Safety:

Safety is a common sense look, think, done to save yourself and

others. Or

Safety is a state where the risk has been eliminated or reduced to an acceptable
level.

Purpose of safety:

To carry out any work in safe manners.

Safety procedure:

Procedure is a written instruction of top management

regarding the task which is deal rules, regulation and limitation for all safe method.

Safety standards:

Helmet 89.1(ANSI)

Safety Glass 87.1(ANSI)

Safety Harness 359.1(ANSI)

Safety Shoes 47.1(ANSI)

Respirator 88.1(ANSI)

Safety on scaffolding 10.4(ANSI)

HSE Orientation/Safety induction:

Every employee or the workers has to undergo a safety training

to know the rules and regulation of the company at joining time to get ID
(Identification card). The main reason behind this orientation is to give awareness
of safety of the site to stop all kind of incidents, accidents and property damages
and environment issues.

Responsibility of safety officer:

 1. Identify potential or existing risk.
2. Monitor daily tool box meeting and keep record.
3. Make sure work permit available on site.
4. Arrangement of sufficient barricade, warning tape and sign boards on site.
5. Supervision of equipment operator and flagman.
6. Responsible to communicate with area construction supervisor for
rectification of safety observation.
7. Responsible to check workers welfare facilities such as drinking shelter and
prayer shelter are available.
8. Evacuation of site workers, guide to assembly point and head counting
during an emergency.

What is PPE?

Personal Protective Equipment include: safety shoes, hard hate,

hand gloves, safety glass, face shield, ear plugs or muffs and safety harness.

Confined space:

A space having limited access or egress but large enough to

bodily entrance and perform work is called confined space. For example vessels,
pipes, tank, boiler, sewer, deep excavation more than 1.2m in depth etc.

 LEL of flammable gasses or toxic gasses should be zero.

 If lighting is required, lighting is of low voltage does not exceed 12 volts.
 Oxygen should be 20.8% in volume.
 Carbon Mono Oxide should be less than 35 ppm.
 Hydrogen sulphide should be less than 10 ppm.
 Oxygen level in confined space is 19.5% to 23.5%.
 In case of emergency in confined space, inform the ERT (Emergency
Rescue Team) rescue team, security and higher authority.
 Hazardous jobs in confined space are Grinding, Cutting, chemical cleaning,
use of gas cutting, erection of materials.
  In a confined space inside 24 volts DC and outside 110 volts DC will be
used
 All compressed type of cylinder will not be stored in confined space i.e.
Acetylene, propane, butane or oxygen.

Confined space Hazards:

Oxygen deficiency and enrichment, presence of toxic or

flammable gasses, chemical hazards, fire hazards, sleeping, high temperature and
high noise etc.

Toxic Gasses:
H2s – Hydrogen Sulphide, CO – Carbon Monoxide, CH –
Chlorine, Ammonia.

Flammable Gasses:
Acetylene, Propane, Hexane, Nonane, Methane.

Flammable Liquid:
Any liquid having a flash point below 60c (140f).
Combustible Liquid:
Any liquid having a flash point above 60c (140f) and below 93c
(200f).

Flash Point:
The minimum temperatures, at which a substance gives off a
flammable vapor which in contact with a spark or flame, will ignite.

Confined space Requirements/Precautions:

To avoid hazards make sure following precautions are followed.

 Confined space entry permit.

 Confined space attendant/watchman
 Log sheet
 Gas test should be conducted before entry into confined space.
 State on work permit the frequency of repeated gas tests (e.g., at least every
two hours)
  Proper PPP,s
 Barrication,warning tap and sign board
 Proper access and egress
 Proper means of communication
 Dust mask
 Trained persons
 Proper ventilation
 Sufficient lighting
 Rescue team
 Pressure horn

Who is confined space attendant/watch man?

The trained person who stands outside the entrance of the confined
space with the entry log sheet and record the details of the entrants. He always
keeps communication with the entrants, in an emergency, he call for assistance.

Duties of confined space attendant/watch-man:

He is responsible for the safety of entrants, should be present

whenever people are working in a confined space.

Record the details of the entrants such as name, trade ID number, time going in,
time coming out etc. keep communication with the entrants. Call for rescue in case
of an emergency.

In which circumstances a confined space work permit can be issued:

If properly ventilated, gas test readings are

Satisfactory, properly barricaded and warning signs are posted; trained standby man is present
with log sheet, sufficient lighting and low voltage electricity (24V-110V), proper means of
communication, locked and tagged out if necessary, lifeline and man retrieval system if
necessary, etc.

Hot Work:
Any work in which we use energized equipment’s. There is a chance of fire and
producing sparks. E.g., welding, grinding, sand blasting, cutting by means of power tools etc.
What are the safety requirements for doing a hot work?
Following are the requirements of hot work.
 Valid work permit.
 Remove all combustible materials from the area (with 10 meters), possible.
 Use fire blanket to protect immovable materials and also for welding slugs.
 Cover the area with fire blanket for containment of park generated while
doing hot work.
 Provide proper fire extinguisher in sufficient numbers.
 Appoint a fire watchman.
 Barricade the area and post proper signage.
 Use of proper PPE
 Proper housekeeping
 Inspected tools and equipment’s
 Grounding of the equipment’s
 Conduct gas test if presence of combustible gases expected prior to work.
 Keep distance 6m of fire extinguisher from a hot work activity
Who is Fire watch?
Fire watch is the person design to identify and eliminate fire
hazards, alert and extinguish fire in case of any outbreak of fire and to protect the
person and properties from fire.

Responsibilities of fire watchman:

 Assure that hazardous situation do not arise
 Be alert and remain on the job site
 Assure that all required firefighting equipment are available and in working
condition
 Assure that all permit condition are maintain
 At job completion, he remains at the site 30min
Scaffolding:
It is a temporary elevated platform used to support men material or
both.
Types of Scaffold:
It has been categorized into;
1. By structure
2. By weight
3. By height

1. By structure:
i. Tower scaffold
Under hang scaffold
ii. Bracket scaffold
iii. System scaffold
iv. Frame scaffold
v. Mobile scaffold
vi. Fix scaffold
2. By weight:
i. Light duty:
A scaffold designed and constructed
To carry a working load not to exceed 125kg or 25 pounds per square foot.
ii. Medium duty:
A scaffold designed and constructed to
Carry a working load not to exceed 250 kg or 50 pounds per square foot.
iii. Heavy duty:
A scaffold designed and constructed to
Carry a working load not to exceed 375 kg or 75 pound per square foot.
3. By height:
12m, less than 12m or greater than 12m
Components of Scaffold:
Sole boards, Base plate, Screw jack, couplers, Bracing,
Posts/Standards, Runners/Ledgers, Hand rail, Mid rail, Toe board, Reveal pin, Spy
got, u-cups, Platform, Ladder and Drop bar.
Scaffolding requirements:
Following are some commons requirements.
 Work permit
 Capacity (scaffold and scaffold components shall not be loaded in excess of
their load rating)
 Stability
 Barricading, warning tape and sign board
 Competent scaffolders
 Full body harness
 Ladder
 Guard rail
 Tags etc.
Hazards of scaffolding:
 Fall from elevation
 Slipping
 Collapse of scaffold
 Falling objects/tools
 Structure failure
 Electric shock
 Instability
 Tripping hazards
Scaffold safety:
 Only designated scaffolders are allowed to erect or modify any type of
scaffold.
 A competent person shall be carried out periodic inspection for scaffold.
 Employees are not allowed to work on incomplete scaffolding.
 Scaffolders should wear full body harness while erecting/ dismantling the
scaffolding.
Coupler:
A device for locking together the components parts of a tubular metal
scaffold which shall be designated and used to safety support the maximum
intended loads.
Types of coupler:
1. Adjustable/Swivel/Round coupler
2. Double coupler/Right angle Coupler
3. Sleeve coupler/End to End coupler/ Joint Box coupler
4. Girder coupler/Beam coupler
5. Single coupler/Put luck coupler
Brace:
It is used for stability of scaffold. Or a tie that holds one scaffolds
member in a fixed position with respect to another member.
Types of Brace:
 Zigzag bracing
 Transverse bracing
 Longitudinal
 Cross bracing
Guard rails:
Guard rail system consists of top rail, mid rail and toe board. It
prevents men and material from falling down. Guard rail has the capacity 90 kg.
Toe board:
The plank or metal sheet kept vertical to the platform at a minimum
height of 4 inches and maximum 9 inches in order to avoid material from falling
down.
Tag system:
A tag system is put on scaffolding, by a competent person, indicating
the present condition whether it can be used and whether fall protection needed or
not.
  Red tag – Do not use
 Yellow tag – can use with 100% fall protection
 Green tag – safe to use
General information about scaffold:
 Height of the top rail from the platform 38 inches to 45 inches or 0.95m to
1.15m.
 Length of Lanyard is 1.5m
 Minimum overlapping of two adjacent planks in a platform is 1 inches.
 The angle of ladder is 75 degree or ¼.
 The gap or space is 12 inches or 30 cm between two ladder rungs.
 Scaffolding erecting over 37 meter height should be provided by qualified
engineer.
 Mid rail b/w the top rail and platform
 Aluminum ladders and wooden ladders shall not be painted.
 Scaffolding shall be examined at least once in ever seven days.
 Toe board capacity 23kg.
 Top board capacity 90kg.
 Scaffold platform 2m.(1m=39inches=100cm=1000ml)
Life line:
Where ever no other fall arrest system area feasible, life lines can be
provided with wire rope. The life line should be able to support a minimum of
5000 pounds per person hooking (thickness 12.5/13mm)

Fire:
Fire is the chemical reaction of three things i.e., fuel, heat and oxygen.
Or Fire is a chemical reaction involving rapid oxidation or burning of a
fuel.(F.Find,I.inform, R.Restrict, E. Extinguisher)
Classification of fire and their fire extinguishers:
Class A: Ordinary combustible materials:
Example: wood, cloth, rubber, plastic.
Extinguishers: water, DCP, Foam, CO2,
Haloon.
Class B: Combustible Liquids and Gasses:
Example: Gasoline, Diesel, Oil.Grease,Oil based, paint etc.
Extinguishers: CO2, Foam, DCP.
Class C: Energized Electrical Equipment
Extinguisher: DCP, FM 200, Haloon, Carbon Dioxide.
Class D: Combustible metals:
Example: magnesium, potassium, zinc, calcium, titanium.
Extinguishers: Metal x-Type, Combustible Metal type.
Class k Fires:
It is fires occur in kitchens grease and oils.
Fire extinguishers:
There are six types of fire extinguishers
1. Water fire extinguisher
2. Foam fire extinguisher
3. Dry chemical powder fire extinguisher (this type of fire extinguisher
available in different sizes 3, 6 and 12kgs)
4. Carbon dioxide fire extinguisher (this type of fire extinguishers are available
in different sizes 2kg, 6kg, 10kg, 20kg, 30kg)
5. Haloon fire extinguishers (this type of fire extinguisher are available in
different sizes 1kg, 3kg, 6kg, 12kg etc)
6. Liquid powder fire extinguisher (kitchen)
What are the types of Fire:
A. Solid Fire (all combustible material e.g., wood, trash, paper etc.)
B. Liquid Fire (oil, paint, lub, grease etc.)
C. Electric Fire (all energized equipment,)
D. Metal type (magnesium, titanium, any metallic)
E. Special Fire (when any chemical drop on other things its generated fire)
What is Fire Triangle?
FUEL+ OXYGEN+HEAT
Some example of flammable liquids:
Kerosene, Diesel, Acetylene, Gasoline etc.
Some example of combustible metals:
Calcium, Lithium, Sodium, Potassium titanium etc.
Fire extinguisher method base on PASS:
P –Pull the pin
A –Aim the place
S –Squeeze the handle
S –Sweep the nozzle

Methods of Fire extinguishing/Fire Control methods:

Starvation/Curtaining: Eliminate the fuel supply.
Smothering: Eliminate the Oxygen e.g. by covering with foam or
blanket.
Cooling: Eliminate the heat by putting water etc.
Fire fighting rules:
i. Assist people in danger
ii. Sound the alarm
 iii. Ensure safety of everybody quite
iv. Fight the fire if you are safe
v. Crawl on the floor, don’t stand up
vi. Don’t use lift during fire (if electricity switch off, you will remain in lift)
Main causes of Fire:
 Ignorance
 Carelessness
 Poor housekeeping
 Welding spar
 Source of ignition
 Overloading of electric circuits etc.
What is MSDS:
Material Safety Data Sheet – it is a document which gives information
about using chemical.
Contents of MSDS:
 Chemical/product name
 Producer address
 Emergency contact number
 Information of ingredient possible hazards
 Chemical and trade names of the material
 Physical characteristic
 Fire and explosion data
 Dangerous properties
 Precautions for safe handling
 Labeling and other useful information
What is JSA:
A procedure in which we divide our jobs in steps, identifying hazards
in each step and then defining safe precautions to eliminate or minimize those
hazards.
Or Job Safety Analysis; breaking task into pieces, finding hazards for each key
step and developing methods to organize it. Or
Job Safety Analysis is the step by step analysis of job to determine the safe
working procedure.
Benefits of JSA:
Time saving, Increase production, Decrease injury rate, Increase
quality, Safety and health awareness is raised.

Who will responsible of doing JSA:

Work responsible supervisor should develop JSA but can be assisted
by work crew, safety representative, foreman, who is doing the job.
What are the Basic stages of conducting JSA:
Four basic stages in conducting a JSA are;
 Selecting the job to be analyzed
 Breaking the job down into a sequence of steps
 Identifying potential hazards
 Determining preventive measures to overcome these hazards
Use of JSA:
 Watch the job being done
 Breaking the job down into steps
 Describe the hazards In each step of task
 Identify the desired control measures
 Implement these counter measures in the job execution

What is Risk Assessment?

Risk assessment is the process of collecting information and making judgments
against standards, often set out in law, to establish whether or not risks are adequately
(suitably and efficiently) managed. Or
A task which assesses risk in terms of both severity and probability.

What is the use of Risk assessment?

Its use is to;
 Create awareness of hazards and risks
 Identify who may be at risk (employees, cleaners, visitors, contractors, the public,
etc)
 Determine if existing control measures are adequate or if more should be done.
  Prevent injuries or illness when done at the design or planning stage.
 Priorities hazards and control measures.

Steps involved in making a Risk assessment:

 Look for the hazards
 Decide who might be harmed and how
 Evaluate the risks and decide whether existing
 Precautions are adequate or more should be done
 Record the finding
 Review the assessment and revise it if necessary

How make Risk Assessment:

 What can go wrong
 What can cause it to go wrong
 What can be done to prevent it to go wrong
 What can be done to minimize the negative consequences if it does go wrong

What is Severity?
The outcome of an event or situations expressed quantitatively or qualitatively
being a loss, injury, disadvantage or gain.
What is Likelihood?
A quantitatively description of probability and frequency.

What is Probability?
The likelihood of a specific outcome, measured by the ratio of specific outcomes
to the total number of possible outcomes.

Last Minute Risk Assessment (TAKE-TWO):

The “Take Two” method is used to help employees to think and implement safety
precautions before any job is started. “Take two” means to take two minutes before starting
any job to think about (thinking before acting)
T= “Talk” – about the upcoming job
A= “Actions” – decide what actions will be needed
K= “knowledge” – decide what knowledge is needed
E= “equipment” – decide what equipment is needed
Take-Two assessments are carried out in the field prior to starting any routine and non-
routine task/jobs by the people doing the work.
Excavation:
Digging of the land with machine or with men.
Or any work done by breaking the surface of the earth by using hand tools or by machine.

Methods of Excavation:

1. Shoring:
A structure that supports the sides of an excavation and protects against cave –in.
2. Trenching:
A narrow excavation, where the depth is greater than width but not more
than 15 feet or 4.57m.
3. Benching:
A technique to excavate an excavation in steps.
4. Slopping:
A technique to excavate on a specific angle. Or To make the side of the
excavation cure.

Basic requirements of Excavation:

 Work permit
 Drawings
 Survey of soil
 Type of excavation (manually or mechanically)
 Underground utilities
 Area should be determined
 Barrication
 Sign board/warning tape
 Keep material 1 meter away from edge of excavation
 Provide access

Hazards of Excavation:
 Cave in is the greatest hazard of excavation
 Fall of moving machinery near the edge of excavation
 Oxygen deficiency
 Toxic gasses (co2, Ammonia, H2S etc)
 Load surface
 Fire
 Underground utilities
 Dropping of material
  Water accumulation l
- If any excavation is deeper than 1.2m and more than 100mtr than after every 25m
access will be provided.
- ECC, Excavation Clearance Certificate
- Excavated soil should be placed 1metre away from the edge of excavation.
- No mechanical excavation is allowed within 2 meter of any underground service.
- Equipment and other heavy objects must be kept at least 2meter away from the edge of
the excavation.

Soil classification:
A competent person must do soil analysis to determine the soil or rock type;
i. Stable Rock Vertical 90 degree
ii. Type A/Clay 250mm(3/4feet) 300mm( 1feet) 530
iii. Type B/Mud 300mm(1 feet) 300mm(1 feet) 450
iv. Type C/Sandy 450mm( 1-1/2f) 300mm(1feet) 340

What is the maximum distance between two adjacent accesses in a long excavation?
A ladder must be present within 25ft., of employees working in excavation.
In open excavation – At every 30 meters on the perimeter, if less than 1.2 meters deep.
At every 7.5 meters on the perimeter, if more than 1.2m deep.

Electric Safety:

LOTO Or Lock Out Tag Out:

A process used to lock energized machine, pipeline or equipment to avoid sudden
maintenance of all equipments.

What is the use of LOTO:

Isolating device to avoid uncontrolled operation and give details of the lock out
schedule.
Where will we use Multi Lock out and Tag out:
When more than one team working on same equipment but different jobs like 1
team working on electrical and other mechanical.

GFCI:
Ground Fault Circuit; to protect the workers from shock in case of current
leakage. Interrupter
 ELCB:
Earth Leakage Circuit Breaker; to protect the workers from shock in case of
current leakage.

What is Dead Man Switch and its use:

To cut off the power supply to the tool in emergency.

Safety devices attached with portable Grinder:

Dead men Switch, Safe guard, handles, and double insulation.

Electrical hazards:
Fire and Explosion.

Main types of Electrical Injuries:

Electric shock, burn

What is the difference b/w GFCI and ELCB?

Functionally they are all intended to perform the same function. ELCB is
primarily used in Europe while GFCI is used in North America.

Who will issue Lock out/tag out permit:

The operation supervisor shall issue a safe work authorization (work permit)
Who will sign Lock out/tag out :
Electrician who installed lock/Tag and area operator. In case of absent of
electrician, Electrician Supervisor with his duplicate key removes lock.

What is the minimum strength of Tag out device?

50 pounds breaking strength and environment tolerance.
What is the name of Gas Testing device us in in IR:
GT-303
What is the safety device attached with Compressed gas cylinder:
Flash Back Arrestors:
It prevents the flame to travel through the hose and into the cylinder.

- The color of Oxygen hose is Green

- The color of Acetylene hose is Red
- The color of Argon hose is White.
- Acetylene and Oxygen both gases combined used for simple cutting.
- It is non-flammable gas and used for welding gas (x-ray).
 - The minimum distance b/w Oxygen gas Cylinder and Fuel gas Cylinder is 6.1 meters
(20feet)

Check valve:
A check valve allows flow in one direction only. This prevents oxygen reaching
acetylene cylinder and acetylene reaching oxygen cylinder in the event of blockage in the
torch or line or pressure variations.

What are the hazards of Electricity:

The primary hazards of electricity and its use are:
 Shock
 Burns
 Arc-Blast
 Fires and explosion

 Shock:
Electric current travel in closed circuit through some kind of conducting material.
You get a shock when some part of your body becomes part of electric circuits.
An electric current enter the body at one point and exit the body at another
location. High voltage shocks can cause serious injury, burns or death.
 Burns:
Burn can result when a person touches electrical wiring or equipment that is
improperly used or maintained.
 Arc-Blast:
Arc blasts occur when high amperage ( ) currents jump from one
conductor to another through air, generally during opening or closing circuits.
 Explosions:
Explosions occur when electricity provides sources of ignition for an explosive
mixture in the atmosphere.
 Fires:
Electricity is one of the most common causes of fire both in the home and
workplace. Defective or misused electrical equipment is a major cause.

Causes of Electrical Accident:

 Unsafe equipment and installation
 Unsafe workplaces caused by environment factors
 Unsafe work practices
Preventing Electrical Accidents:
Protective methods to control electrical hazards include;
i. Insulation
ii. Electrical protective devices
iii. Guarding
iv. Grounding
v. PPP
vi. Good work practices

Electrical Protective devices:

EPD including fuses, circuit breakers and GFCI are critically important to
electrical safety.
These devices interrupt current flow when it exceeds the capacity of the conductor and should
be installed where necessary.

Guarding:
Any “LIVE” parts of electrical equipment operating at 50 volts or more must be
guarded to avoid accident contact.

Grounding:
Grounding is necessary to protect you from shock safeguard against fire and
protect against damage to electrical equipment.

Safe/ Good work practices:

Use appropriate equipment, remember if you are not sure, and don’t touch.

Crane:
A mechanical device which is used for lifting the load from one place to another
place or location is called crane.

Lifting operation:
The operation in which item or equipment being lifted or shifted is called lifting
operation.
Load:
The item or equipment being transported or lifted is called Load.
Lifting:
The process of moving the material from one location to another location is
called lifting
Types of lift:
i. Non-engineering lifts
ii. Engineering lifts

i. Non- engineering lifts:

Vessels
Vertical = under 30 Ton
Vertical = 8 feet diameter
Horizontal = under 60 Ton
All other equipment and structure under 60- Ton.

ii. Engineering Lifts:

It has three types of lifts.
 “A”Type Lift:
Lift up to 100 ton per the following requirements.
Vessels:
Vertical = 30 Ton and over
Vertical = 8 feet diameter and over
Horizontal = 60 Ton and over
All other equipment and structure over 60 -Ton.
 “ B” Type Lift:
Lift 100 Ton up to 600- Ton.
 “C” Type Lift:
Lift 600 – Ton and above.
All engineering lifts must be carried out under the supervision of owner/contractor rigging and
load engineers, third party rigging consultant, rigging manager, site manager and project
manager.

Critical lifts:
 Around energized power lines.
 Near and over hydrocarbon and pressurized piping system.
 Around and over populated/traffic areas. If any load is more than 15 ton.
 Tandem, multiple or trailing lifts.
 High level and long reach lifts.
 Personal platform (man basket)
JSA and lifting plan must be required.
Tendum Lift:
A lift in which two crane are used for lifting is called Tandem lifting.
Lifting Plan:
It is the document prepare for planning a critical lift by calculating and
considering all factors which is going to effect the lift and there by select the correct tools and
cranes and ensure the safe lifting procedure to be followed for the particular lift, which is used
for lifting.

Parts of Crane:
Boom, Sling, Shackle, Fly jib, Anti two block, Outrigger, Main hoist, Auxiliary
hoist, Pulley, Web sling, LMI, Counter weight, air fan etc.

Types of Crane:
i. Mobile crane
ii. Crawler crane
iii. Tower crane
iv. Overhead craned
v. Mounted crane
vi. Rough terrain crane
vii. Side lift crane
viii. All terrain crane
ix. Floating crane
x. Telescope crane
xi. Hammerhead crane
xii. Gantry crane
xiii. Loader crane
xiv. Jib crane etc.

Hazards of Crane:
 Instability
 Contact with power line
 Load and capacity ratio
 Incorrect radius
 Operator untrained
 Rigger untrained
 Wind velocity more than 32kph
 High speed of boom swing
 Underground utilities
  Soil unstable
 Electrical hazards
 Inadequate inspection and maintenance

Crane Lift Requirement:

 Valid work permit
 Crane TUV
 Client sticker
 Operator license
 Qualified Rigger (TUV)
 Crane boom swing area free and barricade
 Outrigger fully extended and must be on pad
 Check the ground level and stability
 Check the SWL
 Load capacity
 Visual inspection of all equipment
 Anybody not allowed under suspended load
 Tag line will be used
 Maintain safe distance from energized line.
 Never place load under power line.

Work Radius:
Distance from the center pin of the crane to the centre of the load is called work
radius (dia *dia*8) (1``*1``*8=8 Ton).

Safe Work Load (SWL):

Safe work load is the maximum load that can apply to the lifting tool safely.

Load Movement Indicator (LMI):

Load movement indicator means a system which aids the equipment operator by
sensing the overturning moment on the equipment i.e. loads multiplied by radius.
It compares this lifting condition to the equipment rated capacity, and indicates to the operator
the percentage of capacity at which the equipment is working.

Load Chart:
Each crane has a load chart that specifies the crane capabilities, detailing its
features and how its lift capacity varies when considering distance and angle.
Outriggers:
Outriggers are extendible or fixed members attached to the crane base to support
the crane during lift.

Jib:
Jib is an extension to the end of the boom to provide added boom length for lifting
specified loads.

Dry Run:
Dry run is an unloaded lift cycle test to ensure load clearance boom reach will be
adequate for critical lift.

Counter Weight:
Counter weight is any weight used to supplement the weight of the crane to
provide additional stability for lifting loads.

Anti-Two Block:
A device which prevent collision (impact) of hook and boom.
Boom:
Boom is a member hanged to the rotating superstructure and used for supporting
the hoisting tackle.

Crane Safety Devices:

Following are the crane safety devices.
i. Warning light
ii. LMI
iii. Outrigger lock pin
iv. Emergency shutdown button in the cabin
v. Safety lever for control
vi. Fire extinguisher
vii. Emergency control system
viii. First aid kit

Common things in different Crane:

These few things are similar in different cranes.
- Carrier
- Machine Deck
- Boom
- Counter weight
 - Hoist system
Physical inspection of Crane:
i. Check capacity of crane
ii. Lifting plan
iii. Capacity of main hook
iv. Capacity of wire rope slings
v. Capacity of shackle
vi. Capacity of spreader boom
vii. Stability of crane
viii. Inspection TUV sticker
ix. Operator license
x. Qualified rigger( have TUV)
xi. Never place load under power line
xii. Check ground level and ground utility
xiii. Outrigger must be extended

 Crane wind velocity capacity:

9 m/PS (meter per second) or 32k/mph (per hour)

 Man Basket wind velocity capacity:

7 M/Ps or 25 k/mph (1mps=3.6k/ mph i.e. 25/7=3.6)

 Man lift wind velocity capacity :

12 m/pHs or 43k/mph (43/12=3.6)

 The Safety angle of the Crane is 450

 The clearance of the boom with electrical lines 20 feet (2meter)
 Above 10 Ton lift is called critical lift
 Below 10 Ton lift is called Tail lift
 Generally there are two types of Crane Boom i.e. telescopic boom and Lattice boom.

Man basket:
A basket with which human being lifted above to the high elevated area to
perform work.

Requirement of a Man basket:

It should be designed and fabricated according to standards, have third party
certificate, two guide ropes, damage free lifting gears, the load bearing capacity should be
written on man basket, shackle with cotter pin only to be used.
Minimum clearance distance Electrical line in lifting area:
50kv power line 10 feet (3m)
50kv to 200kv 15 feet (4.6m)
200kv to 350kv 20 feet (6.1m)
350kv to 500kv 25 feet (7.6m)
500kv to 750kv 35 feet (10.6m)
750kv to 1000kv 45 feet (13.7m)
What is Rigging:
The process of moving loads. Or Rigging is the connecting of a load to a source
of power so that it can be lifted and moved safely and predictably.

Rigging equipment’s:
Counter weight, eye bolts, shackle, hooks, ropes/slings, outer rigger, safety
latches.

Four principles of Rigging:

1. Know the capacity
2. Know the weight
3. Retain the load
4. Control the load

Types of Sling:
Steel chain slings, wire rope sling, metal mesh sling, synthetic fiber rope sling,
synthetic web slings.

Rigger’s duties and responsibilities:

 Wear correct personnel protective equipment.
 Understand the basic requirements of a lifting plan
 Make pre-operational functional checks any communication/rigging equipment.
 Ascertain or accurately assess the center of gravity of the load to be lifted
 Ensure all of the lifting tackles selected of correct type of the planned lifting job.
 Have the ability to measure the load radius from the center of the crane.
 Understand that the gross load on a crane boom includes hook, auxiliary jib,
weight of rigging etc. as well as the actual weight of the load.
 Have the authority to sign to stop operations in the event of developing defect or
hazard.
 He must be aware of the effect of wind on lifting operation
 Fully understand the need to report all actual and suspected defect immediately.
Rigging plan check list:
Things that must be checked before commencing a lift are;
 The approved rigging plan/work permit.
 The shape and substance of the load
 The maintain of the slings and lifting gear
 The working radius established and marked
 The weather condition.

Work At Height:
The work which is being carried out 1.8 m (6 feet) above the ground level and
where there is hazard of falling of material and people is called work at height.
Planning before to perform work at height.
1. Fall prevention (Guard rail system)
2. Fall arrest (full body harness)
3. Fall recovery (using some mean to come/bring down)

Fall Protection:
The system which is installed to protect the workers, material or both from falling
is called fall protection.
Types of fall protection system:
 Guard rail system
 Personnel fall arrest system
 Safety net system
 Safety monitoring system etc.

Accident:
An undesired, uncontrolled, unplanned event that results in undesirable
consequences to the personal injury/illness or to property damage/loss or to environment.

Types of Accidents/Classification of Accident:

1. Fatality Case
2. Lost Worked Day/Lost Time Injury
3. Restricted Work Case
4. First Aid Case

1. Fatality Case/Human loss:

Death resulting case from work related injury/illness.
 2. Lost Worked Day (LWI)/Lost Time Injury(LTI):
Any injury/illness because of which the employee is unable to work the next
Working day. OR
When the injured person doesn’t come back at the job site in 24 hours.

3. Restricted Work Case:

Any injury/illness because of which the employee is unable to perform one or
more of the routine functions of his job, so duty of that employee changes to light
activates to whom he could perform easily.

4. First Aid Case:

Any injury/illness that requires First Aid treatment only, with no necessary
follow up medical facilities.

Procedure for Reporting Incident/Accident:

CLASS ‘A” Accidents
Verbal: Immediately
Written: within 6 hours after declaring emergency over

CLASS “B” Accidents

Verbal: Immediately
Written: 10:00 am of next working day for all class B incidents.

CLASS “C & D” Incident

Verbal: Immediately
Written: After completion of the investigation.

Use of Accident Report:

To find out the root cause of accident and to prevent it from re-occurrence.

Who makes an Accident Report:

Concerned area supervisor or site safety representatives.

Purpose of Incident/Accident investigation:

To find out the root cause and establish preventive measure to re-occur same.
Near Miss:
An event which occurs without damage to property, person and loss.
Or all incidents which did not result in but have the potential to result in undesirable
consequences to personal (injury/illness), property (damage/loss) or to environment is called
near miss.

INCIDENT/NEAR MISS:
An event or condition that doesn’t cause harm but has the potential to do so.

In many organizations these events will be recorded as near misses.

Who makes an accident investigation report:

A team of front line supervisor, HSE manager, Sub-Contractor representative if
sub-contractor personnel are injured, high officials depending upon the severity of
accident.

What is the use of the accident investigation report:

To find out root cause of the accident, make recommendations to prevent re-
occurrence and evaluate the effectiveness of emergency response.

What is waste management:

Waste management means safety disposing the by-product of a process or a work
to the environment (after proper treatment, if necessary) so that no threat for livings,
properties and environment exists.

What is Isotope:
Isotope means one or more species of atoms having same atomic number but different
mass number.
Isotope can be stable or unstable. Radioactive isotopes are unstable substances, which emits
heavy particles (alpha and beta) and higher energy electromagnetic waves (Gama) from their
nucleus by decay.

Why is an Isotope hazardous?

Isotopes are hazardous because it emits uncontrolled energy in the form of radioactive
waves which is hazardous to all living things as it can destroy the its living tissues that causes
fatality or can convert it in cancer.
What is radio activity:
Radio activity is the spontaneous disintegration of atomic nuclei, the nucleus emits
ALPHA particles, BETA particles, GAMA particles, or electromagnetic rays during this
process.

What is the unit for measuring radiation:

Micro Silver or Mille - Rem.

In what condition a work permit can be issued for Radiography:

The controlled area is calculated, evacuated and barricaded with yellow/black tapes,
warning signs (a minimum of 4nos.), and red or yellow flash lights.

What are the safety measures to be taken while doing radiography:

Ensure a competent person is surveying outside the barricaded area with survey meter.
The crew is authorized and following safety precautions. The controlled area is calculated,
evacuated and barricaded with yellow/black tapes, warning signs (a minimum of 4nos.), and
red or yellow flash lights.

What is the controlled area:

Any area where the radiation dose is more than 0.75 mRem/h (7.5 micro sivert).

Who is an authorized exposed person:

He is one who got formal training in the used of sealed source and x-ray equipment
used in industrial radiography.

Hazard:
Hazard is the exposes of danger, unwanted and undesired situation.

Tool Box Talk:

Awareness about work situation to the employee is called tool box talk.

Who is competent person:

He is one who is properly trained and authorized to perform a specific work in a safe
manner.

Tool Box Meeting:

The workers can be educated about safe work rules and procedure, and their
awareness can be improved on some task.
Radiography:
It is use for welding x-rays (if the wind velocity is up the 32km or 20 miles than
work should be stop).

Risk:
Risk is the probability of injury or harm. The risk is the chance, high or low, that
somebody could be harmed by these and other hazards.

Cold work:
Any work in which we do not use any energized equipment is called cold work.
For example, carpentry works painting, surveying, steel fixing and manual excavation etc.

Work Permit:
It is a legal document which authorizes us to do a specific work at specific
location. Or It is a written document authorized a person to do a specific work in a specific
area.
Types of permit to work (PTW):
Cold wok permit, Hot work permit, Confined space work permit, Scaffolding
permit, Excavation permit, Crane Lifting permit, Elevated works permit, Radiography permit,
Electrical permit etc.

Purposes of work permit system:

 The system helps to protect the human beings from danger and the
machinery/equipment from damage.
 To eliminate the chances of accidents and hazards.

Color Coding System:

All tools and equipment’s are inspected periodically by concerned competent
person and color coded accordingly.

Emergency:
It is an accident that has potential to cause serious injury and loss of life.

What is ERP (EHS Emergency):

Emergency response procedure; To deal any type of emergency with proper
procedure.
Emergency evacuation procedure to follow in the event of a Gas release:
 Don’t get panic on hearing alarm
 Switch off all the equipments and energized circuits.
 Observe the direction of wind flow
 Obey further instruction from emergency response team
 Resume work after getting clearance only

Actions in case of Plant Emergency:

- Stop the work immediately
- Ask workers inside confined space to come out.
- Make sure all workers have evacuated
- Take people to muster point

What is an Emergency Evacuation Plan:

It is the procedure to provide concise guidelines for evacuation in case of some
emergencies and to identify the emergencies in advance. This also helps us to plan and to
define resolves and responsibilities of all building custodian, fire wardens and occupants.

What is Evacuation:
Stop the work and switch off equipment and proceed to nearest assembly ground.
Always walk wind cross direct (we can see wind direction by wind socks).

Assembly Muster Point:

The area determined and marked for assemble of people working the area in case
of any emergency.

Head Counting and its Purpose:

On hearing emergency alarm, all people have to assemble in “Assembly Muster
Point”. Area supervisor will call his workers with attendance sheet and confirm that nobody is
trapped in the site. This procedure is called head counting.
It purposes is to ensure all workers are present in the assembly area. They are safely evacuated
and identify the person if anybody is trapped and take necessary action to rescue these trapped
workers.
Work Method Statement (WMS):
It is the document submitted by contractor to client, covering the general work
procedure of a particular job in a safe manner as per required standard.

What is the use of WMS:

We can plan and execute the work easily and safely. It helps to know the codes
and standard used for each activity.

In which situation “Ear Protection is needed”:

In the areas, where sound pollution is more than 85DBA (Decibel At Scale).

SCBA:
Self-Contained Breathing Apparatus, use in confined space or where oxygen
deficiency exists or where concentration of toxic gasses is harmful to humans.

DBA:
The frequency of noise at which we should use ear plug or muffs is 85dba
(Decible at Scale A).

 Ear muff/Ear defender/Ear plug; it’s protect our hears from high noise.
 Body harness protect from falling in high elevated areas.

Daily check list:

It is to be filled by equipment operator after physical check of the equipments.

Monkey Ladder:
It is a metal ladder covered by gage and it is used to reach different platforms in
live plant.

Injury:
A harmful condition as the result of an accident.

Atmosphere hazards:
An atmosphere that may expose the employee to the risk of death or injury.
Oxygen:
Oxygen the air we breathe is about 21 percent oxygen. Fire only needs an
atmosphere with at least 16 percent oxygen.

Flash Point:
Flash point is the lowest temperature at which a fuel produces enough vapors to
ignite in the presence of a heat source.

Heat:
Heat is a form of energy. Heat can be produced by chemical means e.g. by
burning aviation fuel or by mechanical means, by fiction.

First Aid:
First aid is the immediate care given to victims of an accident or illness before
qualified medical assistance arrives.

What is Chemical:
Any organic/inorganic substances

What is Ergonomics:
Ergonomics is a discipline that involves arranging the environment to fit the
person in it.

What is Industrial Hygiene:

 Air contaminants
 Chemical hazards
 Biological hazards
 Physical hazards
 Ergonomic hazards

What is HI Pot Test:

It is the insulation leakage test done for high voltage electrical cables, with
voltage megger (a name of test equipment).

What is Statistics:
 Counting of number is called statistics, in HSE this term is used to count the safe
working men hours, recordable injuries, damage to property, lost time injuries is called
statistics.
What is IDLH?
IDLH stand for, Immediately Dangerous to Life or Health.
Any condition which poses an immediate threat of loss of life; may result in irreversible or
immediate sever health effects.

Leakage/Tightness Test:
To check the joint of flanges/welding for leakages.

Hydro Test:
The pressure test done in pipe, vessels etc. by filling with water and giving
pressure in order to find any defects related to leakage.

Hazards:
 Injury to personnel
 Property damage
 Inadequate access
 Slipping, tripping, falling
 Sudden release of fluid (water)
 Defective tools can damage equipment
 Equipment accident
 Fire

Precautions/Control Measure:
 Obtain correct permit to work
 Ensure proper housekeeping at work site
 All work areas to be kept clean and free of tripping hazards
 Barricade the area, post warning sign, used for hydro testing (such as, hose
pumps, coupling, pressure gauges, gasket etc.) are free from any defect and
suitable for the pressure rating of the system.
 During the testing operation all non-essential personnel will be kept out of the
test areas.
 Never increase the Hydro-Test pressure more than the maximum allowable
pressure
 No bolt tightening work will take place while the line under pressure or during
pressure-up stages.
 Pre-Commissioning:
Pre-commissioning activities are the non-operating work responsibilities such as
adjustment, cold alignment checks, testing etc., performed by the contractor prior to the
commissioning or mechanical completion.

Commissioning:
Commissioning activities are associated with preparing or operating the plant or
any part of the plant prior to the initial startup and are usually the owners work
responsibilities.

Pre-Commissioning requirement:
 Valid work permit (JSA, RA,STA)
 Ensure proper housekeeping at work site
 All work area to be kept clean and free of tripping hazards.
 Walkthrough (before 24 hours
 Method statement, check list, Risk assessment
 Barricade the areas with orange mesh and post warning signage
 Ensure the equipment/tools to be used for test such as hose, psv, pg. (pressure
gauge), gasket etc. are free from any defects and suitable for the pressure rating
of the system.
 Drawings
 PSV (Pressure Safety Valve), it is used to release the pressure above the capacity,
it is calibrated for one week as per procedure.
 PG (Pressure Gauge) valid for one month
 Manifold calibrated (valid for six month)
 Whip Flash Arrestor (to control pipe for some time)
 Hose
 During the testing operation all non-essential personnel will be kept out of the
test areas.
 Never increase the test pressure more than the maximum allowable pressure.

 PSI – pound square inch

 1 bar = 14.5 psi
 1 bar makes 100 passkels.
Expand the following:
STARRT- Safety Task and Risk Reduction Talk
COSHH- Control of substance hazardous to Health.
OSHA- Occupational Safety and Health Administration.
OSHAS- Occupational Health and Safety Assessment Series.
ELCB- Earth Leakage Circuit Breaker.
GFCI- Ground Fault circuit Interrupter.
BSI- British Standard \institute.
SWL- Safe working Load.
ANSI- American National standards Institute.
LTI Lost Time injuries
ASTM- American Society for Testing of Materials.
JSA- Job Safety Analysis.
LEL- Lower Explosive Limit.
UEL- Upper Explosive Limits.
PEL- Permissible Explosive Limit.
REL- Recommended Exposure Limit\
PSI- Pounds/Square Inch ( 1 bar= 14.7 psi)
STEL- Short Term Exposure Limit.
WBGT- Wet Bulb Globe Temperature
APR- Air Purifying Respirator
ASR- Air Supplying Respirator.
SCBA Self Contain Breathing Apparatus.
RSO- Radiation Safety Officer

NFPA- National Fire Protection association

IDLH – Immediate Danger to life & health.
CABA- Compressed air breathing apparatus