ballies with cracks should not be used for scaffolding purpose.

(3) Guard rails and toe boards shall be installed on all scaffolds that are ten (10) feet or more in height, and on all scaffolds immediately adjacent to excavations, deep-water, machinery, or other sources of danger.

C-2 RIGGING AND HOISTING:

(1) Man in charge of working party shall be responsible for the safe loading and use of ropes, chains, cables, slings, jacks, skids and other hoisting and rigging apparatus. In no case shall such equipment be used until the supervisor has determined that it is free from defects and safe for use.

(2) Before operating crane, derrick or other hoisting equipment, the operator should sound warning and accept only one person’s signal to start raising, lowering or swinging load. However, the operator shall stop immediately upon signal from anyone.

(3) Never place yourselves near cables under tension, and under no condition within the angle formed by ropes or cables. When anyone is in this or other dangerous position, the hoist operator shall never place tension on a rope or cable.

(4) Employees shall familiarise, themselves with the proper use of knots, ties, and hitches, and safe methods of hooking and slinging required in their work.

(5) Particular care must be exercised to see that cables, chains and other hoisting equipment are not unduly stressed by improper use. All ropes, cables chains etc. shall be discarded when they have worn or deteriorated to the point where their safe use may be questionable in the judgement of the supervisor.

(6) Chains shall not be spliced or joined by make shift means such as open links, bolts, or wire. New links

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shall be inserted by some competent person, or the chain returned to the manufacturer for repairs.

(7) Wire ropes or cables should not be allowed to kink as this weakens them.

(8) When applying U-bolt clips to cables, a sufficient number should be used.

(9) Hooks, rings, clevises and other fittings used on chains or cables shall exceed the carrying capacity of the chain or cable.

(10) Fibre rope shall be properly cared for to retain its strength and lasting quality. Following precautions will preserve the strength and life of rope.

a. Where a rope sling passes over sharp edges, pads should be used to protect the fibres against cutting and undue stress.

b. Do not drag rope on the ground unnecessarily as dirt chafes the fibres.

c. Do not use too small a sheave.

d. Do not use sheaves with rough surfaces or broken edges.

e. Do not let rope slip on winch drum or lie idle on moving drum.

f. Do not place kinked rope under stress.

g. Do not allow rope to unravel. Finish the ends.

h. Do not tie the knots where splices should be used.

i. Do not allow ropes to become oil-soaked nor exposed to acid or corrosive substances.

j. Do not allow rope to remain dirty or gritty. Wash and dry.

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k. Do not allow rope to remain exposed to weather any more than necessary. Carefully dry rope when it becomes wet.

L. Do not use excessive heat when drying rope.

C-3 WELDING, BURNING, CUTTING (GENERAL):

(1) The primary hazards encountered during welding are-Electric shock, burns, radiant energy, toxic metal fumes, fires and explosions.

(2) Avoid burns from electric arcs, gas-welding flames, hot slag, or touching welded parts before cooling by the following precautions.

a. Gauntlet gloves should be worn while welding or cutting. Outer clothes should be free from oil and grease.

b. Suitable goggles or welding helmets shall be worn for protection while welding. Barriers should be erected to protect other persons from rays or electric arcs or welding flames. Goggles should be worn by the helper also. Ultraviolet, infrared and excessively bright visible-light rays are injurious to eyes.

c. Clean goggles should be worn while chipping the slag.

d. Adequate ventilation shall be provided while welding in confined spaces or while brazing, cutting or welding zinc, brass, bronze, galvanised or lead-coated material. Poisonous fumes may be generated during the welding process by metallic oxides, coatings on the material being cut or welded, or by the electrode or flux rod.

e. Never use a cutting or welding torch where there is danger of starting a fire. Move work, if practicable, to a location where possibility of starting a fire is not likely. Danger of fire always exists when welding near flammable material or explosive gases.

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Where flammable material cannot be removed from exposure to sparks; it should be protected by a barrier of sheet metal or other suitable material and a fire extinguisher kept handy.

f. When welding or cutting in elevated positions, precautions should be taken to prevent sparks or hot metal falling on to people or flammable material. Asbestos cloth can be used.

g. No welding or cutting should be attempted in dusty or gaseous areas where there is danger of causing explosion.

h. Before welding or cutting a pipe, tank or container that has held flammable material, drain it thoroughly out and fill the container with water, or thoroughly wash the container with a caustic solution, and spray sufficient carbon-tetrachloride into the container to fill it with non-explosive vapour.

(3) Avoid personal contact with the electrode or other live parts of electric welding equipment. Alternating currents are dangerous even at low voltage.

(4) When changing, electrodes keep them insulated from ground or other nearby metal objects.

(5) Extreme caution should be exercised to prevent accidental contact of electrode with ground. When passing the electrode through doors, or close clearance, and when the welder is not in use, the main switch should be off. Welding ground should be close to the job.

(6) In acetylene burning and welding, never allow oil or grease to come in contact with any cylinder, regulator, or connection of gas-welding equipment. Oil or grease in the presence of oxygen may cause a violent explosion.

(7) Never use matches to light a blowpipe. Use a friction lighter, stationary pilot flame or other suitable source of ignition.

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(8) LPG cylinders should not be used for gas cutting jobs. Acetylene cylinder should be used.

C-4 HANDLING AND STORING COMPRESSED GASES:

(1) Cylinders containing acetylene, oxygen, chlorine, hydrogen, nitrogen, carbon-dioxide, etc. should be stored upright in approved safe places where they cannot be knocked over, and well separated from radiators, furnaces and combustible material.

(2) Oxygen cylinders should be isolated from acetylene cylinders, and full cylinders separated from empty ones.

(3) Gas cylinders should be protected from direct rays of the sun.

(4) Empty cylinders should be plainly marked EMPTY, and the valves closed.

(5) Gases like carbon dioxide, chlorine have a tendency to settle down when released in air. They also diffuse very slowly. Therefore when working in manholes and basements, care must be taken to see that an accidental leak will not lead to suffocation. In such locations the gas cylinders should be placed away from the manhole openings or entrances to basements.

C-5 EXPLOSIVES: STORAGE & TRANSPORTATION

(1) Detonators for exploding dynamite are of two kinds. Those ignited by fuse are known as blasting caps, those fired by electric current are known as electric blasting caps.

(2) Only persons who are qualified by training and experience shall be permitted to handle, use or transport explosives.

(3) Dynamite and caps shall be stored in separate magazines, containers and marked. While transporting, Dynamite and caps shall be placed in separate locked containers. Such containers will be kept as far apart as possible but not less than 3 ft.

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(4) All surplus explosives shall be returned to magazines as soon as possible following completion of a job.

(5) The area within 28 feet of a magazine shall be kept free of flammable debris, and magazine floors shall be kept clean.

(6) Smoking and open flames are prohibited within 50 feet of any magazine or explosive.

(7) Trucks carrying explosives must not be left parked in congested areas, or subject to major repairs.

C-6 HANDLING AND USE OF EXPLOSIVES

(1) Smoking and open flames are strictly prohibited within 50 feet of explosives.

(2) Explosives, either in containers or otherwise, shall not be thrown from trucks, slid along floors or handled roughly in any manner.

(3) Do not expose explosives to direct rays of the sun for a long time.

(4) Do not leave dynamite and caps unguarded.

(5) During approach and progress of a lightning storm, and all personnel shall seek a place of safety.

(6) Do not leave explosives should be destroyed by methods recommended by the manufacturer. They should not be thrown into streams or bodies of water, nor buried in the ground.

C-7 EXCAVATIONS

(1) Proper and adequate timber shoring and bracings shall be provided to prevent sliding or slipping of loose or unstable earth, rock or other material or caving in of excavation.

(2) Under cutting of banks of trenches and other excavations shall be avoided.

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(3) Excavated material shall be dumped away from the edge of the excavated trench to avoid the slipping of the excavated material in to the trench.

(4) Excavations shall be properly fenced to protect men and animals from falling in.

(5) Warning signals shall be placed near the excavation to warn the approaching traffic and men. At night, red danger light shall be displayed at a conspicuous place near the excavation.

C-8 CONCRETING AND CEMENTING

(1) All form raising and form stripping operations shall be conducted under proper supervision. If working at a height, the workers should use lifelines or safety belts.

(2) Workers handling cement or concrete shall protect themselves by wearing goggles, hard hats, and rubber boots and rubber gloves as required.

(3) Proper guards and covers shall be provided on mixer gears, chains and rollers.

(4) While grouting or gunniting the nozzle, men shall be provided with suitable respirators.

(5) All pipes or hoses used to convey grout shall be of sufficient strength to withstand the maximum pressure likely to be reached during the operation.

(6) While gunniting the workers shall be protected against rebound material.

TRANSPORTATION

T-1 GENERAL PRECAUTIONS

(1) Equipment should be kept in good operating condition, and driven in a safe manner so as to prevent injury to you and others and save damage or loss of valuable equipment. Driving of a company car or truck is a responsibility, not a privilege.

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(2) No employee shall operate a company car or truck upon a public thoroughfare unless he has the proper license in his possession.

(3) Every driver of company car or truck shall be thoroughly familiar and comply with the State and City traffic laws covering the territory where he operates.

(4) Before operating a company vehicle each driver should make sure that it is in proper operating condition. Observe especially the following precautions :

a. Test brakes, clutch, horn and lights.b. See that tyres are in good condition and

properly inflated.c. Check emergency equipment such as first-

aid kit jacks and tools. Any equipment found missing or defective should be reported immediately.

(5) Every driver shall report any vehicle’s defect detected.

(6) Before filling the petrol tank, the motor should always be shut off. The hose nozzle should be kept in contact with the tank to avoid static sparks.

(7) While filling the petrol tank, smoking or using an open flame near the vehicle should be avoided.

(8) Driver and co-passengers in vehicle should wear seat belts while driving / travelling in vehicle.

T-2 DRIVING

(1) Most traffic accident can be prevented by faithful observance of three things.

a. Control Speeds. Speeding is dangerous. A few minutes saved at the cost of an accident is no bargain.

b. Avoid Distractions. Give your undivided attention to the job of driving. Keep your eyes on the road.

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c. Drive Defensively. Don’t insist on your right of way. Try to anticipate the intention of other drivers and pedestrians. Their failure to observe traffic regulations does not justify your running into them.

(1) Company vehicles shall be operated within the legal speed limit at all times and at lower speeds where conditions like bad road, poor visibility and weather conditions warrant it.

(2) Keep a safe distance from vehicle in front.

(3) Do not attempt to pass another vehicle going in the same direction unless you can plainly see far enough ahead to be sure you can pass safely. Proper horn signal should be given before passing.

(4) Do not drive to the right of road centre when approaching the crest of a hill, an intersection, railroad crossing, or curve where full view of the roadway ahead is obstructed.

T-3 PARKING

(1) Park on the proper side of the street close to the curb, or of the highway so as not to interfere with traffic.

(2) When parking along a highway at night parking lights shall be left on. If any work is to be done, flares shall be set opposite ends to warn other drivers.

(3) When parking on a grade, place vehicle in gear, set hand brake, turn wheels to curb, or otherwise block the car so it cannot accidentally roll.

(4) To change a tyre or make other necessary repairs along the highway, pull off to the side of the road as far as possible.

(5) Before leaving a parked vehicle, always remove the ignition key to prevent theft or unauthorised starting of car.

(6) Leave or enter parked vehicles on the curbside wherever possible. Use extreme care if doors are

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open on roadside to see that no other vehicles are near.

(7) Before starting a parked vehicle, observe front and rear to make sure that persons and objects are out of the way.

T-4 OPERATION OF TRUCKS AND TRAILERS

(1) Before starting a truck, the man in-charge of party should carefully inspect the loading of materials and see that wherever necessary the material is secured safely and that all men are safely aboard.

(2) Loading of vehicles should not exceed their rated capacity, and objects should not be permitted to extend beyond the sides unless the necessary permit has been obtained from the Authorities.

(3) The passengers carried in trucks should not exceed the legally permitted number.

T-5 PROCEDURE IN TRAFFIC ACCIDENTS

(1) Do not become involved in an argument as to who was responsible for an accident, but endeavour to get all the facts in the case. Remember that accidents that may appear trivial often result in claim for personal injury or property damage.

(2) Do not lose your temper; try to be courteous and helpful.

(3) Following instructions should be observed in the order given, if possible, when you are involved in a traffic accident :

a. STOP- Pull over to the curb or out of traffic, if possible. Never leave the scene of an accident without stopping to identify yourself and render such assistance as possible.

b. Assist injured persons in so far as you are able, giving immediate attention to severe bleeding. Do not move seriously injured persons unless necessary for their protection against further injury. Send for doctor and ambulance, if necessary.

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c. When requested give your name, address, company affiliation and show driver’s license to the other party.

d. Secure name, address and license number of the other driver, car license number, and names and address of car owner and Insurance Company.

e. Record names and address of witness.

f. Unless some policeman is present at the scene of the accident, notify police having jurisdiction in the territory.

g. Sketch the location showing position of vehicles or pedestrians involved, and any special conditions such as obstructions, parked cars, skid marks. Show date, time of day, weather and road conditions and any other information which you may consider useful.

h. Notify your supervisor, and also submit written report with all useful information which you possess.

F. FIRST AID

The principles of First-aid are based on the principles of practical medicine and surgery, a knowledge of which, in case of accident, injury, or sudden illness, enables a trained person to give such assistance as will preserve life, shorten the recovery period of recovery and give relief from pain.

First aid is limited to the assistance rendered at the time of the emergency with such material as may be available.

F-1 PRINCIPLES OF FIRST AID:

(1) Death is not to be assumed; it is better to render First aid to a cadaver than allow a living person to die from absence of First aid.

(2) If the breathing and / or the heart beats have stopped, try to restore the same by giving Artificial Respiration and, if required, Cardiac Massage. (Cardio-Pulmonary-Resuscitation.)

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(3) Stop any bleeding.(4) Treat the patient of circulatory shock by lowering the

head and raising the legs.(5) Keep crowds away as fresh air is essential.(6) Keep the patient warm.(7) In case of fracture, apply a splint to immobilise the part.(8) In case of burns wash the affected area with copious

amounts of water till pain subsides or for half an hour.(9) Do not try to force feed fluids to a semi- conscious or

unconscious person. Arrange for prompt Medical help and evacuation of the person to a Medical facility.

F-2 RESTORATION OF BREATHING BY ARTIFICIAL RESPIRATION.

(1) If normal breathing stops due to any reason, and the same is not restored within 3 minutes, then permanent brain damage can occur, and if the delay is more than 5 minutes, it could result in death.

(2) To check whether the person is breathing or not, place the palm of the hand in front of the nostrils to feel the warm air coming out of the nose. One can also look at the chest and abdomen for heaving movements that take place when a person breathes. Absence of warm air from the nose and heaving movement of the chest and abdomen indicate cessation of breathing.

(3) Begin the process of Artificial Respiration without delay. There are 2 important methods of artificial respiration: Mouth to mouth method and Holger – Nielson’s method.

(4) Mouth to mouth method: a) Position of Casualty:

1) Keep the casualty on his back and tilt his head backwards and support the neck.

2) Check the mouth for any foreign body and mop up the secretions with cloth. Do not remove artificial dentures.

3) If necessary, roll the injured on his side and slap him between the shoulder blades. Sometimes this alone may resume the breathing.

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(5) Holger – Nielson method (Back pressure – arm lift method)

a) Position of Casualty : 1) Remove pointed objects from chest and pants pockets & loosen the belt.2) Place distance foot on the nearer foot and turn the casualty face and chest downwards.

2) Give a sharp tap between the shoulder blades, place casualty’s hands one over the other with head slightly turned to one side. Above points are prerequisites of back pressure – Arm lift method (Holger-Nielson method) & Schafer’s method.

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b) Position of the operator:1) Place one knee with the inner side in line

with the casualty’s cheek six to twelve inches from the top of his head.

2) Place the other foot with the heel in line with the casualty’s elbow.

3) Place the hands on the casualty’s back with the lower part of the shoulder blades, the thumbs along side the spine, and the fingers pointing to casualty’s feet.

c) Movements of the Operator:1) Movement 1: While counting “One-Two”

gently rock forward until your arms are vertical to casualty’s body (Operator should not bend his elbow) see fig.1. This compression is to be effected by the weight of operator’s body.

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2) Movement 2: With count “three” catch the casualty’s elbows as in Fig. 2.

3) Movement 3: While counting ‘four and five” gently rock backwards, pulling and elbows until there is little tension on them, as in fig.3. This allows entry of fresh air into the casualty’s lungs by expanding his chest.

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F-4 EXTERNAL CARDIAC MASSAGE.a) Lay the injured person on his back on a firm

surface and kneel at his side.b) Place the heel of one hand on the lower half of the

injured person’s sternum (breastbone).c) Place your other hand on top of the first hand and

exert downward pressure till breastbone dips by 1 ½ inches.

d) Then quickly release the pressure (fig.7.)e) Repeat this cycle 60 times per minute.

F-4 CARDIO-PULMONARY RESUSCITATION. If both respiration & circulation have stopped then-

1) First give 5 to 6 quick breath by mouth to mouth method and check carotid pulse. If pulse is felt, continue mouth to mouth respiration only.

2) If carotid pulse is not felt after 5 to 6 mouth to mouth breaths, compress chest 15 times as described in external cardiac

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massage and then give 2 quick mouth to mouth breaths. Continue this rhythm of 15 compressions followed by 2 quick mouth breaths till medical help is available. If any assistance is available, one person should give one quick mouth breath while other gives 5 chest compressions immediately after it. Maintain this 1 to 5 rhythm till medical assistance is available.(fig.7)

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F-5 EXTERNAL BLEEDING Place the casualty in comfortable (horizontal)

position. Elevate the bleeding part, except in the cabs of fractured limb.Expose the wound but do not disturb the blood clots if they have formed.Apply direct pressure with thumb or palm and give firm pad and bandage.If direct pressure does not stop bleeding, then use indirect pressure by 1) pressure on relevant pressure point 2) constrictive bandage.1) Pressure points:

a) neck pressure point: (fig. 8.) place the thumb in the hollow between the lower part of voice box and sterno mastoid muscle, on the injured side and compress the artery below the levels of wound.

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b) Arm pressure point- compress the artery against the arm bone (as shown in fig. 9.)

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c) Thigh pressure point- with knee flexed, press directly downward in the centre of the groin with both the thumbs as shown in fig. 10.

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2) Indirect pressure by constrictive bandage: (Tourniquet) in severely bleeding injury where it is necessary to maintain indirect pressure for a long time, use constrictive bandage as shown in fig 11.

a) After every 15 minutes it should be loosened for a minute or two & retighten.

b) It should only be tied between elbow and shoulder or between hip and knee.

c) Constrictive bandages should never be covered by other bandage or applied under splints.

d) Time of application of constrictive bandage should be carefully noted and conveyed to Doctor.

e) It should be tight enough to stop the bleeding.2) Bleeding from the nose: sit the casualty in a chair with

his head slightly thrown forward.Pinch the soft part of nose (do not plug the nose). Warn the casualty not to blow the nose.

3) Bleeding from mouth cavity: give ice to suck. Compress the bleeding part with cotton plug.

F-6 BURNS(1) General Rule for the Treatment of Burns:

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(a) Apply running water over the burnt area till pain stops or for 30 minutes.

(b) Avoid frequent handling of the part affected by burn.(c) Cover the burnt area with clean or prepared sterile

dressing (Burn dressing).(d) If sterile dressing is not available, use a freshly

washed & sun-dried cloth to wrap the area.(e) Immobilise the affected part.(f) Treat circulatory shock.

F-7 SHOCK Shock is a condition of severe depression of

vital functions. In this condition patient has cold moist skin, nausea pallor and giddiness. This circulatory shock is different from electric shock. Every electric shock need not lead to circulatory shock.

1) Treatment of circulatory shock:a) Lay the casualty on his back in head low position.b) If casualty vomits, turn the head to one side.c) Wrap him in a blanket.d) If casualty is able to swallow, give him weak tea or coffee.e)Reassure the casualty &send for medical help.e) Do not apply heat or friction to limbs

2) Electric shock:Act at once- delay may be fatal, send for doctor immediately but never wait for him.Switch off the current. If this is not possible, remove the casualty from the contact with the current by help of a dry rope, a walking stick, rubber gloves, folded newspaper or a dry garment. While doing so, rescuer should stand on insulating material like wooden board, piles of newspapers or rubber soled shoes.Unless casualty is breathing normally, give artificial respiration and continue till doctor declares death of casualty. Give artificial respiration by 1) mouth to mouth method or 2) Holger-Nielson method or described elsewhere.Also check the carotid pulse and give external heart massage as described under ‘external cardiac massage’If pulse is not felt & normal breathing has also stopped give card- pulmonary resuscitation as described under cardio- pulmonary resuscitation.Treat casualty for circulatory shock as stated under circulatory shock

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Treat the burns if any, as stated under ‘general rules for the treatment of burns .see f-6

Every electric shock case should be kept under medical observation for at least 24 hours. Because casualty’s condition is liable to worsen when effects have seemed to be mild.

3) Electrical injuries: alternating current is more dangerous than direct current as the muscles are thrown into spasm causing casualty to remain in contact with the current. A/c current 50 cycles 15 to 20 milli. Amps prevent victim from releasing grasp. More than 20 milli. Amps may cause breathing difficulty.Moisture is a powerful conductor of electricity and when present, will facilitate the passage of the current. If the skin at the point of contact of earth is wet, even lower voltages may be dangerous. More important than the current is the path it takes through the body in finding its way to earth. Thus a very strong current passing to earth through the lower limb might be less dangerous than a much weaker current crossing the chest as unfortunately it is likely to do if it enters through the hand or arm. In these cases there may be immediate fatal paralysis of the heart or more commonly a sudden stoppage of breathing from paralysis of the muscles of respiration. If the nerves controlling the heart and circulation escape, the heart may continue to function even though the breathing has stopped. It is for this reason that in electrical injuries the face is blue rather than white and that artificial respiration may have to be carried on for a very long-time. As long as the heart beats, life may be saved. F-8 GENERAL RULES FOR TREATING AN

UNCONSCIOUS CASE

1) Ensure supply of air to the casualty by:a) Removing harmful gases if any or by shifting

the casualty to suitable place.b) Opening the doors and windows and keeping

the crowds away.c) Keeping passage of breathing clear by

removing false teeth and taking the tongue away from the back of the throat of the casualty.

2) If breathing has stopped give artificial respiration by Holger – Nielson Method or mouth to mouth method as

described elsewhere.3) If breathing is noisy, on account of blood, vomit or

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saliva etc. in the throat, keep the casualty in 3/4th prone position as shown in fig.12.

4) Wrap the casualty in a blanket after loosening the tight clothing.

5) Do not leave the casualty until he has been placed in charge of a responsible person

6) Do not attempt to give food or fluids while casualty is unconcious.

7) Remove him to a shelter on a stretcher.

F-9 GENERAL RULES FOR TREATMENT OF FRACTURES.

1) Do not attempt to move the casualty until a trained person immobilises the injured part.2) Steady and support the injured parts if necessary, with rolls of blankets or sandbags3) Treat the physical shock.4) Treat external bleeding if any.

F-10 TREATMENT FOR CHEMICAL BURNS1) Acid burns:

a) Thoroughly flood the part with water.b) bathe the part freely with an alkaline solution

prepared as follows :- one teaspoonful of baking soda (bicarbonate of soda) dissolved in a glass of water

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c) Remove acid contaminated clothing by cutting it with scissors.

2) Alkali burns:a) Thoroughly flood the part with waterb) If alkali is in powder form, brush it off from the skin

before flooding the part with water.c) Bathe the part freely with weak acid solution

prepared as follows: equal quantities of lime juice or vinegar and water mixed together.

d) Remove alkali contaminated clothing by cutting it with scissors

3) When an alkali goes in the eye:Casualty should be asked to blink the eyelid under water or alternatively flush the eye with copious amount of water. Do not use acid or alkali for washing the eye. Soft pad of cotton wool should be kept over the eye and bandage should be applied lightly.

F-11 FOREIGN BODY IN THE EYE

Prevent the casualty from rubbing the eye. Advise the casualty to blink the eye under water (eyewash).

F-12 SNAKE BITE

Treatment for snakebite should always be prompt.1) arrange for medical help immediately 2) In the meanwhile, arrest circulation in the snake

bitten limb by using constrictive bandage between shoulder and elbow or between hip and knee joint (as the case may be) till the pulse is not felt beyond the constrictive bandage. Constrictive bandage should be kept in a position for 20 minutes, then released for 1 minute or until skin becomes pink and again tightened. Repeat the procedure till the arrival of the doctor.

3) Immediately after the constriction is applied, wash the wound with a solution of potassium permanganate, in order to remove any venom that may have dried on the skin.

4) Make a deep cut with a sharp knife or razor blade at the bitten site in order to bleed the bitten site.

5) Assure the patient and keep him warm by means of blanket.

6) Patient should be absolutely still7) If he is able to swallow, give him strong tea or

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8) If breathing stops, give artificial respiration by mouth to mouth or Holger-Nielson Method.

F-13 HEAT EXHAUSTION

Heat exhaustion occurs among the workers in stuffy atmosphere or in overheated, poorly ventilated room. There may be feeling of giddiness or fainting, skin is always cold and moist. Prevention by wearing loose clothing, drinking large quantities of water is possible.1) Active first-aid treatment of heat exhaustion;a) Remove patient to cooler conditions in the fresh air.b) Lay him down and loosen all clothing around the neckc) Dash cold water around the neck to stimulate.d) Fan him vigorously.e) If severe shock is present, use stimulants.

F-14 HEAT STROKE

Heat stroke proper is an entirely different reaction in the human body, to the same conditions which favour heat exhaustion. It is serious and often fatal condition. Hot, still humid atmosphere and inadequate drinking of water favours development of heat stroke. Alcohol consumption and constipation also favour its onset.

Casualty shows mental excitement, restlessness, vomiting, muscular cramps and high temperature in the range of 104F or above. If temperature reaches 106F patient may become unconscious.

1) treatment for heat stroke:a) Send for doctor.b) Commence active treatment before temperature

reaches 104F.c) Strip the patient naked and wrap him up completely

in cold-water soaked bed sheet.d) Fan vigorously and when the temperature of body

comes down to 102 F, cooling process should be stopped.

e) Later on, patient should be dried and covered with light blanket.

f) Water can be given to drink to eliminate poisons

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