Bhel Ocp

SAFETY MANAGEMENT
OPERATIONAL CONTROL PROCEDURES
OCP/Rev Title
001/03 Emergency Preparedness and response
002/03 Mock drill management
003/04 Incident / accident management
004/03 Collection, documentation, evaluation and communication of safety indices
005/03 Personal Protective Equipment Management
006/03 Internal Safety Management Communication
007/03 External Safety Management Communication
008/03 Pre-Start up Safety Review
009/04 Work Permit Management
010/03 Hazardous area management
011/03 Safety Stewards Scheme
012/03 Safety Coordinators Scheme
013/03 Storage and handling of gas cylinders
014/03 Safety in operations
015/03 Plant safety inspection
016/03 Central Safety Committee

BHARAT HEAVY ELECTRICALSL LIMITED: TIRUCHIRAPPALLI
Safety, Health and Environmental Management Systems
Master List of Operational Control Procedures
Dept: Safety Management As on: 11-01-2007
Sl. OCP No.& Purpose Performance

No. Rev No. and Title criteria
1 001/03 To identify the potential emergency locations Record of mock
Emergency Preparedness to establish procedures to handle emergencies drills
and response with a view to
- reduce risk to human health and life both
within factory and outside.
- Minimize damage to machineries,
equipment and environment.
2 002/03 To ensure conducting, monitoring and Record of mock
Mock drill management reporting of on-site emergency preparedness drills
mock drills. To review emergency
preparedness and response procedures.
3 003/04 To ensure that all incidents/accidents are Accident Trend
Incident / accident reported, investigated, analysed, corrective and CSC review
management and preventive actions taken for reducing
frequency and severity.
4 004/03 To know the accident trend in the Company. Accident Trend
Collection,
documentation,
evaluation and
communication of safety
indices
5 005/03 To identify the required type and ensure the Availability,
Personal Protective availability and effective usage of PPE. utilization reports
Equipment Management and user
feedbacks.
6 006/03 To create and sustain safety Feed back and
Internal Safety awareness audit finding.
Management
Communication
7 007/03 To ensure safety communications with all Feed back from
External Safety concerned. external agencies.
Management
Communication
8 008/03 To ensure safety of employees and Deviation reports
Pre-Start up Safety machineries while commissioning of and feed back.
Review equipments.
9 009/04 To define and implement safe work permit Work permit
Work Permit system for specified activities having reports and
Management potential for incidents and accidents deviation reports.
1
Sl. OCP No.& Purpose Performance
No. Rev No. and Title criteria
10 010/03 To ensure the safe working conditions in Reports on
Hazardous area potentially hazardous areas inspection and
management audits.
11 011/03 To enhance the involvement of the supervisor Reports on
Safety Stewards Scheme and equivalent category in the On-the-job activities and feed
safety promotional activities. back.
12 012/03 To enhance the involvement of the supervisor Reports on
Safety Coordinators and equivalent category in the Off-the-job activities and feed
Scheme safety promotional activities. back.
13 013/03 To ensure safe handling, storage and Plant inspection
Storage and handling of transportation of compressed gas cylinders reports
gas cylinders
14 014/03 To ensure safety in various activities carried Reports on
Safety in operations out in the factory. activities and feed
back.
15 015/03 To identify unsafe conditions of the Accident trend
Plant safety inspection workplace and unsafe practices of employees. and CSC review.
16 016/03 Assisting and guiding the management in Accident trend
Central Safety achieving the better safety and health and CSC review
Committee performance by effective participation of all
employees.
2
HEALTH,SAFETY AND ENVIRONMENTAL Rev. 03
MANAGEMENT SYSTEM Date 11.01.07
70-943
OCP:SAF:001:H OPERATIONAL CONTROL PROCEDURE Page 1 of 4
FOR EMERGENCY PREPAREDNESS AND
RESPONSE
1.0 Purpose :
To identify the potential emergency locations to establish procedures to handle

emergencies with a view to
- reduce risk to human health & life both within factory and outside.
- minimise damage to machineries, equipment and environment.
2.0 Scope : BHEL, Factory premises.(As per annexure I)
3.0 Responsibility : Head / Safety Management .
4.0 Performance criteria : Record of mock drills.
5.0 Cross reference : OHSAS 18001 Clause 4.47 , ISO 14011 Clause 4.4.7 , MSIHC
Rules & site specific emergency preparedness plans
6.0 Activities :
Sl. Activity Responsibility

No.
01. Identification of potential emergency locations and types of Head/Safety
emergencies. (As per Annexure 1) Management
02. Identification of protective system (As per annexure 2 ) Head/Safety
Management
03. Preventive measures to avoid emergency situations Concerned HOD
04 Making arrangements to install monitoring equipment (if required) Concerned HOD
to prevent hazardous situation
05. Ensuring availability of PPE to employees Concerned HOD
06. Development of site specific emergency preparedness and Concerned HOD
response plan &
Head/Safety
Management
07. Identification of persons to take charge during emergency Concerned HOD
including during odd hours / holidays
08. Identification of Safe Assembly points, Emergency Assembly Concerned HOD
point, Control center with adequate facilities
09. Communication of Emergency preparedness plan Head/Safety
Management
10. Training of personnel on emergency preparedness Head/Safety
Management
and concerned
HOS
11. Preserving data and relevant records, which will be useful in the Concerned HOD
future investigation.
12. Analyse the causes of accident and suggest measures to prevent Head/Safety
recurrence. Management
13. Review and revision of this procedure, after the occurrence Head/Safety
of emergency situations/ mock drill. Management
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RESPONSE
14. Taking corrective and preventive actions including disposal and Concerned
treatment of wastages after accidents. HOD
15. Communication of facts to relevant statutory authorities. Head/Safety Mgt
and HR
16. Communication to other fire services as per mutual aid scheme. Fire Services
7.0 Checking, Corrective and Preventive Action : Concerned area head shall
ensure implementation of this procedure and in case of any deviation
Corrective & preventive action shall immediately be taken
8.0 Records
Title Location Retention period

Emergency preparedness plan Concerned area and 2 years
Safety Management
Incident analysis Safety Management 2 years
Prepared by Reviewed and Approved by
(E.Thirumavalavan) (G.Moses)
Sr. Manager /Safety Mgt. AGM/Safety Mgt.
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RESPONSE
ANNEXURE 1 TO OCP: SAF : 001:H
List of potential emergency locations
Sl. Area
No
01 Producer gas plants
02 Gas fired furnaces
30 T / Bay 1 / Bldg.1
40 T / Bay 1A/Bldg.1
101 T/Bay 1D/Bldg.1
150 T/Bay 1D/Bldg.1
50 T /Bay 1D/Bldg.1
301 T/Bay 197/Bldg.1
CDF/Bay 2 / Bldg.50
HDF/Bay 3 / Bldg.50
03 HT & Electroplating section
04 Inflammable stores including fuel storage areas
05 Acetylene plant
06 Steam testing station/Bldg.7
07 LPG area/ SSTP
08 Pickling plant / SSTP
09 Protective Gas Plant / SSTP
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RESPONSE
ANNEXURE 2 TO OCP: SAF : 001:H
List of protective devices
Sl. Emergency Location/Activity Protective Remarks

No devices
01 Fire Producer gas plants Gas detectors *
Gas fired furnaces* Fire hydrants 30 T / Bay 1 / Bldg.1
Heat treatment and Fire extinguishers 40 T / Bay 1A/Bldg.1
Electroplating shop Smoke detectors 101 T/Bay 1D/Bldg.1
Inflammable stores Fire alarms 150 T/Bay 1D/Bldg.1
Acetylene Plant Flash back 50 T /Bay 1D/Bldg.1
Fuel storage tanks arrestor 301 T/Bay 197/Bldg.1
Water seals CDF/Bay 2 / Bldg.50
02 Explosion Producer gas plant Fire extinguishers HDF/Bay 3 / Bldg.50
Gas fired furnaces Flash back
Heat treatment and arrestors
Electroplating shop Automatic self
Inflammable stores closing fire door
Acetylene Plant Safety relief valve
Fuel storage tanks
Steam testing station
03 Toxic gas Producer gas plant Fire extinguishers
release/ Gas fired furnaces Water seals
Poisoning Gas mask
04 Spillage of Inflammable stores Fire extinguishers
chemicals Heat treatment and Fire hydrants
Electroplating shop Eye wash
fountains /
showers
05 Occupational Electrical work Personal
accidents All work involving safe protective
work permit system equipment
Radiography
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FOR MOCK DRILL MANAGEMENT
1.0 Purpose: a. To ensure conducting, monitoring and reporting of on-site

emergency preparedness mock drills
b. To review emergency preparedness and response procedure.
2.0 Scope : BHEL complex.
3.0 Responsibility : Head/Safety Management.
4.0 Performance Criteria: Record of mock drills.
5.0 Cross reference : OHSAS 18001 Clause 4.4.7 , ISO 14011 Clause 4.4.7 , MSIHC
Rules & site specific plans (as per annexure)
6.0 Activities:
Sl. Description Responsibility
No.
01. Conducting mock drill as per site specific emergency Concerned HOD
preparedness plan once in six months and
Head/Safety
Management
02. Posting of observers at mock drill site, control room and first- Head/Safety
aid area and recording the observations regarding the Management
conduct of mock drill as per the checklist.
03. Preparation of mock drill report and communication of Head/Safety
observations and suggestions to concerned HODs. Management
04. Dissemination of mock drill findings to all concerned Concerned HOD
employees
05. Implementation of suggestions regarding conduct of mock Concerned HOD
drill
06. Feed back regarding implementation of remedial measures Concerned
on mock drill to Head/Safety Management HOD
07. Review of Emergency preparedness and response Head /Safety
procedures based on observations on mock drill or findings Management
on analysis of accidents or whenever necessary.
7. CHECKING, CORRECTIVE AND PREVENTIVE ACTION: Concerned area head

shall ensure implementation of this procedure and in case of any deviation
Corrective & preventive action shall immediately be taken.
8.0 Records

Mock drill reports Concerned area and Safety Mgt. 2 years
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FOR MOCK DRILL MANAGEMENT
ANNEXURE TO OCP: SAF : 002:H
List of potential Hazardous areas
Sl.N Area
o
01 Producer gas plants
02 Gas fired furnaces
30 T / Bay 1 / Bldg.1
40 T / Bay 1A/Bldg.1
101 T/Bay 1D/Bldg.1
150 T/Bay 1D/Bldg.1
50 T /Bay 1D/Bldg.1
301 T/Bay 197/Bldg.1
CDF/Bay 2 / Bldg.50
HDF/Bay 3 / Bldg.50
03 HT & Electroplating section
04 Inflammable stores including fuel storage areas
05 Acetylene plant
06 Steam testing station/Bldg.7
07 LPG area/ SSTP
08 Pickling plant / SSTP
09 Protective Gas Plant / SSTP
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INCIDENT / ACCIDENT MANAGEMENT
1.0 Purpose : To ensure that all incidents / accidents are reported,

investigated, analyzed , corrective / preventive actions taken for reducing frequency and severity.
Definitions :
Incident - any event which gave rise to an accident or had the potential to lead to an
accident. Incident includes near misses.
Accident - any undesired event giving rise to death, ill health, injury, damage or other
losses.
Personal injury - Any bodily harm to any person
First-aid injury - Any injury to a person in which he resumes his work immediately after getting
first-aid
Lost time injury: If an injured employee is not able to resume his work immediately after getting
the first-aid and is referred for further treatment at hospital. It can be either a non-reportable
accident or a reportable accident.
Non - Reportable Accident - Any injury to a person during course of his / her duty causing
disablement for a period of less than 48 hours immediately after incident.
Reportable Accident - Any injury to a person during course of his / her duty causing
disablement for a period of more than 48 immediately after incident.
Fatal Accident - A Fatal Accident is one which causes death of a person / persons
immediately on the spot or subsequently arising out of that accident.
High Potential Accidents / Incidents (Near misses) - Any accident / incident (near miss)
which has potential to convert into High potential accident / incident under slightly
different circumstances shall be termed as High potential accident / incident (near miss).
Dangerous Occurrence - Any event of the following classes whether attended or not
they are attended by personal injury or disablement:
i) Bursting of a plant used for containing or supplying steam under pressure greater than
atmospheric pressure
ii) Collapse or failure of crane , derrick , winch, hoist or other appliances used in raising or
lowering persons or goods, or any part thereof , or the overturning of a crane.
iii) Explosion or Fire or bursting out, Leakage or Escape of any hot (molten) metal, liquid or gas
causing damage to any person or any room or place in which persons are employed.
iv)Explosion of a receiver or container used for the storage at a pressure greater than
atmospheric pressure of any gas or gases (including air) or any liquid or solid resulting from the
compression of gas.
v)Collapse or subsidence of any floor, gallery, roof, bridge, tunnel, chimney, wall, building or any
other structure.
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vi) Bursting of centrifugal machines.
2.0 Scope: Factory premises.
4.0 Performance Criteria : Accident trend and Central Safety Committee Review.
5.0 Cross reference: OHSAS 18001 Clause 4.4.6 & 4.5.2 and TN FR’1950, The
Explosives act
6.0 Activities
Sl.no Activities Responsibility
INCIDENTS (NEAR MISSES ) & DANGEROUS OCCURRENCES
01 For all incidents / near misses filling up the incident/accident Concerned Shift
report "( 70-907/B ) in duplicate Incharge
02 Send one copy of the incident /accident report to Safety Concerned Shift
Management directly and keep second copy as office copy. Incharge
03 Investigation all Incidents / Near misses and report Concerned

submission in specified format (310 – 003/C). Safety officer &
area executive
04 Formation of Investigation committee for dangerous Head /Safety
occurrences comprising members from Safety Management, Management
Concerned line area and concerned service personnel.
05 In case of Dangerous occurrences , fill in Form 18 A as Head /Safety

specified in TN Factories rules and report to Inspectorate of Management &
factories. PO/Welfare
06 Investigation of dangerous occurrence and report submission Concerned

in specified format (310 – 003/C). including details of property investigation
damage. committee
07 Communication of investigation findings to all concerned Head/Safety

departments for taking corrective and preventive action. Management
08 Implementation of corrective and preventive action. Concerned

section heads
09 Follow up for Implementation of suggested remedial Head/Safety

measures Management
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10 Communication to other similar areas on the findings and Head/Safety

remedial measures to prevent such occurrences in the areas. Management
NON - REPORTABLE ACCIDENTS and REPORTABLE ACCIDENTS
01 In case of injury to person, fill in the incident /accident Shift incharge

report"( 70-907/B ) in triplicate and send 2 copies to OHS /
FMC along with the injured person or at the earliest.
02 In case of odd hours ( When OHS / FMC is not functioning ) Shift incharge.
fill in the incident /accident report"( 70-907/B ) in triplicate
and send 2 copies to Hospital along with person or at the
earliest.
03 Recording the details of injured person, in the Injury -On-Duty- Doctor/OHS/FMC
Register (kept in OHS/ FMC and also in Hospital). or
Doctor/Hospital
04 For the injured person requiring only first-aid, fill up the incident Doctor/OHS/FMC
/accident report and send to Safety Management or
Doctor/Hospital
05 For injured persons requiring further treatment at Hospital, Doctor/OHS/FMC
send the injured person to Hospital with a medical advice slip
and also send incident /accident report to Hospital later.
Immediate communication of details to Safety Management, in
case of major injuries likely to become reportable accidents.
06 Recording of treatment , fitness and leave recommendation Doctor / Hospital
in the register and send the filled in incident /accident report
one copy to Safety Management and other copy to Welfare
department.
07 Preparation of FORM-18 for Reportable accidents as Head / Safety
specified in TN Factories rules and forward to personnel / Management
welfare department.
08 Report all the reportable accidents to Inspectorate of Head / Safety
factories Management &
PO / Welfare
09 Investigation of non–reportable accidents by a team of safety Head/Safety

and concerned area supervisor/executive and suggest Management
remedial measures in the specified format (310 – 003/ C)
10 Investigation of reportable accidents and submission of a Head/Safety
detailed report along with format by the Investigation Management
Committee constituted by Head / Safety Mgt.
11 Sending investigation reports of both reportable and non- Head/Safety
reportable accidents to all concerned departments for taking Management
corrective and preventive action.
12 Communication to other similar areas on the findings and Head / Safety
13 Ensuring implementation of suggested remedial measures. Concerned HOD

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14 Review of the status of implementation and assessing the Head / Safety

effectiveness/adequacy of implemented measures. Management
FATAL ACCIDENTS
01 In case of Fatal accident occurs inside factory premises , Concerned area

report the matter immediately to incharge
- OHS
- Safety Management - Security and Fire services
- Personnel / Welfare
- Concerned Senior line management
02 Prepare Incident / Accident report and send to OHS/FMC Concerned area

in charge
03 Identify the witnesses and keep them under custody to Concerned area
depose witness statement in charge
04 Attend to the victim and reference to Hospital Doctor/ OHS/
FMC
05 Obtaining of report from concerned department about the Security Officer
accident, handing over to Local police and organising for
inquest.
06 Cordoning of the area free from disturbance and posting of Security Officer
security personnel till completion of statutory inspection .
07 Spot inspection and Preliminary enquiry about the accident Safety officer
08 Information to C&PR for photographic coverage of the Safety officer
accident (8 sets of copies)
09 Reporting of accident to DCIF , Trichy and CIF, Chennai Welfare officer &
by Telegram immediately. Safety officer
10 Preparation of Form 18 and handing over to Inspectorate Welfare officer &
of Factories in person Safety officer
11 Co-ordination for the inspection of Factory inspectorate on Welfare officer
the accident
12 Intimation to family of accidentee with the help of Welfare officer
security and concerned department
13 Preparation of medical report and send to Police Medical officer /
Hospital
14 Provision of necessary vehicles for officials and for medical Head / Transport
purpose
15 Co-ordination for post-mortem and obtaining necessary Welfare officer /
reports Security officer
16 Formation of Accident investigation committee comprising Head /Safety
senior level officers Management
17 Detailed enquiry and submission of report Convener /
Investigation
committee
18 Communication of investigation findings to concerned Head /Safety
department for taking corrective and preventive action. Management
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19 Communication to other similar areas on the findings and Head /Safety

20 Submission of Accident investigation report to Inspectorate Head /Safety
of factories Management
21 Further follow -up with Inspectorate of Factories Head /Safety
Management
22 Assessment on the effectiveness of remedial measures Head /Safety

Management
SPECIFIC ACCIDENTS
In case of occurrence of accidents involving gas cylinders , pressure vessel , etc under
the purview of Explosives act the following shall be followed in addition to the procedure
given above
01 Notice of accident to the CCOE(Chief controller of Concerned HOD

explosives, Nagpur) by Express telegram (Telegraphic
address – Explosive, Nagpur).
O2 Notice of accident to the CCOE (Chief controller of Concerned HOD

explosives, Nagpur) by a Letter within 24 hours with the
particulars of the accident.
03 Notice of accident to the officer in – charge of the nearest Concerned HOD

police station by the quickest route
04 Cordoning of the area free from disturbance and left Concerned HOD
untouched except under the conditions which warrant
clearance till completion of statutory inspection
05 Co-ordination and conduct of Inquiry into accident / serious Head /Safety
accident by a Magistrate or equivalent statutory authority as Management
specified in the concerned act /rules.
ANALYSIS
01. Recording of all the Incidents / accidents and to analyse them Head /Safety
area-wise monthly for causes, trade-wise & body part-wise. Management
02. To suggest corrective actions based on the above analysis Head/Safety

Management
03. Communication of incident/accident analysis to concerned Head /Safety

HOD/HOS monthly to update the register of hazards and Management
risks.
04. Dissemination of incident/accident analysis details to Concerned HODs
employees.
05. Implementation of suggested measures and communication Concerned HODs
to Safety Management
06. Review of implementation and sending MIR to top Head/Safety
management Management
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7.0 Checking, Corrective and Preventive Action : Concerned area head Shall
ensure implementation of this procedure and in case of any deviation Corrective &
preventive action shall immediately be taken
8.0 Records
Sl.No RECORD TITLE RECORD No. MAINTAINED RETENTION
BY
01. Report of Accident Form-18 Safety 2-Years
Management
02. Dangerous Occurrence Form-18A Safety 2-Years
Management
03. Incident /Accident Report 70-907/B Safety 2-Years
Management
04. Incident / Accident (310 – 003/ C). Safety 2-Years
investigation Report Management
05. Reports on implementation Safety 2-Years
of remedial measures Management
06. Monthly report Safety 2-Years
Management
07. MIR Safety 2-Years
Management
08 Minutes of meeting of CSC Safety 2-Years
Management
70-943
FOR COLLECTION, DOCUMENTATION,
EVALUATION AND COMMUNICATION OF
SAFETY INDICES
1.0 Purpose : To know the accident trend in the company.
2.0 Scope : All areas inside the factory premises.
3.0 Responsibility & Authority : Head /Safety Management.
4.0 Performance Criteria : Accident trend
5.0 Cross Reference : OHSAS 18001 Clause 4.4.6
6.0 Activities :
S.No Activities Responsibility

01. Collection of data such as total number of employees , Head /Safety
total man hours worked , total number of incidents Management
/accidents and total man-days lost etc.
02. Area-wise calculation of i) Frequency Rate, ii) Severity Head /Safety
Rate, iii) Incident Rate , iv) Frequency Severity index v) Management
longest accident-free period, vi) Man-days lost, once in 3
months.
03. Communication of safety indices to all concerned areas Head /Safety
Management
04. Arrange to disseminate safety indices to all concerned Concerned HOD
employees in each area.
05. Sending MIR to management. Head/Safety
Management
06. Submission of relevant data to agencies as applicable Head /Safety
Management
07. Evaluation of legal compliance periodically and Head/Safety
communication to the concerned heads of section for taking Management
corrective / preventive actions
08. Register complaints with respect to safety from external Head/Safety
parties and Regulatory Bodies Management
7.0 Checking, Corrective and Preventive Action: Periodical interaction/review with

concerned areas for any deviation and improvement.
8.0 Records

Safety Indices Safety Management 5 years
MIR Safety Management 2 years
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FOR PERSONAL PROTECTIVE EQUIPMENT
MANAGEMENT
1.0 Purpose : To identify the required type and ensure the availability and effective
usage of PPE.
2.0 Scope : Entire Factory
3.0 Responsibility & Authority : Head /Safety Management
4.0 Performance Criteria : Availability, utilisation reports and user feedbacks.
5.0 Cross Reference : OHSAS 18001 Clause 4.4.6 & PPE Manual
6.0 Activities :
No.
01. Preparation of PPE manual containing detailed technical Head/Safety
specification, drawings, identification of PPE area-wise/ Management
activity-wise (Refer annexure) , etc . Updation of PPE
MANUAL once in 5 years based on the user's feedback and
necessary changes.
02. Estimating the quantity and Raising the indent for the PPE Head/Safety
along with specification and drawing and forwarding the Management
same to Management Services Department.
03 Selection and approval of PPE Head/Safety

Management
03. Clearing the indent and forwarding it to Purchase Head / Mgt.
Department for procurement. services
04. Sending the enquiry for different PPEs as per the Head / PSS /
specification of PPE manual.
05. Forwarding the quotation along with the sample to SM for Head / PSS /
evaluation.
06. Evaluation of the sample and recommendation to Purchase Head /Safety
to place order for the PPE ‘s Management
07. Place order on selected parties to supply PPE.. Head / PSS
08. Verification of received PPEs at stores for the quantity and Head /Safety
inspection of PPE with the approved sample before Management
accepting.
09. Issue of PPE to employees from Stores. Incharge /
Stores
10. Maintenance of minimum inventory of PPE and recouping it. Concerned IM
Stores
11. Issue of Spectacle type Safety goggles available at SM to Head /Safety
the employees as required. Maintenance of the record in Management
Safety Management
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FOR PERSONAL PROTECTIVE EQUIPMENT
MANAGEMENT
12. Placing Order for Power Corrected Goggles based on Head /Safety
company Opthalmalogist's recommendation to the needy Management
employees
13. Inspection and certification of the Power Corrected Goggle Duty Doctor /
received by the employees from the optician. Opthalmologist
14. Maintenance of Breathing Apparatus set . Head/Fire

services
15. Study on usage of PPE and sending report Head /Safety
Management
16. Obtaining feed back from users. Head /Safety
Management
7.0 Checking, Corrective and Preventive Action: : Concerned area head shall
8.0 Records
Sr. Title File Name Location Retention

No. Period
1. PPE Files PPE Files Safety 3 Years.
Management
2. PPE manual Safety 5 years
Management
3. Report on PPE Safety 5 Years
usage and feedback Management
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FOR INTERNAL SAFETY
MANAGEMENT COMMUNICATION
1.0 Purpose : To create and sustain safety awareness.
2.0 Scope : Entire Factory
3.0 Responsibility & Authority: Head /Safety Management
4.0 Performance Criteria : Feed back and Audit finding.
5.0 Cross Reference : HSEMS Manual , OHSAS 18001 Clause 4.4.3
6.0 Activities :

No.
01. Identification of the applicable legislation and regulations and Head /Safety
updation Management
02. Ensuring that the Register of Applicable H S E Regulations is Head /Safety

communicated to all concerned heads of section Management
03. Giving safety suggestions All employees
04. Circulation of OH&S Policy to all employees Head /Safety

Management
05. Safety Instruction to employees Safety officer &
HOS
06. Publication and Circulation of Safety Newsletter to all Head/Safety
employees every month. Management
07. Organise Safety classes / courses periodically for employees, Head/ HRDC &
trainees and contractors. Head /Safety
Management
08. Display of safety instructions, slogans, posters and hoarding Head /Safety
boards Management
09. Conducting Central Safety Committee Meetings once in 3 Head /Safety

months Management
10. Arrange for Safety Pledge taking by all employees on 4th Head/Safety
march every year through concerned line executives Management
11. Half yearly award for lowest accident rate to the areas and Head /Safety
issue of gift article to the winning area employees. Management
12. Conducting Housekeeping competition every year Head /Safety

and issue of gift articles for the winners Management
13. Periodical meetings of safety stewards and safety Head/Safety

coordinators Management
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FOR INTERNAL SAFETY
14. Conducting various Safety competitions Head/Safety

Management
15. Issue of safety circulars Head/Safety
Management
16. Dissemination of information from Factory inspectorate, NSC Head /Safety
and other professional bodies Management
17. Identify training needs for Safety Management personnel and Head /Safety
organize for training programmes Management
18. Maintenance of Internal Safety Communication Register Head /Safety
Management
7.0 Checking, Corrective and Preventive Action : Periodical meetings with

concerned area incharges
8.0 Records
Sl. Record title Maintained Retention

no.
1 Minutes of meeting of CSC Safety Management 3 years
2 Plant Inspection reports Safety Management 2 years
3 MIR Safety Management 2 years
4 Internal Safety Communication Safety Management 1 year
Register
70-943
FOR EXTERNAL SAFETY
1.0 Purpose : To ensure safety communication with all concerned .
2.0 Scope : All external interested parties such as Factory Inspectorate ,

Explosives inspectorate , NSC, LPA , etc..
3.0 Responsibility & Authority: Head /Safety Management
4.0 Performance Criteria : Feedback from external agencies
5.0 Cross Reference : HSEMS Manual , OHSAS 18001 Clause 4.4.3
6.0 Activities :

No
01. Reporting of Reportable accidents in Form 18 and Incidents / Head/Safety

Dangerous Occurrences in Form 18A to factory inspectorate. Management
02. Making available the Accident / Incident investigation reports for Head/Safety
information to factory inspectorate. Management
03. Liaison for inspection of Pressure vessel by Inspector of Factories Welfare officer
04. Maintaining the Records as applicable to be shown to factory Head/Safety

inspectorate. Management
05. Traffic instruction / Regulation programme by Safety co-ordinators Welfare officer

during peak hours & on pay day at main crossings in
township.
06. Organising & Participating in programmes by Safety Head/Safety

professional bodies Management
07. National Safety Day Celebration Head/Safety
Management
08. Maintaining External Safety Communication Register. Head /Safety
Management
09. Communication to regulatory bodies with respect to safety Head /Safety
Management
7.0 Checking, Corrective and Preventive Action : Periodical interaction with

concerned personnel.
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FOR EXTERNAL SAFETY
8.0 Records
Report of accidents Safety Management 2 Years
Incident/accident investigation reports Safety Management 2 Years
Programme reports Safety Management 2 Years
Records (Statutory) Welfare 2 years
External Safety Communication Safety Management 2 Years

Register
70-943
FOR PRE-START UP SAFETY REVIEW
1.0 Purpose : To ensure safety of employees and machineries while commissioning

of equipments.
2.0 Scope : This covers commissioning of newly bought and relocated equipment
3.0 Responsibility & Authority : Head /Safety Management
4.0 Performance Criteria : Deviation reports & Feedback
5.0 Cross Reference : OHSAS 18001 Clause 4.4.6
6.0 Activities :

No
Part A - Equipment
01. Layout preparation for modification of existing equipment Head/MS
and new equipment.
02. Layout clearance with respect to safety . Head/Safety
Management
03. Cordoning of area , restricting unauthorised entry , compliance Concerned
to various safety provisions. executing
agency
04. Communication regarding commissioning of the equipment Management
Services
05. Checking of physical clearance , access , Guard for rotating Head /Safety
parts, layout , emergency exit , etc. after installation . Management
06. Checking of Lighting , Ventilation , Noise, Vibration, Fumes,
Smoke, ergonomics , etc. after installation Head/ OHS
07. Checking of availability and suitability of fire extinguisher and Head / Fire
access for fire fighting. Service
08. Carrying out any modification to cater to Safety & Health Concerned
requirements. executing
agency
09. Obtaining pre-start up Clearance from SM , OHS & Fire dept. Management
Services
Part-B Buildings
01. Communication to SM , Fire , OHS on the proposed facilities / Head /Civil /
provisions with respect to Safety , Health & Fire for the new Design
buildings to be constructed.
02. Checking of physical clearance , access , layout , emergency Head /Safety

exit , etc. Management
03. Checking of provisions regarding Lighting , Ventilation , Head / OHS
Noise, Vibration, Fumes, Smoke, ergonomics , etc.
04. Checking of provisions of Fire Prevention , fire fighting , access Head / Fire
for fire fighting , etc. Service
70-943
FOR PRE-START UP SAFETY REVIEW
05. Carrying out any modification to cater to Safety , Health & Fire Head / Civil
requirements
06. Obtaining Clearance from SM , OHS & FIRE prior to Management
occupation of buildings. Services
8.0 Records

Layout copies Management Services 2 Years
Clearance certificates Concerned Areas and 2 Years
Safety Management
70-943
FOR WORK PERMIT MANAGEMENT
1.0 PURPOSE : To define and implement Safe work permit system for specified
activities having potential for incidents and accidents.
2.0 SCOPE : Applicable to the following specified activities.
SL. Activities Department

NO
1 Construction , Erection & commissioning of new and CIVIL
modification of existing civil structures
2 Periodical civil maintenance work at height
3 Fragile roof work
4 Excavation & Blasting
5 Cranes erection & modification work M&S
6 Work at height including - Roof Light maintenance &

Furnace work
7 Welding and Gas cutting work at process plants

including pipe lines (PG and acetylene plants)
8 Confined space work (Cellars, furnace ducts)
(Note: Safe work permit for electrical line maintenance shall be as per M&S procedure.)
3.0 RESPONSIBILITY & AUTHORITY : Primary - Concerned HOD ; Secondary - Head /

Safety Management
4.0 PERFORMANCE CRITERIA : Work permit reports & Deviation reports
5.0 CROSS REFERENCE : OHSAS 18001 Clause 4.4.6 & Specific Safe work permit
format
6.0 ACTIVITIES :

No.
01. Initiation of Safe Work permit , in triplicate, for the Concerned
activities specified above. Department
70-943
FOR WORK PERMIT MANAGEMENT
02. The first copy of the permit will be retained by the work All concerned
executing department, the second copy will be with Safety
Management and the third copy of the permit shall be with the
Contractor or his representative.
03. Obtaining Clearance from the connected agencies like Concerned
Production , M&S, etc. as applicable and SM. Department
04. Ensuring the availability of safety devices , protective Concerned
wears , caution boards , etc. and compliance with safety Department
instructions given in the respective safe work-permit formats.
05. Ensuring Supervision during the execution of Work Concerned
department
06. Safety surveillance to ensure adherence of employees Head/Safety
to safety and safe method. Management
07. Certifying the completion of work in the form. Concerned
department
08. Informing the concerned departments about completion of the Concerned
work. department
09. Submission of completed work-permit form to Safety Concerned
Management. department
10. Reporting of incidents/accidents in areas where work is Head/Safety
carried out after obtaining work permit Management
11. Monitoring the implementation of the work permit Head/Safety
Management
12. Monitoring the safe working of Contractors Head/Safety
Management
8.0 Records

Safe Work permits Concerned area and 1 year
Safety Management
Work Permit Deviation reports Safety Management 1 year
70-943
FOR HAZARDOUS AREA MANAGEMENT
1.0 Purpose : To ensure the safe working condition in potentially hazardous areas.
2.0 Scope : This covers Producer gas plants, Acetylene Plant, Furnaces
Inflammable stores and Heat Treatment & Electro plating shop.
3.0 Responsibility & authority: Head /Safety Management
4.0 Performance criteria : Reports on Inspection & Audit
5.0 Cross reference : OHSAS 18001 Clause 4.4.6
6.0 Activities :
SL Activity Responsibility
NO
01 Periodical Safety surveillance Head /Safety
Management &
02 Reporting of deviations (Check list) Head /Safety
Management &
Fire Services
03 Correction of deviations reported. Concerned HOD
04 Issue of code of conduct for safety to all employees Head/HRM
05 Adherence to safety code of conduct. All Employees
06 Ensuring the employees adherence to safety code of Concerned HOD
conduct
07 Conducting of mock drills and implementation of remedial Concerned HOD
measures.
08 Display of safety instructions. Concerned HOD
09 Compliance to license conditions in all licensed premises. Concerned HOD
8.0 Records

Inspection reports Safety Management 2 Years
70-943
ANNEXURE TO OCP : SM : 010:H
SAFETY MANAGEMENT
SAFETY INSPECTION CHECKLIST FOR PG PLANT
Date of Safety Inspection :
Sl.no. Expected Observed Corrective/

Preventive action
1. No leakage of CO in the pipeline or
generator area
2. Availability of 'CO' monitor or CO
leakage indicator
3. Proper functioning of 'CO' monitor
4. Environment to be free from CO
5. Electrical fittings are to be in good

condition.
6. No temporary wiring
7. No unguarded opening in the floors
8. Steps are provided with hand rail
9. Availability of toe boards
10. Suitable PPEs are provided to the

employee
11. Employees are using the PPE
12. Availability of emergency siren and

working condition
13. Functioning of hot line telephone
14. Floor to be free from slippery

condition
15. Availability of emergency light and
working condition
16. Emergency is to be free from
obstruction
17. Earthing of Conveyor belt
70-943
Sl.no. Expected Observed Corrective/

Preventive action
18 Provision of coupling guards for the
motors
19 Covering of motor terminals
20 Rubber mat provision for panel

boards
21 Fencing for panel boards
22 No leakage of tar and phenol
23 Clearance and disposal of ash

properly
24 Maintenance of fire extinguishers
and hydrants
25 Coal stacking in heaps
26 Provision of wind direction indicator
27 Proper ventilation arrangement
28 Display of ‘No smoking’ and

restriction
Specific comments if any :
Signature of Safety Mgt Signature of Area in-charge

70-943
SAFETY MANAGEMENT
SAFETY INSPECTION CHECKLIST FOR ACETYLENE PLANT
Sl.no. Expected Observed
1 Storage of calcium carbide away from water source
2 Proper ventilation of Calcium carbide room
3 Provision of flame-proof electrical fittings
4 Availability of Fire extinguishers
5 Display of ‘No Smoking’ board
6 No leakage of acetylene gas
7 Availability of non-sparking tools
8 Good working condition of flash back arrester
9 Proper lighting
10 Proper ventilation
11 Flange joints to be free from leakage
12 Provision of proper bonding/Earthing
13 Pulley blocks to be in good condition
14 Platform is to be in good condition
15 Area free from any unwanted material
16 Area is to be free from cob web
17 No loose wiring
18 Usage of suitable PPE
19 Motors in the generator area are to be of flame proof

70-943
20 Availability of caps for the gas cylinders
21 Availability of chain arrangement for the gas cylinders
22 Sand bucket are filled with sand
23 calibration status tags for all gauges

70-943
SAFETY MANAGEMENT
SAFETY INSPECTION CHECKLIST FOR FURNACES
S.No Expected Observed Corrective/

Preventive action
01 Availability of details for proposed
process
02 Clearance obtaining from PG plant
03 Good working condition of the exhaust
04 Provision of proper Illumination
05 Detailed instruction for start-up and shut
down
06 No leakage (Burner, Control valve, Air
line)
07 Area is to be free from any unwanted
materials
08 Good Housekeeping
09 Suitable PPE used by the employees
1. Safety shoes 2. Hand gloves
10 Valves are in fully operable condition
11 Easy access of Electrical power supply
12 Perfect closing/opening of furnace door

70-943
13 Calibrated pressure gauges used at:
1. Control valve 2. Control room
14 Adequate number of enclosures
15 Obstruction free furnace control room
16 Safe Ladders at:
1. Furnace 2. Duct
17 Guard for Blower motor coupling
18 No overflow in Tar pit
19 Corrosion/Erosion free Damper duct
20 Safe Damper motor control room

70-943
SAFETY MANAGEMENT
SAFETY INSPECTION CHECKLIST FOR INFLAMMABLE STORES
S.No EXPECTED OBSERVED CORRECTIVE/

PREVENTIVE
ACTION
1 Gas cylinders are to be provided with
cap
2 Empty and full cylinders are to be
separately
3 Gas cylinders are to be stored
separately under each category
4 Cylinders are to be kept under shade
without sunlight
5 All flammable material are to be stored
separately away .
6 Flammable material are to be grouped
and stacked properly under shade
7 All the electrical fittings are to be of
fire and explosion proof.
8 Electrical wiring is to be properly
maintained
9 All the electrical switches are to be in
good condition
11 Proper illumination
12 Fire extinguishers are to be in good

working condition
13 Prohibition of Smoking and display
of board
14 Proper Earthing for Diesel / Petrol
tanks
15 Proper maintenance of the earth pits
16 Availability and usage of non -
sparking tools
Signature of SM Signature of Area in-charge

70-943
SAFETY MANAGEMENT
SAFETY INSPECTION CHECKLIST FOR HEAT TREATMENT AREA
Date of Safety Inspection

PREVENTIVE ACTION
1 Chemicals are to be properly labled
and stored
2 Provision of proper ventilation
3 Exhausts are to be in working

condition properly
4 Proper illumination i and around

area
5 Sufficient aisle is to be
maintained
6 No chemical / water spillage
7 No unwanted material lying in the

area
8 Proper house – keeping is to be
maintained
9 Availability of suitable PPE and
usage by the employees
10 Waste water is to be treated
properly
11 Functioning of the effluent
treatment plant is to be ensured
12 Ph value is to be maintained in
the outlet water
13 Availability of there eye wash
fountain / shower
14 Eye wash fountain /Shower working
condition maintained
15 Hand tools are to be maintained
properly
16 Hoists , Lifting appliances , rope
and the slings are to be
inspected periodically and records
maintained
17 MSDS for the materials are to be
made available and displayed
18 Spill kit is to be made available
70-943
19 Safe operating procedure to be

made known to employees and
displayed
20 Emergency preparedness of area
employees is to be assessed

70-943
FOR SAFETY STEWARDS SCHEME
1.0 PURPOSE : To enhance the involvement of the Supervisors & equivalent

category in the ON - THE - JOB Safety Promotional Activities .
2.0 SCOPE : This covers both production and non- production areas.
3.0 RESPONSIBILITY & AUTHORITY: Head /Safety Management
4.0 PERFORMANCE CRITERIA : Reports on activities & Feedback
5.0 CROSS REFERENCE : OHSAS 18001 Clause 4.4.6
6.0 ACTIVITIES :
SNO Activity Responsibility

01 Sending Nomination call letters to all Production (For Group I ) Head /Safety
& Services areas ( For Group II ). Management
02 Nomination of employee from the category of Supervisors or Concerned

equivalent level as a Safety Steward. HOD
03 Selection of office bearers for each group. Stewards
04 Arranging for Safety Stewards meeting once in a month to Head /Safety

discuss their achievements, Management
05 Submitting Monthly Reports Stewards
06 Sending consolidated monthly reports on salient work done to Head /Safety

stewards. Management
07 Performing the activities as given in the Stewards activities list Stewards

(Refer Annexure)
08 Providing incentives to Stewards who have maintained NIL / Head /Safety

Minimum accidents in their area and for regular attendance of Management
meetings.
09 Selection and issue of Annual Gift Head /Safety

Management
10 Selection of best stewards for Gold / Silver medals Head /Safety
Management
11 Organising annual safety stewards and coordinators meet Head /Safety
Management
7.0 Checking, Corrective and Preventive Action : : Concerned area head

shall ensure implementation of this procedure and in case of any deviation
70-943
8.0 Records

Nomination letters Safety Management 2 Years
Installation reports Safety Management 2 Years
Monthly reports Safety Management 2 Years
Activity list Safety Management 2 Years
70-943
Annexure to OCP:SM:011:H
ACTIVITIES OF SAFETY STEWARDS
01. Display of Safety Information.
02. Display of Safety Slogans.
03. Communication to Safety Management regarding Incidents / Accidents.
04. Instruction to employees for wearing of PPE.
05. Giving " Safety-Talks " to Employees.
06. Removing Unsafe conditions and correcting Unsafe practices.
07. Communication to Safety Management regarding the points observed during

activities under Safe Work Permit System.
08. Maintaining Housekeeping in their areas.
09. Assisting for implementation of remedial measures to prevent incident /accident.
10. Filling of water in the Flash back arrestors.
11. Maintaining easy access to Fire extinguishers and Electrical Panel Boards.
12. Communication to Safety Management for arranging Personnel Protective

Equipment (PPE) on need basis.
13. Arrange to provide guards for rotating parts.
14. Arrange to send Scrap / Unwanted materials to Stores.
15. Arrange to provide guards for Pneumatic Grinders & Grinding machines.
16. Display of details in Pedestal Grinding machines.

70-943
FOR SAFETY COORDINATORS SCHEME
1.0 PURPOSE : To enhance the involvement of the Supervisors & equivalent

category in the 'OFF-THE-JOB' Safety Promotional Activities .
2.0 SCOPE : This covers both factory and township premises.
3.0 RESPONSIBILITY & AUTHORITY: Head /Safety Management
5.0 CROSS REFERENCE : OHSAS 18001 Clause 4.4.6
6.0 ACTIVITIES :
SNO Activity Responsibility

01 Selection of Safety Co-ordinators from the Safety Stewards Head /Safety
for a term of 4 years. Management
02 Communication and seeking acceptance from the concerned Head /Safety
HOS/HOD for nomination to the Safety coordinators scheme Management
03 Selection of office bearers Head /Safety
Management
04 Arranging meeting of Safety Co-ordinators Head /Safety
Management
05 Performing safety promotional activities as arranged by Safety Safety co -
Management ordinators
06 Arranging Refreshment for Safety co-ordinators. Head /Safety
Management
07 Selection and issue of Annual Gift Head /Safety
Management
08 Selection of best Safety Co-ordinators for Gold / Silver medals Head /Safety
Management
09 Organising annual safety stewards and co-ordinators meet Head /Safety
Management
8.0 Records

Programme schedules Safety Management 2 Years
70-943
FOR STORAGE AND HANDLING OF GAS
CYLINDERS
1.0 Purpose: To ensure safe handling, storage and transport of compressed gas
cylinders.
2.0 Scope : BHEL complex.
3.0 Responsibility : Concerned HOD/HOS
4.0 Performance Criteria: Plant inspection reports.
5.0 Cross reference: OHSAS 18001 Clause 4.4.6 & Indian gas cylinders rules
6.0 Activities:

No.
01. Receipt of compressed gas cylinders from various suppliers. Inflammable
Precautions: Stores
- Before unloading, identify the cylinders by their colours as per incharge
the standard colour code or labels. (Refer Annexure-1)
- In case the consignment does not conform to the
requirements, do not accept the consignment.
- Unload cylinders carefully by taking necessary precautions
(Refer Annexure-2)
02. Storage of compressed gas cylinders in the specified area ( as All Stores
per the compatibility given in MSDS). incharges/
- Storage quantity including all locations should not exceed Concerned
licensed quantity. area incharges
- Storing cylinders in a cool, dry, well ventilated place.
- Securing or racking all cylinders in upright position.
- Storing full cylinders and empty cylinders separately.
- "Full" or "Empty" notices should be displayed on each
relevant
stack.
- Storing cylinders away from highly flammable materials,
highly
corrosive materials and from heat sources, flames and
sparks.
- Ensuring all empty cylinders are closed by valves.
- Ensuring valve caps are position as far as possible.
- Posting of "No smoking" signs at the place of storage
- Electrical installation must be of flame proof construction.
03. Issue gas cylinders only after confirming the contents of Stores
cylinders. incharge
04. Handling cylinders carefully. (Refer Annexures - 3 & 5) All concerned
departments.
05. Transport the gas cylinders only under secured condition. Concerned
Flammable gases must not be transported along with other area incharge
compressed gases. Cylinder valves to be protected during
transport.
70-943
CYLINDERS
06. Keep record of compressed gas cylinder stored. Concerned

Area incharge
For cylinders owned by BHEL keep the following records Stores
07. - Manufacturer’s name and the rotation number incharge
- The Specification number
- Date of original hydro/hydro stretch test
- Test and inspection certificates
08. In case of leakage. the gas cylinder has to be brought to an Concerned
open area, unless specialized persons come over to arrest the area incharge
leakage.
09 Keeping suitable fire extinguishers at the place of storage/use Concerned
to handle any fire situation. Area incharge
10. Ensure appropriate fire extinguishers are provided, inspected Head/Fire
periodically and kept in order. Services
11. Inspecting cylinders storage area (Refer annexure-4) Head/Safety
Management
12. Ensure provision of Gas detectors in case of Hydrogen and Concerned
acetylene. HOD
13. Ensure MSDS of all cylinders are prominently displayed and Concerned
employees are made aware of it. area incharges
7.0 CHECKING, CORRECTIVE AND PREVENTIVE ACTION: : Concerned area

head shall ensure implementation of this procedure and in case of any
deviation Corrective & preventive action shall immediately be taken
8.0 Records
Inspection register Concerned areas 2 Years
MSDS Concerned areas Permanent
70-943
CYLINDERS
Annexure to OCP:SAF:013:H
Annexure-1
Industrial gas cylinders used at BHEL
Gas Colour of the body Colour of the band

Oxygen Black ---
Nitrogen Grey Black
Carbondioxide Black White
Ammonia Black Red & white

Argon Blue ---
Chlorine Yellow ----
Hydrogen Red ----
Acetylene Maroon ----
Annexure-2
Guidelines for unloading of cylinders
01. Whenever possible unload directly on a raise platform, preferably by rolling over a coir
mattress.
02. Ensure bottom end of gas cylinder touch the mattress first and then roll it away. At no
point of time, the valve end should touch the floor.
03. Do not use a lifting magnet for unloading or loading any cylinder.
04. A fibre rope sling may used to lift one cylinder -- never more than one at a time,
provided it is adequately strong and correctly adjusted to prevent slipping. Use of chain
sling is unsafe as it is very likely to slip, over a cylinder.
05. If more than one cylinder has to be handled by a crane, a properly designed cradle
with proper suspension should be used.
70-943
CYLINDERS
Annexure-3
Care in handling compressed gas cylinders
1. Do not keep oily or greasy cotton waste or rags or clothes on a cylinder. Oil or grease
will ignite in the presence of oxygen and may even lead to explosion in case oxygen is
under pressure. Oxygen cylinders and regulator fittings should be kept away from all
sources of contamination such as oil drums, storage batteries, paint drums, underneath a
bench or machine-bed etc.
2. Ensure that grit or dirt of any sort or oil does not enter regulator assemblies.
3. Do not lubricate cylinder valves.
4. Use only the standard keys for opening the valves and make sure that these are free of
any oil or grease. Do not increase the leverage of keys or spanners and do not make any
attempt to get gas from cylinders with broken valve spindles. Any of these actions may
damage the cylinder valves and render the cylinder useless.
5. Do not use cylinders as rollers, work supports or jacks.
6. Lift a cylinder with a fibre rope sling. Cylinders must not be lifted with magnets.
7. Cylinders should not be loaded loosely in a vehicle failing which they will come in
violent contact and be subjected to jolting and damage during vehicle movement.
8. Never allow cylinders to come in contact with electrical apparatus or live wires.
9. Keep cylinders away from sparks, flames, or slags from welding or cutting operations.
10. Cylinders that have become damaged in transit or in the course of being used in the
plant or any other course should be handled in the same manner as leaking cylinders.
11. Special precautions against accidents:
- No person shall commit or attempt any act that will cause fire or explosion
- Every person storing, handling, transporting and the in charges shall at all times
comply with all the provisions of gas cylinders rules and also the licensing
c o n d i ti o n s .
-Preventing any person from committing any act as referred in (1) above.
12. Cylinder subjected to action of fire:
- Shall not be used unless proper examination and hydro/stretch test is done
70-943
CYLINDERS
- Dissolved acetylene cylinders damaged by fire shall be condemned and

destroyed with due precautions by an experienced and competent person
13. Leaky Cylinders:

- Shall not tender or transport leaky cylinder
- Remove leaky cylinder to an isolated open place away from any source of
i g n i ti o n a n d t h e p e r s o n re s p o n s i b l e f o r t r a n s p o r t a t i o n s h a l l c o n t a c t t h e c o n c e rn e d
fo r immediate action
Annexure -4
Checklist for storage of gas cylinders:
1. Are all cylinders secured or racked?
2. Are empty gas cylinders stored separately from full cylinders?
3. Are gas cylinders stored away from highly flammable

materials?
4. Are gas cylinders stored away from highly corrosive materials?
5. Are corrosive gas cylinders used within 6 months?
6. Are empty gas cylinders marked clearly with the word

"Empty"?
7. Are valves on all empty cylinders closed?
8. Are gas cylinders stored away from heat sources, flames, and
sparks?
9. Are all flammable cylinders stored at levels above the
basement?
10. Is a gas cylinder cart used for transporting the cylinders?
11. Cylinders are never rolled as means of transport?
12. Are all control valves removed before moving a cylinder?
13. Is the valve protector on the cylinder wherever it is being

transported?
14. Have cylinder shippers/receivers and handlers been
specifically trained in the hazards of compressed gases?
15. Is training updated annually?
70-943
CYLINDERS
ANNEXURE V
RESTRICTED PRACTICE
01. Restriction on delivery and despatch of cylinders:
- No delivery / despatch to a person not holding a license.

- Type of gas, quantity of gas to be as permitted in the license
02. Restrictions on filling:
- Welded cylinders shall not be used for filling permanent, or high pressure
liquefiable gas or highly toxic gases
- - Do not use ‘once coal gas handled cylinders’ for filling any other gases
- No cylinder shall be filled with any gas that is capable of combining chemically so
as to endanger its serviceability
03. Restriction on transport
- Flammable gases not to be transported along with other type of compressed

gases
- Toxic and corrosive gases not to transported along with food stuffs
70-943
FOR SAFETY IN OPERATIONS
1.0 PURPOSE : To ensure safety in various activities carried out in the factory.
2.0 SCOPE : Activities carried out in the Factory.
3.0 RESPONSIBILITY & AUTHORITY: Concerned HOD/HOS and Head /Safety

Management
5.0 CROSS REFERENCE : OHSAS 18001 Clause 4.4.6 , Safety hand book &
Occupational Safety Manual (OSM)
6.0 ACTIVITIES :

No.
01 Make themselves familiar with activities assigned and be All concerned
aware of the hazards involved in them. employees
02 Wear applicable personal protective equipment. (Ref All concerned

OCP:SAF:015:H) employees
03 Follow the safety instructions given by superiors / Safety All concerned

Management staff. employees
04 Reporting of hazards existing in machineries to their superiors. All employees
05 Informing the accidents/incidents to concerned supervisors/ All employees

executives.
06 Maintaining good housekeeping in the area. All employees
07 Giving suitable safety instructions to employees while allotting Concerned incharges

work. (Refer to instructions given in safety handbook in Tamil
and Occupational Safety Manual)
08 Supervision of all activities so that they are carried out safely. Concerned supervisors
09 Ensure all machinery and equipment are properly maintained Concerned supervisors
and safe to use
10 Ensure that all defects in the work place are reported and Concerned supervisors
rectified.
11 Ensure availability of necessary PPE, their usage by Concerned supervisors

employees and use of all protective devices provided for
machines.
70-943
FOR SAFETY IN OPERATIONS
12 Reporting of all accidents/incidents to SM/OHS as appropriate Concerned supervisors

in proper forms
13 Ensure that all activities with high accident potential are Concerned executives
adequately supervised.
14 Extend cooperation with Safety Management for ensuring Concerned executives

safety of men and machines.
15 Bringing to the notice of SM department for new activities Concerned executives

undertaken for which safety instructions are not available.
16 Developing safety instructions for new activities. Head/Safety

Management
17 Follow respective OCPs developed by the concerned areas Concerned executives
for the activities to which hazards have been identified as
significant in addition to the reference to Safety hand book &
Occupational Safety Manual.
18 Display of safety instruction for accident potential activities Concerned executives

near the work place
7.0 Checking, Corrective and Preventive Action: Concerned area head shall
Corrective and preventive action shall immediately be taken
8.0 Records
MIR Safety Management 5 Years
Accident reports Safety Management 5 Years
70-943
FOR PLANT SAFETY INSPECTION
1.0 Purpose : To identify unsafe conditions of the work place and unsafe practices of
employees
2.0 Scope: Factory premises.
4.0 Performance Criteria : Accident trend and Central Safety Committee Review
5.0 Cross reference: OHSAS 18001 Clause 4.4.6
6.0 Activities
Sl.No Activities Responsibility
01 Identification of activity wise / area wise possible hazards and Concerned

risk for all plant areas HOD/HOS
02 Development applicable list of check points activity wise and Head /Safety
area wise including potential emergency locations Management
03 Scheduling of Plant Inspection of all areas Head /Safety

Management
04 Carrying out plant safety inspection Concerned
safety officers /
personnel
05 Reporting of deviations and unsafe conditions Concerned
safety officers /
personnel
06 Correct unsafe practices
07 Carrying out job safety studies Head /Safety

Management
08 Taking action to correct the deviations and unsafe conditions Concerned HOD
09 Follow up for implementation of corrective / preventive Concerned

measures safety officer /
personnel
10 Assessment of effectiveness of the remedial measures Head /Safety
Management
7.0 Checking, Corrective and Preventive Action : Concerned area Head shall
Corrective and preventive action shall immediately be taken
70-943
8.0 Records
Sl.no Record title Maintained Retention
by
01. Safety inspection check list Safety Management 2-Years
02. Inspection records Safety Management 2-Years
03. Minutes of meeting of CSC Safety Management 2-Years
70-943
ANNEXURE I to OCP :SAF: 015:H
PLANT INSPECTION CHECK LIST
S.No Expected Observed Corrective /

Preventive
Actions
1 Guard provided in the machine adequately
2. Earthing in good condition
3. Switches are in good condition
4. 24 V is used for portable hand lamp
5. Guard in the lamp is in good condition
6. 3 pin top is used for taking connection
7. Any temporary wiring? Is insulation good?
8. Panel boards provided with fencing
9. Proper approach is provided for panel board
10. Rubber mat is provided in front of Panel board
11 Are the details exhibited in the pedestal/ bench
grinders
1. Shaft speed
2. Wheel diameter
12. The tool rest is in good condition
13 The grinding wheels are in good condition
14 3 mm gap is maintained between wheel and tool
rest
15 Suitable grinding wheel used to match with
Spindle speed
16 Guard provided
17 Wheel fitted in proper condition
18 The air hose is in good condition
19 Proper clamp used for fixing the hose
20 Welding earth properly connected
21 Welding cable is having good insulation
22 Lugs are fixed properly
23 Cylinder key available
24 Cylinder caps are provided
25 Specified hoses are used gas lines
26 Gas torch is in good condition
27 Hose are in good condition
28 Flash back arrester filled with water
29 Proper stand is available for lifting tackle
30 Lifting tackles properly kept on stand
31 Rope/Chain is good condition
32 Crane hook is in good condition
33 Hoist rope is in good condition
34 SWL and crane numbers are clearly marked
70-943
35 Limit switches are in good condition

36 Bell is in good condition
37 Paining is carried out in the booth
38 Proper ventilation is provided
39 Any temporary wiring
40 Paint and thinner drums / tins are stored safely
41 All empty drums are disposed properly
42 Availability of “NO SMOKING” board
43 Availability of Fire Extinguisher
49 Shots in the floor cleaned ( free from slippery
Condition)
50 Fitted with water filter Filters in good condition?
51 Lights are in working condition
52 Ventilation is sufficient
53 Exhaust are working
54 PPE ion good condition
55 Calibration of pressure gauges done in
hydraulic test
56 Use of 2 Pressure gauges
57 Clear visibility of or gauge to pump operator
58 Illumination
59 PPE (Apron, gloves, gum boot, helmet, face
shield)used during test
60 Floor (Slippery, damaged)
61 Use of standard/proper hand tool.
62 Caution Boards / lights
63 All the employees involved for erection work
wear safety helmets.
64 - All the employees working at height wear
safety belt
65 Proper work permit obtained for work at height.
66 Work at height should be stopped before sunset.
67 Before starting work ascertain the underground
utilities
68 All excavations shall be barricaded.
69 All excavation shall have adequate ladder for
emergency evacuation.
Note:
Inspected By : Area in-charge
Name :
Designation :
70-943
SAFETY MANAGEMENT
ELECTRICAL CHECKLIST
Dt. of Inspection Bldg. / Bay No.
Sl. Description Observation Preventive

No. action
1 Are the Panel Boards provided with fencing
and rubber mat?
2 Are the incoming and out going voltage clearly
marked in the Panel Boards?
3 Are the out going lines identified clearly in the
Panel Boards?
4 Is the danger board provided in the MP’s?
5 Are there double earthing provided?
6 Are there earth pits maintained?
7 Is the earth resistance measured periodically
and record maintained?
8 Is there any contact with Electrical earth &
welding earth?
9 Are the main switches/isolators provides with
handle?
10 Are the main switches working properly (on &
off indication)
11 Is the cable trench properly covered at the
Panel Board?
12 Are the cable properly laid on the trays in the
cable trench?
13 Are the cable trench free from water?
14 Are the cable trench free from unwanted
materials?
15 Are cable trenches covered at the columns?
16 Are the main switches properly
covered/closed?
17 Are the switches in good condition?
18 Are the switches/panels board free from
obstacles?
19 Are the switches fixed properly?
20 Is there any temporary wiring?
21 Is there any damage in the cable/wires?
22 Is the proper insulation at the joints?
23 Is the armoured cable provided with glands?
Are the glands properly connected with earth?
24 Are there proper clamps used for taping the
supply?
70-943
25 Are the clamps properly fixed and free from

loose connections?
26 Are the hand lamps/machine lamps provided
with 24 V supply?
27 Are the hand lamps provided with guard?
28 Are the focus light provided with earthing?
29 Is there any cable lying on the floor?
30 Are there proper socket/plugs used for taping
the supply?
31 Are there 3 pin plugs used for taping supply?
32 Are there motors provided with proper covers?
33 Are there terminal covers properly fixed?
34 Are the motors provided with end/fan covers?
35 Are the motor/electrical fittings away from water
source?
36 Are there electrical resistance gloves?
37 Are gloves in good conditions?
38 Is there first aid chart available?
39 Are the electricians trained on First Aid?
40 Are there suitable Fire Extinguisher/Fire
Buckets are in good condition?
41 Are the electrical tools are properly stored?
42 Are all the electrical tools insulated?
43 Is there proper lock out system available?
44 Is there proper work permit/line clearance
available for maintenance work?
45 Are the transformer rooms free from unwanted
materials?
Note.
Inspected By. : Area in-charge

Signature :
Ref. : DNV Check list
ELECTRICAL POWER SYSTEMS (16):
a. High-voltage and control panels closed and secured

b. Control panels identified and accessible
c. Good condition of wiring, insulation and fixtures
d. Grounding tested
e. Explosion-proof fixtures in flammable dust or vapour areas
f. Flexible cords free of splices
g. Lockout provisions as prescribed
h. Equipment being locked-out provided with individual disconnects
70-943
i. Electrical equipment protected from fluids

j. Adequate provisions for manual restarting after power failures.
SAFETY MANAGEMENT
INSPECTION CHECKLIST FOR CRANES / TACKLES
Date: Crane No. Bldg./Bay:
Sl. Description Observation Remarks

no
01 What type of Lifting Tackles are used in the
area?
02 Is there number provided in each lifting tackle?
03 Is there any defects noticed, if so, what is the
defect – What are the action taken for
repair/replacement?
04 Is there any stand used for keeping the slings,
if stand is available, all the slings are placed in
the stand?
05 Are the Control Switches are properly labeled
in the Pendant switch box?
06 Is the Emergency Switch function properly?
07 Are all the brakes provided in the crane
working properly what defect noticed while
applying brake?
08 Are all the DSL lamps working?
09 Is the Hoist Rope in proper condition, if any
wire cut is noticed, what is the cause for that?
10 Is the casing of the hook in good condition are
the pulley’s in the casing greased periodically?
11 Are the pulleys in good condition, is the grove
in the pulleys are free from defects?
12 Are the hooks in crane marked with its
capacity?
13 Are the hooks in good condition, is there any
deformation/defects noticed in the hook?
14 Are there any limit switches provided in the
hoist rope, if provided, are the switches in good
condition?
15 Are all the Control Switches working properly?
16 Is the Foot Pedal Switch provided with guard?
70-943
17 Is the warning bell/signal provided in the crane

working properly?
18 Are the couplings, revolving parts, gears, etc.,
are provided with guard, if not available, what
are the action taken?
19 Are there stoppers provided at the end of the
crane rails, if provided, are the stoppers are in
good condition?
20 Is the Limit Switches provided in the crane rail,
if provided, is the switch in working condition?
21 Are the Resistance Box provided with proper
cover, if provided, are there in proper
place/position?
22 Is the crane provided with Number Plate, and
the lifting capacity is marked on the crane?
23 Are the clamps and ‘D’ shackles rings etc are in
good condition, if any defect noticed, what
action taken?
24 Is there any board available for indicating Safe
Working load of ropes & slings? and properly
placed?
25 Is the Hoist Rope provided with lubrication?
26 Are there any loose material/unwanted material
kept on the top of crane?
27 Is there any Fire Extinguisher provided in the
crane operator cabin? If provided it is in
working condition?
28 Are the light and fan provided in the operator
cabin in working condition?
29 Is the crane walk-way free from obstruction?
30 Are the ladders and steps in good condition
free from slippery condition?
31 when the ropes are examined?
32 When the crane is examined/inspected by
competent person, are the points given during
examination corrected?
33 Are there any record maintained for lifting
tackles?
34 Are the operators examined for eye vision if
examined, when?
Note:
Inspected By : Area in-charge
Signature :
Designation :
70-943
Ref: DNV Check list
LIFTING GEAR/EQUIPMENT (19):
a. Good condition, no damage, cleanliness, lubrication, servicing

b. Legibly labeled as t o capacity and load testing
c. Fitted with overhead guards
d. Areas designated for refueling or recharging
e. Controls operational
f. Safe access (steps or platforms to cab/seat
g. Limit stops operational
h. Hoist motor brakes operational
i. All controls operational
j. Controls permit full, unrestricted operation by operators wearing
appropriate clothing and equipment
k. Cable/rope in good repair
l. Hoist chain/rope free of kinks and twists
m. Hooks not deformed or damaged and safety latches intact
n. In-running nip points guarded
70-943
FIRE CHECK LIST
S. Description Observation
No.
1 Are the ventilation ducts, pneumatic
conveyors and similar equipment
provided with flame arresting or
automatic fire extinguishing
appliances. Or
Fire resisting dampers electrically
inter locked with heat
sensitive/smoke detectors and the
air conditioning plant system.
2 Are the protection from the lighting is
provided for
a) Buildings in which explosive
or highly flammable
substances are
manufactured, used or
stored.
b) Storage tanks containing oil,
paint, or other flammable
liquids
c) Grain elevator
d) Buildings, tall chimneys or
stacks where flammable
gases likely to be present.
e) Substation buildings and out
door trans and switch yards.
3 Are there any precaution against
ignition where ever there is danger if
fire or explosion.
a) Are all the elect equipment
installed and maintain to
prevent the danger of their
being a source of ignition.
b) Are effective measures taken
to prevent accumulation of
static charges.
c) Are the workers wear shoes
without nail causing spark by
friction.
d) Are the smoking, lighting or
carrying material lighters etc
prohibited.
e) Are the transmission belts
used without fasteners.
f) Any other precaution taken to
present ignition.
70-943
4 Are there any precautions taken to

prevent spontaneous ignition.
5 Are the compressed gas cylinders
stored away from highly flammable
substance, furnace or hot process.
Are the rooms where cylinder stored
is ventilated adequately.
6 Are the flammable liquids stored in a
work room is minimum required for
the process.
a) Any flammable liquid stored
in a closed container, in well
ventilated room.
b) Are there any steps taken to
prevent leakage of such
liquids into basement sumps
or drain.
7 Are there any steps taken to removal
or prevention of accumulation of
flammable dust, gas, fume, or
vapour likely to be dangerous.
8 Are there fire exits - the fire exits
visible, suitably illuminated and
maintained.
a) Are the fire exits are clearly
marked.
b) Are doors in the exits are fire
resistant
c) Are the exit door are provided
with suitable width.(101 cm,
unit width 50 cm)
d) Are the exit doors open
outwards.
9 a) Are the fire extinguishers
are conform to relevant IS
b) Are the fire extinguishers
similar type and operating
method.
c) Are the fire extinguishers
placed in a reading and
easily accessible position for
immediate use
d) Are all water filled with clear
water.
e) Are all sand buckets filled
with clean dry and fine sand.
f) Are the extinguishers
charged in accordance with
the manufactures
70-943
9
g) Are the fire extinguishers
provided with serial number
referred to
h) In the records with the details
Sl.No., date of last filling,
date of last Inspection.
i) Are the fire extinguishers are
placed on the platform or the
cabinet such a way the
bottom is 750 mm above
gram level.
j) Are the fire buckets are
placed on a hook such a way
their bottom is 720 mm above
floor level.
k) Are all the extinguishers
thoroughly cleaned and
recharged immediately after
discharge.
l) Are sufficient refill material
kept readily available.
m) Are the maintenance
inspection and testing is
carried out for the
extinguisher periodically.
n) Are the maintenance
inspection and testing is
carried out as per relevant IS.
o) Are the fire extinguishers
distributed over the entire
floor area that a person to
travel not more than 15m to
reach.
p) Are operating instructions of
the extinguisher affixed on
them legibly
10 a) Is the adequate water supply

provided for fire fighting
b) Is the pump capacity
adequate to meet the
requirement of water (as per
relevant std)
c) Are the trailer pumps
provided with suitable
equipments
d) Are the trailer pumps housed
in a separate shed/sheds
70-943
10
e) Are the vehicle towing the
trailer pump in good condition
and periodically inspected.
f) Are there suitable trained
personnel, responsible
persons available as in-
charge for the fire fighting
equipment and fire
extinguishers.
g) Are there sufficient number of

personnel trained in proper
handling of fire extinguisher/
equipment
h) Are the fire fighting persons
provided with suitable PPE
for fire fighting.
i) Are there sufficient number of
trained persons available for
driving fire vehicle when need
arises.
j) Are there fire fighting drills
conducted as often as
necessary or at least once in
every period of two months.
11 a) Are there any automatic

sprinklers and fire hydrant
system available
b) Are the automatic systems
tested periodically for its
working condition.
c) Are the trans former room
provided with DCP / CO2
with in 15 m of the
equipment.
d) Are the fire extinguishers
distributed over the entire
floor area that a person to
travel not more than 15m to
reach.
e) Are operating instructions of
the extinguisher affixed on
them legibly.
70-943
DNV checklist
FIRE PROTECTION (34):
a. Portable extinguishers appropriate for types of materials and readily available

and maintained
b. Extinguishers inspected monthly
a. Fire hoses properly mounted, accessible and maintained
b. Fire equipment visibly marked
c. Fire doors, lids and shutters in good repair and unobstructed with fusible links
intact
WARNING SYSTEMS: (32)
a) Fire/emergency alarm systems operational

b) Hazard warning systems on appropriate vehicles and equipment
c) Overpressure warning systems on pressure vessels
d) Overpressure warning systems on fired pressure vessels, hazardous material
storage, powered equipment
e) Warning signs and devices for railway sidings available
70-943
SAFETY INSPECTION CHECKLIST FOR PG PLANT
Sl. Expected Observed Corrective/

Preventive action
no
1. No leakage of CO in the pipeline or

generator area
2. Availability of 'CO' monitor or CO

leakage indicator
3. Proper functioning of 'CO' monitor
4. Environment to be free from CO
5. Electrical fittings are to be in good

condition.
6. No temporary wiring
7. No unguarded opening in the floors
8. Steps are provided with hand rail
9. Availability of toe boards
10. Suitable PPEs are provided to the

employee
11. Employees are using the PPE
12. Availability of emergency siren and

working condition
13. Functioning of hot line telephone
14. Floor to be free from slippery

condition
15. Availability of emergency light and
working condition
16. Emergency is to be free from
obstruction
17. Earthing of Conveyor belt
70-943
Sl.no Expected Observed Corrective/

Preventive action
18 Provision of coupling guards for the
motors
19 Covering of motor terminals
20 Rubber mat provision for panel

boards
21 Fencing for panel boards
22 No leakage of tar and phenol
23 Clearance and disposal of ash

properly
24 Maintenance of fire extinguishers
and hydrants
25 Coal stacking in heaps
26 Provision of wind direction indicator
27 Proper ventilation arrangement
28 Display of ‘No smoking’ and

restriction
Signature of Safety Mgt. Signature of Area in-charge

70-943
SAFETY INSPECTION CHECKLIST FOR ACETYLENE PLANT
Sl.no. Expected Observed
1 Storage of calcium carbide away from water source
2 Proper ventilation of Calcium carbide room
3 Provision of flame-proof electrical fittings
4 Availability of Fire extinguishers
5 Display of ‘No Smoking’ board
6 No leakage of acetylene gas
7 Availability of non-sparking tools
8 Good working condition of flash back arrester
9 Proper lighting
11 Flange joints to be free from leakage
12 Provision of proper bonding/Earthing
13 Pulley blocks to be in good condition
14 Platform is to be in good condition
15 Area free from any unwanted material
16 Area is to be free from cob web
17 No loose wiring
18 Usage of suitable PPE
19 Motors in the generator area are to be of flame proof
20 Availability of caps for the gas cylinders

70-943
21 Availability of chain arrangement for the gas cylinders
22 Sand bucket are filled with sand
23 calibration status tags for all gauges

70-943
SAFETY INSPECTION CHECKLIST FOR FURNACES
S. EXPECTED OBSERVED CORRECTIVE/

No PREVENTIVE ACTION
01 Availability of details for proposed
process
02 Clearance obtaining from PG plant
03 Good working condition of the exhaust
04 Provision of proper Illumination
05 Detailed instruction for start-up and shut
down
06 No leakage (Burner, Control valve, Air
line)
07 Area is to be free from any unwanted
materials
09 Suitable PPE used by the employees
1. Safety shoes 2. Hand gloves
10 Valves are in fully operable condition
11 Easy access of Electrical power supply
12 Perfect closing/opening of furnace door
1. Control valve 2. Control room

70-943
14 Adequate number of enclosures
15 Obstruction free furnace control room
16 Safe Ladders at:
1. Furnace 2. Duct
17 Guard for Blower motor coupling
18 No overflow in Tar pit
19 Corrosion/Erosion free Damper duct
20 Safe Damper motor control room

70-943
SAFETY INSPECTION CHECKLIST FOR INFLAMMABLE STORES

PREVENTIVE
ACTION
1 Gas cylinders are to be provided with
cap
2 Empty and full cylinders are to be
separately
3 Gas cylinders are to be stored
separately under each category
4 Cylinders are to be kept under shade
without sunlight
5 All flammable material are to be stored
separately away .
6 Flammable material are to be grouped
and stacked properly under shade
7 All the electrical fittings are to be of
fire and explosion proof.
8 Electrical wiring is to be properly
maintained
9 All the electrical switches are to be in
good condition
11 Proper illumination
12 Fire extinguishers are to be in good
working condition
13 Prohibition of Smoking and display
of board
14 Proper Earthing for Diesel / Petrol
tanks
15 Proper maintenance of the earth pits
16 Availability and usage of non -
sparking tools
Signature of SM Signature of Area in-charge

70-943
SAFETY INSPECTION CHECKLIST FOR HEAT TREATMENT AREA

PREVENTIVE ACTION
1 Chemicals are to be properly
labeled and stored
2 Provision of proper ventilation
3 Exhausts are to be in working

condition properly
4 Proper illumination i and around

area
5 Sufficient aisle is to be
maintained
6 No chemical / water spillage
7 No unwanted material lying in the

area
8 Proper house – keeping is to be
maintained
9 Availability of suitable PPE and

usage by the employees
10 Waste water is to be treated

properly
11 Functioning of the effluent

treatment plant is to be ensured
12 Ph value is to be maintained in
the outlet water
13 Availability of there eye wash

fountain / shower
14 Eye wash fountain /Shower working

condition maintained
70-943
15 Hand tools are to be maintained

properly
16 Hoists , Lifting appliances , rope

and the slings are to be
inspected periodically and records
maintained
17 MSDS for the materials are to be
made available and displayed
18 Spill kit is to be made available
19 Safe operating procedure to be

made known to employees and
displayed
20 Emergency preparedness of area
employees is to be assessed

70-943
SAFETY MANAGEMENT
SAFETY INSPECTION CHEKLIST FOR STEAM TESTING STATION / BLDG.7
Date of Safety Inspection:

PREVENTIVE ACTION
I AIR / STEAM TESTING AREA
a ACCUMULATOR
01 Noise level within the TLV
02 Good silencer system
03 Good exhaust system
04 No leakage of steam in pipe line.
1.Accumulator 2. Test bed
b HYDRO TEST
06 No water leakage
07 Valves are in fully operable condition.
c COMPRESSOR
08 No leakage of air/ oil.
09 Provision of guard.
10 Provision of double earthing for Motor
11 No leakage in Coolant Motor.
12 Proper drainage
d BENCH GRINDER
13 No worn out grinding wheel
14 Proper tool rest
e ELECTRICAL PANEL BOARD
15 Provision of Rubber mats
16 Provision of Fencing
f GENERAL
17 Proper Illumination
18 Adequate Ventilation
II STEAM TESTING S TATION - I (110 Kg/cm2)
04 No leakage of steam in the pipe line.
05 Calibrated pressure gauges are used.
08 Corrosion/Erosion free roof structures.
70-943
09 No heat radiation
STEAM ACCUMULATOR PIT
10 No water/steam leakage
11 No accumulation of water .
III STEAM TESTING AREA - II (40 Kg/cm2)
04 No leakage of steam in the pipe line.

08 Corrosion/Erosion free roof structures.
09 No heat radiation
IV BOILER ROOM
01 Calibrated water flow meters are used.
03 No leakage in pipe lines.
04 No leakage in distributor
05 No Roof leakage
08 Proper drainage
V WATER TREATMENT PLAT
01 No leakage in feed water pumps.

02 No open cable trench
03 No uneven floor
04 Corrosion /erosion free Staircase.
07 Proper drainage
08 Storage of HCl carboys in a separate
room..
09 Proper labeling of HCl acid.
10 Availability & display of MSDS.
VI OIL FILTERATION ROOM
01 Identification of room
02 No oil leakage
VII LDO TANK
01 Hand rails for ladders
02 Proper earthing
03 Record for earth measurement.
04 Fencing
70-943
05 Sand buckets are filled with sand.

VIII COMMON
01 Safe operating procedure to be known
to employees and displayed.
02 Better visibility of pressure gauges.
03 Availability of fire extinguishers.
04 Free access to fire extinguishers.
05 No temporary wiring
06 Suitable PPE are provided to the
employees such as:
Spatter proof goggles
Leather gloves
Apron
Ear plug & Muff
07 Switch box in Jib Crane
(6067-8566)
70-943
ANNEXURE II to OCP :SAF : 015:H
CHECK LIST FOR INCOMING VEHICLES AT FACTORY GATES
I - FOR TWO WHEELERS
- Wearing of crash helmets

- Rear view mirror should be fixed
- Possession of Driving license
- Possession of Vehicle Fitness certificate (validity, authority)
- Possession of Vehicle Emission check certificate
- Possession of Identity Card and vehicle pass
II - FOR CARS

- Rear view mirror should be fixed
- Possession of Vehicle Fitness certificate (validity, authority)
- Possession of Identity Card and vehicle pass
- 20 kmph speed limit sticker to be pasted in the driver's direct vision region
III - FOR TAXIS

- Possession of Fitness certificate (validity, authority)
- Entry pass to be drawn at the gate
- 20 kmph speed limit sticker in the driver's direct vision region
IV - FOR TRAILORS

- Possession of Fitness certificate and tyre condition
- 20 kmph speed limit sticker in the driver's direct vision region
- Red flag and red lamp provision to be ensured
- Tightness of the tie up rope when the vehicle carrying load
- Painting on vehicle body giving details about:
a) size of the carrier
b) maximum load carrying capacity
V - FOR DANGEROUS OR HAZARDOUS GOODS CARRIER
- Possession of valid registration certificate to carry the goods

- Possession of vehicle Fitness certificate and tyre condition
- Possession of Vehicle Emission certificate
70-943
- Possession of passed course certificate to drive the vehicle which is carrying

dangerous or hazardous goods
- Possession of information regarding the properties of goods carried (MSDS)
- Possession of Anti-dote for the goods carried
- Display a distinctive mark of the class level appropriate to the type of dangerous or
hazardous goods
- Emergency panel should give the details of:
# Correct technical name of dangerous or hazardous goods
# United Nation class number
# Name & tel. no. of emergency services to be contacted in the event of
fire or any accident
# Name & tel. no. of consigner
- Max speed limit sticker to be pasted in the driver's direct vision region during
movement inside BHEL premises
- Protection arrangements for emergency such as fire, collision etc.
- Safe mounting and protection of valves and piping equipment
- Two serviceable fire extinguisher of suitable size and type
- In case of gas cylinders:
a) All filled cylinders should be vertical and intact
b) Cylinder valve cap should be provided
- Spark arrestor in the exhaust pipe
#####
HEALTH, SAFETY AND ENVIRONMENTAL Rev. 03
70-943
FOR CENTRAL SAFETY COMMITTEE
1.0 Purpose : Assisting and guiding the management in achieving the better Safety
performance by effective participation of all employees.
2.0 Scope : High Pressure Boiler Plant.
3.0 Responsibility : Chairman / Central Safety Committee &

Secretary / Central Safety Committee.
4.0 Performance criteria : Accident trend and CSC Review
5.0 Cross reference: OHSAS 18001 Clause 4.4.6 and TN FR’1950 (Rule No. 61M)
6.0 Activities
Sl.No Activities Responsibility
I – CONSTITUTION OF CENTRAL SAFETY COMMITTEE
01 Note for constitution of Central Safety Committee as per TNFR Head /Safety
1950 / Rule No 61M ( Refer Annexure) Management
02 Approval for nomination of Chairman, Secretary, Management Executive

Representatives and workmen representatives.. Director
II – FUNCTIONS & DUTIES OF CENTRAL SAFETY COMMITTEE
03 Assisting and co-operating with the management in All members

achieving the aims and objectives outlined in the Health
and Safety Policy of the Occupier.
04 Dealing with all matters concerning health , safety and All members
environment and to arrive at practicable solutions to
problems encountered:
05 Creating safety awareness amongst all workers. All members
06 Undertaking educational, training and promotional All members
activities.
07 Discussing reports on safety , environmental and All members
occupational health surveys , safety audits risk
assessment , emergency and disaster management plans
and implementation of the recommendations made in the
reports :
08 Carrying out health and safety surveys and identifying All members
causes of accidents
09 Looking into any complaint made on the likelihood of All members
an imminent danger to the safety and health of
workers and suggesting corrective measures
70-943
10 Reviewing the implementation of the recommendations All members

made by it
III - Meeting
11 Meeting schedule Head /Safety

- Once in three months Management
- Whenever situation needed to take decision on
important issues like emergency, introduction of new
processes.
12 Agenda points: Head /Safety

- Structuring of agenda points Management
- Consolidating Agenda points to all members.
13 Meeting Intimation: Head /Safety
- Letter with Date, Time & Venue of meeting to all Management
members & special invitees.
- Confirming receipt of the intimation letter by the
members over phone.
IV – Proceedings
14 Welcome address & opening talk Chairman / CSC
15 Presentation of report on Safety promotional activities, Plant Secretary / CSC

inspections, Accident statistics, Reportable accidents, Safety
Education. Safety audit, risk assessment, emergency disaster
management plan & implementation
16 Presentation of reports on Health monitoring & working Medical officer /
environment. OHS
17 Review of minutes of the previous meeting. Chairman / CSC
18 Discussion on new agenda points to arrive practicable All members
Solution
19 Getting commitments form concerned departments Chairman / CSC
20 Discussion on any other points raised by members. All members

21 Vote of thanks Secretary / CSC
V – MINUTES OF MEETING
22 Recording the Points discussed and commitments of

-
the meeting. Secretary/CSC
- Sending copy of the minutes of meeting to the members,
Special invitees & HODs for further action & implementation.
70-943
VI – COMMUNICATION TO EMPLOYEES
23. - Display of salient points of discussion on notice boards Secretary / CSC

for information to all employees.
VII - FOLLOW-UP ACTION
24. - Visit to areas every Saturday to monitor the CSC Sub

implementation of points. committee
- Review with concerned agencies for completion.

Secretary / CSC
- Reminder to the concerned areas after reviewing the
position. Secretary / CSC
25. Maintenance of records of CSC meetings Head/Safety

Management
7.0 Checking, Corrective and Preventive Action : Concerned area head shall
ensure implementation of this procedure and in case of any deviation Corrective
& preventive action shall immediately be taken
8.0 Records
Sl. Record title Record no. Maintained by Retention
No
01. Constitution Approval note Safety 3-Years
Management
02. Agenda points Safety "
Management
03. Minutes of meeting of CSC Safety "
Management
70-943
Annexure – 1 to OCP :SAF: 016:H
(As per TNFR / Rule 61 M)
Tamil Nadu Factories Rule 1950 – Rule No : 61M
1. The representatives of the Management of Safety Committee shall include
a) A senior official who by his position in the Organisation can contribute effectively
to
the functioning of the Committee, shall be the Chairman.
b) A Safety Officer and a Factory Medical Officer, wherever available and the Safety
Officer, in such a case shall be the Secretary of the Committee.
c) A representative each from the production, maintenance and Purchase

Department.
2. The Workers representatives on this Committee shall be as equal to the number

of representatives of the Management, as elected by the workers.
3. The tenure of the committee shall be three years.
4. Safety Committee shall meet as often as necessary but at least once in every
quarter. The minutes of the meeting shall be recorded and produced to the
Inspector on demand.
5. Safety Committee shall have the right to be adequately and suitably informed
of Potential Safety and Health hazards to which the workers may be exposed at
work place.
a. Data on accident as well as data resulting from surveillance of the working
environment and of the health of workers exposed to hazardous
substances so far as the factory is concerned; Provided that the
Committee undertakes to use the data on a confidential basis and solely to
provide guidance and advice on measure to improve the working
environment and the health and safety of the workers.
70-943
ANNEXURE II to OCP :SAF: 016:H
CENTRAL SAFETY COMMITTEE AGENDA STRUCTURE
I – PRESENTATION BY SM
1 Safety Education
- Trade Safety programs for workers,
- General safety programs for Supervisors,
- Safety classes for Contractors,
- Safety classes for trainees & Apprentices
2 Accident Statistics
- Reportable Accidents
- Non-reportable accidents
- Mandays lost due to the accidents
3 Personnel Protective Equipment
- Value of PPE issued in the period
Value of PPE issued until that from the year starting
4 Other Safety Committee performance.
- Off the job Safety programes by Co-ordinators like Traffic regulation,
Cracker safety, Road safety for school children.
- Driving licence checking at Township
- Domestic safety for township residents.
5 Safety Inspections & Audit reports
- Safety Audits by external bodies
- Group plant Inspection
- Mock drills
II – PRESENTATION BY OHS
6 Environmental survey report
- Noise survey
- Fumes survey
- Heat stress survey
- Light survey
7 Occupational health survey report
- Periodical medical checkup
- Observations
III – REVIEW & DISCUSSION

8 Review of minutes of Previous meeting.,
- Discussion on the pending points
- Status of the points
- Action by whom
9 Discussion on new points
- Discussion on new agenda points.
- Suitable action.
- Action by whom.
10 Discussion on points raised by members.
- Suitable action.
- Action by whom.

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SAFETY MANAGEMENT

OPERATIONAL CONTROL PROCEDURES

001/03 Emergency Preparedness and response

002/03 Mock drill management

003/04 Incident / accident management

004/03 Collection, documentation, evaluation and communication of safety indices

005/03 Personal Protective Equipment Management

006/03 Internal Safety Management Communication

007/03 External Safety Management Communication

008/03 Pre-Start up Safety Review

009/04 Work Permit Management

010/03 Hazardous area management

011/03 Safety Stewards Scheme

012/03 Safety Coordinators Scheme

013/03 Storage and handling of gas cylinders

014/03 Safety in operations

015/03 Plant safety inspection

016/03 Central Safety Committee

Sl. OCP No.& Purpose Performance

To identify the potential emergency locations to establish procedures to handle

2.0 Scope : BHEL, Factory premises.(As per annexure I)

3.0 Responsibility : Head / Safety Management .

4.0 Performance criteria : Record of mock drills.

Sl. Activity Responsibility

Title Location Retention period

Prepared by Reviewed and Approved by

ANNEXURE 1 TO OCP: SAF : 001:H

List of potential emergency locations

ANNEXURE 2 TO OCP: SAF : 001:H

List of protective devices

Sl. Emergency Location/Activity Protective Remarks

1.0 Purpose: a. To ensure conducting, monitoring and reporting of on-site

2.0 Scope : BHEL complex.

3.0 Responsibility : Head/Safety Management.

4.0 Performance Criteria: Record of mock drills.

7. CHECKING, CORRECTIVE AND PREVENTIVE ACTION: Concerned area head

Title Location Retention period

Prepared by Reviewed and Approved by

ANNEXURE TO OCP: SAF : 002:H

List of potential Hazardous areas

1.0 Purpose : To ensure that all incidents / accidents are reported,

Personal injury - Any bodily harm to any person

vi) Bursting of centrifugal machines.

2.0 Scope: Factory premises.

3.0 Responsibility : Head/Safety Management.

Sl.no Activities Responsibility

INCIDENTS (NEAR MISSES ) & DANGEROUS OCCURRENCES

03 Investigation all Incidents / Near misses and report Concerned

05 In case of Dangerous occurrences , fill in Form 18 A as Head /Safety

06 Investigation of dangerous occurrence and report submission Concerned

07 Communication of investigation findings to all concerned Head/Safety

08 Implementation of corrective and preventive action. Concerned

09 Follow up for Implementation of suggested remedial Head/Safety

10 Communication to other similar areas on the findings and Head/Safety

NON - REPORTABLE ACCIDENTS and REPORTABLE ACCIDENTS

01 In case of injury to person, fill in the incident /accident Shift incharge

09 Investigation of non–reportable accidents by a team of safety Head/Safety

13 Ensuring implementation of suggested remedial measures. Concerned HOD

14 Review of the status of implementation and assessing the Head / Safety

01 In case of Fatal accident occurs inside factory premises , Concerned area

02 Prepare Incident / Accident report and send to OHS/FMC Concerned area

19 Communication to other similar areas on the findings and Head /Safety