Report 1 Version 1.Gammon Final Report

8/3/2019 Report 1 Version 1.Gammon Final Report

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SAFETY ASPECTS IN ERECTION ACTIVITIES

A PROJECT REPORT

SUBMITTED BY

ARUN KUMAR.M

In partial fulfillment for the internship training

Of

HEALTH SAFETY AND ENVIRONMENT MANAGEMENT

IN

2X600MW THERMAL POWER PLANT PROJECT

GAMMON INDIA LIMITED


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February 2012

BONAFIDE CERTIFICATE

Certified that this project report SAFETY ASPECTS IN ERECTION

ACTIVITIES isthe bonafide work ofM.ARUN KUMAR whocarried out the

project work under my supervision.

SIGNATURE SIGNATURE

Mr. A.V. LAKSMINARAYANAN Mr. SIVA KUMAR

PROJECT MANAGER ASST. MANAGER - HSE

PROJECT

2X600MW THERMAL POWER PLANT PROJECT

GAMMON INDIA LIMITED.

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ACKNOWLEDGEMENT

I first thank my parents who gave me the moral support right from the

moment i told about this project and who have provided me with opportunity to

serve the society as Safety Engineers, even though one can never repay the debts to

his parents.

I express my sincere thanks to Prof.K.R.RAMANA, Dean of NICMAR, Dr.

SARBESH MISHRA, Placement coordinator, Dr. V. SRIHARI, Dy. Dean of

NICMAR, Prof.S.V.S. RAJA PRASAD, Asst. Prof Safety, for giving me such a

wonderful chance to do a project in GAMMON INDIA LIMITED.

My warm thanks to my guides Mr. SIVA KUMAR, Asst. Safety Manager,

Mr. ARON HILTON, Safety Executive and Mr. Chowdhury, Safety Engineer, for

giving the most valuable input for this successful work - the freedom to think. His

leniency is worth mentioning which helped me to succeed.

I express my sincere thanks to Mr. A.V.LAKSMINARAYANAN, Project

Manager and Mr. CHACKO, Project Manager for his valuable guidance during the

course of our project. It would be a big sin if I exempt other people working in this

office. Their care and affection made me feel at home.

My job would remain incomplete if I do not thank all my friends, the

eagerness, support and their good will that had helped us to perform to the best of

our ability.

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ABSTRACT

Health safety and environment (HSE) is a topic in lime light. In this report I have

discussed about safety organization and structure of EPIL along with companies

safety policy and GILs safety procedure. Also safety aspects regarding various

civil activities are also discussed. Check list is been prepared for all these activities

(example: Excavation, Working at heights, inspection of PBDs and Vechicles).

Aim is to make implementation of safety easier. Supervisor must be trained to fill

the check list before starting that particular work (in the absence of safety person at

that location).

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TABLE OF CONTENTS

S.No CHAPTERS PAGE NO

1 Safety policy& procedures 7

2 Safety organizational structure 8

3 Brief introduction about JPSPL project 9

4 Safety aspects followed in JPSL project 12

5 EPILs Environment Protection 15

6 Safety while loading/unloading of pipes 16

6.1 Checklist for loading/unloading of pipes 17

7 Safety aspects while transporting of pipes

in trailers

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7.1 Checklist for transporting of pipes 18

8 Safety in stacking pipes (in pipe yard) 18

8.1 Checklist for stacking of pipes 19

9 Safety in various pipeline activities 20

9.1 Safety while performing survey 20

9.1.1 Checklist for survey 21

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9.2 Safety while ROW 21

9.2.2 Checklist for ROW 22

9.3 Safety while stringing operation 22

9.3.1 Checklist for stringing operation 23

9.4 Safety while trenching 23

9.4.1 Checklist for trenching 24

9.5 Safety while welding 25

9.5.1 Checklist for welding 26

9.6 Safety while performing radiography 27

9.6.1 Checklist for radiography 28

9.7 Safety while joint coating 28

9.7.1 Checklist for joint coating 29

9.8 Safety while lowering of pipe 30

9.8.1 Checklist for lowering of pipe 319.9 Safety while back filling 32

9.9.1 Checklist for back filling 32

9.10 Safety while hydro test 33

9.10.1 Checklist for hydro test 34

9.11 Safety while cathode protection 34

9.11.1 Checklist for cathode protection

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10 Advantages of checklist 35

11 Conclusion 36

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1. SAFETY POLICIES AND PROCEDURES

GILs HSE POLICY:

GIL shall maintain a systematic approach to HSE management in our business

activities to ensure:

Health and safety of its employees and those of its sub-contractors;

including other parties who may be affected by this operation.

Regular safety training programmes are undertaken at the sites.

Compliance with laws of Indian government.

Protection of environment and preventing pollution.

GILs achieves this policy through the following procedures:

Visible management commitment to implement HSE plan.

Encourage team work to achieve HSE targets.

Provide adequate resources and educate workforce to minimize personal risk

to Health and Safety.

Recognize and reward good HSE performance.

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Promote positive approach to HSE among employees and empowering to

stop work if unsafe condition exists.

Safe working procedure is being instructed to every engineer.

2. ORGANIZATION STRUCTURE.

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SENIOR SAFETY

MANAGER

SAFETY OFFICER

PIPELINE DIVISION

HSE HEAD

HSE HEAD EPIL

PROJECT MANAGER

SAFETY SUPERVISOR


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3. BRIEF INTRODUCTION ABOUT 2X600MW TPP.

Client : COASTAL ENERGEN PRIVATE LIMITED

Contractor : GAMMON INDIA LIMITED

Name of project : 2X600MW THERMAL POWER PLANT.

Project Manager : Mr. A.V. LAKSMINARAYANAN and

Mr. CHACKO

Now let us discuss in brief about major activities performed in erection activities.

List of major activities involved in pipeline project are as follows:

Survey

Excavation

Concreting

Welding and Gas cutting

Radiography Testing

Blasting

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Painting

Back filling

Beam and Column Erection

Restoration

Survey:

Survey is for design and construction of linear works. At the end of survey

we can get details of the work going to do. ( ex; number of excavation, Quantity of

concreting etc.,)

Excavation:

Stringing:

The crew that moves the pipe from the pipe yard to the right of way and

positions the joints along the right of way parallel to but sufficient distance from

the ditch line.

Trenching:

Trenching is nothing but a type of excavation in which depth of the pit

is more than the breadth.

Main line welding:

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Main line welding is an ordinary welding process which is done

to joint two or more pipes. Its done in 5 stages.

Radiography:

Radiography/x-ray test is generally performed on plates which are

welded. This is to check the quality of welding. Any cracks or faults in weldingwill be detected in this test.

Joint Coating:

The paint, plastic or dope the bare steel of the pipe is covered with

from the factory or that is applied on the "Coating" crew

Lowering of pipe:

This layer has three sub layers.

Pre-padding

Lowering of pipes

Post-padding

Selected finer material placed in the ditch, beneath, beside and on top of the pipe to

prevent damage to the pipe or coating by rocks. Usually 8" is required under the

pipe and 12" beside and on top of the pipe.

Back filling:

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Its a process of filling back the trench. It is generally done after post-

padding.

Hydro test:

Hydro test is a Process of clearing the pigment in pipe by application of

pressure.

Cathode Protection:

Its nothing but similar to electroplating process, done inorder to protect the pipes from corrosion.

Restoration:

Restoration is a process of displaying information boards at certain

points, which has all details about the project. It also acts as a caution for people

who work in that area, not to damage the pipeline.

4. SAFETY ASPECTS FOLLOWED IN JPSL PROJECT

A senior safety manager is been appointed to assist and advise the site / project

management in the fulfillment of its obligation statutory and otherwise concerning

prevention of personnel injuries and maintaining safe and healthy working

environment. Under him, a safety team is operating which comprises of safety

officer and safety supervisors. They establish safety by implementing engineering

and management control. Here PPE , Permits and Procedures are considered as a

final stage of protection in case engineering and management control cannot be

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implemented or proved to be in effective. Few important aspects are been

discussed below.

Tool box talk is been conducted every day before starting of days work. Its been

given by supervisor/foreman of that site. Its duty of safety department to insist

supervisors to give tool box talk and maintain record for it.

Monthly safety meeting is being organized every month by safety department. The

purpose of this meeting is to give employee an idea of what has happened

(regarding safety) in the organization during previous month. Also employees are

been asked suggestion about how to improve safety. They are also welcomed to

share about the corrective measures for avoiding accidents/near misses. Also they

themselves select the topic of the training to be given, which makes the training

more effective.

Training program is next important aspect. Regular training programs are being

conducted by HSE Department on job specific topics. There are two types of

training programs.

On-site training program

Off-site training program

On-site program is being conducted directly in workplace. Employees are trained

how to react during various instance. When I was in training, FIRE FIGHTING

TRAINING PROGRAM was conducted.

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The above picture was taken during the time of training. Senior safety manager

practically explained the operation of fire extinguisher and how to react in case of

fire.

Off-site training program is being conducted in office. Generally people of higher

cadet are being called for this training. When I was in there, training regarding

Hierarchy of Controlling Hazards was conducted. In which employees were told

about importance of engineering and administrative control. The below picture was

taken during the training in which all the control methods were discussed.

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Induction program is done in effective way. Senior safety manager gives induction

for all the employees/people/trainee who enters the site for first time. This

induction includes all the details about HSE policy of organization and Safety

procedures followed in site.

5. EPILs ENVIRONMENT PROTECTION

ESSAR projects India Limited (EPIL) has always assured least damage to

environment. As mentioned in companys HSE policy, EPIL minimizes the

environmental degradation in following ways.

The project length is 253Km and since its a pipeline project, ROW was mostly

given in forest areas and villages where trees are available in large numbers. So in

order to achieve our project many trees were cut down. The good thing is, ESSAR

STEEL (client of this project) has allocated 2hectares of land for planting trees.

Trees are been planted in ratio of 1:2 (two new trees for every old tree). This is annoble job and certificate is also maintained by company for doing so.

Secondly, the food wastes which is common in construction site is not been

disposed to ground or so. EPIL is maintaining separate garbage in which the waste

food materials are dumped. This dumped garbage is been handed over to Orissa

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state municipality and they dispose it as per government standards. By doing so,

contamination of soil is prevented.

EPIL is using sand in oil storage areas, to avoid contamination of soil. The oil cans

(both filled and empty) are kept over the sand. This is because, if spillage occurs,

oil is absorbed by sand and hence soil is protected. Also these sand is being

changed at regular intervals.

5. SAFETY WHILE LOADING/UNLOADING PIPES

Pipes used for this project is been imported from Korea. It comes in ship to Paradip

port. From there pipes are been transported in trailers to pipe yard. Now we are to

discuss the safety aspects while unloading/loading of pipes.

Generally side booms / cranes are used to life pipes. But here, Hydras are been

used for lifting the pipe. Major hazards while dealing with pipe lifting is fall ofpipes or pipes striking on any object or person. To avoid these accidents, the

following checklist is to be completed before starting the operation.

Note:

This checklist should be filled by the concerned safety in charge of that areaor by the supervisor/foreman depending on the availability of person. Filling this

form before start of work could ensure maximum safety to the workers.

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5.1 CHECKLIST FOR LOADING/UNLOADING OF PIPES

S.No Specification Yes/No1 Is proper equipment been used?

2 Is the equipment certified?

3 Is the sling free from damages?

4 Is the weight of pipe less than OVC of equipment?

5 Is the swing area free from obstruction?

6 Does the operator trained?

7 Is the velocity of air with in limit(30M/S)

8 Is banks man been provided?

9 Is the vehicle provided with reverse horn?

6. SAFETY ASPECTS INVOLVED IN TRANSPORTING OF PIPES

Pipes after loading in the trailer should be transported to pipe yard. Also pipesshould be transported from pipe yard to the place of work. So transportation is

most essential sector on which we should concentrate more.

The major hazard while transporting is accidents or run off of pipes. So the

following checklist must be filled before starting the journey to avoid these

hazards.

6.1 CHECKLIST FOR TRANSPORTATION OF PIPES

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S.No Specification Yes/No

1 Is the length of the pipe smaller than trailer?

2 Is the pipe been properly tied to trailer?

3 Is proper support been given to avoid roll off?

4 Is the driver competent person?5 Is the trailer capable of carrying pipes of this weight?

Note:

This checklist should be filled by safety in charge/Supervisor/site in charge

depending on the availability of person. It is essential to fill this form before

starting the travel.

7. SAFETY WHILE STACKING OF PIPES

Pipes after arrival on port are not directly taken to the site location. Indeed they are

stored in a pipe yard and then taken to the site when needed. Now let us discuss

about the safety precaution that must be taken in pipe yard.

General hazards in pipe yard includes roll off of pipes. To avoid such accident, the

following checklist should be filled before starting of work.

7.1 CHECKLIST FOR STACKING OF PIPES

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1 Are the pipes stacked for more than THREE layers?

2 Are the pipes stacked in pyramid shape?

3 Is the ground level flat and free from water?

4 Is the aisle place provided for trailers and equipments (hydra)to operate?

5 Is the pipes been stored based on their category?

Note:

This checklist is to be filled by safety in-charge/supervisor/foreman/site in-

charge, depending on the availability. These checklist is to be filled before

stacking/unloading of pipes in pipe yard.

8. SAFETY IN VARIOUS PIPELINE ACTIVITIES

The various pipeline activities are already discussed in brief already. Here we

discuss about the safety aspects that are to be followed while performing these

various activities. Also checklists are been prepared for every activity. The purpose

of checklist is, it makes us implement safety easily. Any supervisor can even fill

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the checklist, but implementing things in checklist will ensure the absence of

negligence and henceforth, accident too.

8.1 SAFETY ASPECTS IN ROUTE SURVEY

Its evident that for any pipeline or linear projects, first task will be in confirming

the route of proceedings. This in technical term is known as SURVEY. Survey is

done by team of surveyors. The major hazards that a survey team faces is slip/fall

injuries, obstruction/bite of animals. So in order to protect the survey team from

hazards, the following checklist is to be filled up before starting survey.

Note:

This checklist should be filled by safety in-charge/supervisor/team head

depending on the availability of person. Filling this form could ensure maximum

safety to the worker.

8.1.1 CHECKLIST FOR ROUTE SURVEY


1 Are the surveyors aware about the upcoming danger and is

suitable precautions taken?

2 Are the team members wearing competent PPE (gumboots is

must)?

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3 Is first aid box kept ready?

4 Is the emergency vehicle kept ready?

8.2 SAFETY ASPECTS IN ROW (RIGHT OF WORK)

ROW is the area allocated for us to work for our project. In many cases ROW is

given by Government (in case of road or any public property) and in some cases

its been given by public (in case of private land) also. After getting ROW the crewwill be sent to clean that area and make it suitable for work. Generally graders,

excavators are been used. The predictable hazards are fall/slip, exposure to

unfavorable physical condition (noise, light), and hazards due to operation of

machines, hazards due to external factors (overhead and underground cables). To

protect the workers from the hazards and ensure safety, the checklist below should

be filled before start of work.

9.2.1 CHECKLIST FOR PERFORMING ROW


1 Are the equipments used certified?

2 Presence of any overhead cable?3 Are competent PPE (ie dust mask, ear plug, goggle) been used?

4 Is the equipment used, provided with reverse horn?

5 Is the operator qualified?

6 Is banks man/ lime watch been provided?

7 Is ROW area barricaded from road/land nearby?

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2 Is the equipment certified?




6 Does the operator trained?7 Is the velocity of air with in limit(30M/S)



Note:

The above checklist should be filled by safety in-charge/supervisor/foreman

depending on the availability of person. Filling this form could ensure maximum

checklist to the workers.

9.4 SAFETY WHILE PERFORMING TRENCHING

Trenching is a process similar to excavation. The major difference between

excavation and trenching is, the depth of the pit will be more than the breadth of

the pit in case of trenching. All the hazards which are available for excavation also

exist here. The important fact is that, as per law any pit of deep greater than 1.2M

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is considered as Confined space. So EPIL also treat this as a confined space

while performing jobs in it.

The major hazards involved in trenching are collapse of side wall, Hit/fall on

impact of equipment, overhead/underground cables interference. To avoid such

injuries, following checklist is to be filled before starting of work.

Note:

The below checklist for trenching is to be filled by safety in-

charge/supervisor/site in-charge/foreman depending on the availability of the

person. Filling this form before start of work will ensure maximum safety to the

workers.

9.4.1 CHECKLIST FOR TRENCHING OPERATION


1 Is the equipment used been certified?

2 Has soil test been done?

3 Required slope angle/steps/shoring been done?

4 Is the evacuated soil been placed 5 feet from side walls?

5 Is the distance of half of depth of trench from sidewalls being

barricaded?6 Has the presence of overhead/underground cables checked?

7 Is lime watch been provided?

8 Is the operator well trained?

9 Is mandatory PPE been used?

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9.5 SAFETY WHILE WELDING

Generally speaking welding is of two major categories.

Main-line welding

Tie-in welding

Main line welding is a primary process of welding two pipes. Tie-in welding is a

complicated process. When laying pipes, some place may be left for public passage

or any purpose. But on either side of the gaps, pipes would be laid. Now for laying

pipes in the left area is a challenging job and that process is known as tie-in

welding.

But for a safety person, both the welding has same hazards. So lets not go deep

into classifications.

Major hazards involved in welding are fire/back fire, radiation. To prevent these

hazards the following checklist must be filled before starting welding process.

9.5.1 CHECKLIST FOR WELDING OPERATION


1 Is the proper gas cylinders been used?

2 Is the flash back arresters been used?

3 Are the cylinders kept in vertical position?

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4 Is the valve closed, when not in use?

5 Is the welding cable properly maintained?

6 Is the welder trained to do this job?

7 Does any tent/temporary structure provided during welding?

8 Is the welding area free from flammable materials?9 Are the welders wearing Mandatory PPE?

10 IS the used cylinders stored properly (vertically)?

Note:

This checklist is to be filled by safety in-charge/supervisor/foreman

depending on the availability of the person. Filling this form will ensure maximum

safety to the workers.

9.6 SAFETY WHILE RADIOGRAPHY/X-RAY TESTING

Radiography/X-ray testing is been used to detect any flaws in welding. Actually

there are FIVE stages of welding. After all five stages the X-ray testing is done to

check the completeness of the welding. In JPSPL X-ray testing is been done.

The major and only hazard involved in X-ray testing is exposure to radiation.

When a person is been continuously exposed to radiation without proper protection

he may got his cells damaged which may even result in cancer. To avoid this, its

advised to fill the below checklist before the start of the work.

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Note:

The above checklist has to be filled by safety in-

charge/supervisor/foreman/site in-charge before commencement of the work.

Filling this form could ensure maximum safety to the worker.

9.6.1 CHECKLIST FOR RADIOGRAPHY/X-RAY TESTING


1 Is the x-ray testing been carried out by a trained person?

2 Is the same person exposed always to radiation?

3 Is regular medical attention been given to x-ray person?

4 Is he wearing proper radiation proof clothing during work?

5 Has care been taken to protect nearby people to protect fromradiation?

9.7 SAFETY IN JOINT COATING OPERATION

Generally pipes are being coated. When welding, a foreign part is been attached to

the pipe structure and been welded. The foreign material would not have any

coating. In this case to maintain uniformity in appearance, the joint of pipes are

been coated. This process is known as joint coating.

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The major hazards involved in joint coating are irritation due to spillage, lung

damage due to inhalation and damage of eyes due to external particles. This could

be avoided if the following checklist is been filled before the start of the work.

9.7.1 CHECKLIST FOR JOINT COATING

S.No Specification Yes/No1 Is the person been provided with proper dust mask, to avoid

lung diseases?

2 Is dust been removed frequently before accumulation?

3 Is the person coating by standing upwind?

4 Is the person trained to do that operation?

5 Is regular medical attention been given to that person?

6 Is the person been given mandatory PPE(goggle, full sleve

clothing)?

Note:

The above checklist should be filled by safety in-charge/supervisor/site in-

charge/foreman depending on their availability. Filling this form could ensure

maximum safety to the worker.

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9.8 SAFETY WHILE LOWERING OF PIPES

After the above mentioned processes are over, the next thing is to place the pipe in

its place (ie. Trench). Generally lowering of pipes comprises of three substages.

Pre-padding

Lowering of pipes

Post-padding

Generally some fine particles of sand are put into trenches before lowering the

pipes. This is to ensure protection to the pipe. Also one more layer of fine sand is

applied after lowering the pipe. Generally these pre-padding and post-padding are

done manually.

The pipes are generally very big in size when it is to be lowered. This is due to the

fact that welding is done. So in many cases two or more equipments will be used to

lower the pipes. It is evident that as number of equipment increases, hazards also

automatically increase. I noticed that the pipes lowered are been earthed properly.

The major hazards in this process include hit/fall due to equipment, collapse of

side wall and hindrance of overhead cable. This can be minimized by filling the

checklist before start of the work.

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9.8.1 CHECKLIST FOR LOWERING OF PIPES


1 Is proper equipment been used?2 Is the equipment certified?




6 Does the operator trained?

7 Is the velocity of air with in limit(30M/S)



Note:

The following form should be filled by safety in-charge/supervisor/site in-

charge/foreman depending upon the availability of the person. Filling the above

checklist before work will ensure maximum safety to the worker.

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9.9 SAFETY IN BACKFILLING

Backfilling is the next stage of post-padding. After fine particles of sand is laid, the

trench need to be filled back. So the evacuated soil is again dumped back into the

trench. This is done by excavator.

The general hazards when excavators are used are fall/slip by hit of equipment and

hindrance of electrical lines. To minimize such hazards the below checklist must

be filled before start of work.

9.9.1 CHECKLIST FOR BACKFILLING


1 Is proper equipment been used?

2 Is the equipment been certified?

3 Is the overhead cable presence checked?

4 Has lime watch/ banks man been provided?

5 Is the operator been trained?

6 Is the equipment been placed at certain distance from side

walls?

Note:

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The above form should be filled by safety in-charge/supervisor/site in-

charge/foreman before the commencement of work. Filling this form could ensure

maximum safety to workers.

9.10 SAFETY ASPECTS IN HYDRO-TESTING

Hydro-testing is a process done to clean the interior of the pipes. Since the pipes

are been kept for a longer duration there is chances for animals/dust to accumulate

into the pipe. Through hydro-testing process we send high pressure air from one

side of the pipe by keeping other side at zero pressure. When the air has reached

other side, the pressure is being made zero from sent in side and pigments are

removed from other end.

The major hazard involved in this process is burst of pipe. This could be avoided

by filling the following checklist.

Note:

This form should be filled by safety in-charge/supervisors/foreman/site in-

charge depending on the availability of the person. Filling this form could ensure

maximum safety to the worker.

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9.10.1 CHECKLIST FOR HYDRO-TESTING

S.No Specification Yes/No1 Is the person trained in hydro-testing?

2 Is pressure valve provided at both the ends and is working?

3 Is the pipe kept in stable position?

4 Are the workers on the other side instructed not to open the

flange until pressure becomes zero?

5 Is any holding or display boards provided displaying as pipe

under pressure?

9.11 SAFETY IN CATHODE PROTECTION

Cathode protection is of two major types.

Temporary cathode protection

Permanent cathode protection

This cathode protection process is similar to electro-plating concepts. This is done

to avoid corrosion of pipes, because corrosion may reduce life of pipes in greater

extent. There are two types of cathode protection. But for both of these process,

same safety precautions is to be followed.

9.11.1 CHECKLIST FOR CATHODE PROTECTION

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1 Is the cable drum properly fixed?

2 Are the loose wires free from walking area?3 Is care taken regarding pinch points in the drum?

4 Is proper hand gloves been used?

5 Is fire extinguisher available?

Note:

The above mentioned checklist should be filled by safety in-

charge/supervisor/site in-charge depending on the availability of the person. Filling

this form could ensure maximum safety to the workers.

10. ADVANTAGES OF CHECKLIST

Checklists are nothing but a set of questions which need to be answered (either yes

or no) before starting the concerned operation. The reason why checklist concept is

introduced is, safety persons cannot involve themselves in all the activities. There

may be many activities taking place without the presence of safety persons. In

order to establish zero accidents in those activities, checklists are being introduced.

It is easy to fill a checklist. That is the reason why it is popular.

It is the duty of safety department to train supervisor/foreman/site in-

charge/engineer to educate about the checklist. If a checklist has 10 questions, all

10 need to have positive answers to ensure complete safety. But sometimes our

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supervisor/site in-charge takes risk by neglecting few questions. In that case,

person who filled the checklist will be fully responsible in case of any mis-

happenings.

It is also evidently proved that, implementation of checklist reduces accident in

large numbers. So proper education and proper use of checklist is to be

implemented in any site to achieve zero accident, without at-most strain.

This is the reason I am interested in implementing the checklist concept in JPSPL

project.

11. CONCLUSION

The intention of preparing this report is to make the implementation of safety

easier. I also can assure that maximum safety can be ensured by the proper usage

of prescribed checklist.

Documents

Report 1 Version 1.Gammon Final Report