2018210-Safety Tips Booklet

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OUR VISION
'To be the World's Leading
Power Company, Energizing
India's Growth'
(A Govt. of India Enterprise)
dkS'ky fd'kksj 'kekZ dsUnzh; dk;kZy;/Corporate Centre

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Kaushal Kishore Sharma
Director (Operations)
8th November, 2016
MESSAGE
NTPC the largest Power Company of our country is engaged in O&M and
construction activities at various locations. As a part of learning culture, NTPC
provides enabling environment including safety for its work force. Ensuring safe
working environment is on the highest priority of NTPC management as safety is
one of the Core Values of the Organization. To disseminate the learning of the
last few years, the "Safety Tips" have been compiled in the form of a booklet.
This compendium will be a handy tool for strengthening culture of safety and
ensuring ultimate objective of safe working environment for one and all
associated with the Organization.
I am confident that this document shall be useful for everybody.
With Best Wishes
(Kaushal Kishore Sharma)
Corporate Identification Number L40101DL1975GOI007966

,uVhihlh Hkou] Ldksi dkWEIysDl] 7- baLVhV~;w'kuy ,fj;k yks/kh jksM] ubZ fnYYkh&110003 Vsy-/Tel-01124360232, 24360251 QSDl/Fax : 011-24363478
NTPC Bhawan, SCOPE Complex, 7, Institutional Area, Lodhi Road, New Delhi-110 003 E-mail: kksharma@ntpc.co.in osclkbV/Website : www.ntpc.co.in
SAFETY POLICY OF NTPC
Dated: 7th November 2016
A. Statement of Intent:
Safety is part of our core values. We recognize all accidents are preventable; therefore, safety shall be at
the forefront of all our activities.
The objective is to provide safe working environment and strive for zero incidents at work. This policy
supported by safety rules and procedures are applicable for all business activities carried out by NTPC.
Safety policy is built around following principles:
1. Our activities carry various hazards; however all hazards can be identified.
2. Every job shall be done safely, no matter how important or urgent it is.
3. Putting people to work carries a specific responsibility and accountability for safety which shall b e
visibly demonstrated.
4. Right procedures and actions can bring the risks under control.
5. Trained and committed team can ensure incident free operations.
6. Compliance to all applicable safety regulations and other legal requirements at the minimum.
B. Organization's Responsibility:
We have a three tier approach to make work place incident-free:
1. Top Management responsibility:
a. CMD, Directors and REDs are responsible for:
i. Ensuring that all work activities under their control are carried out in adherence with this
policy;
ii. Ensuring that Heads of Projects / Stations are individually accountable for implementation of
this policy and ensuring they have the necessary skills in safety management;
iii. Setting appropriate standards for safety in their work area;
iv. Putting Safety as a part of appraisal system, both for self and team;
v. Ensuring that safety audit is conducted periodically through third party at all sites
2. Head of the Project/Stations are responsible for:
a. Implementing this policy by introduction of local management systems with high standards
of safety;
b. Ensuring identification and display of all Hazards;
c. Establishing rotating cross functional team for internal audits.
d. Making employees responsible for working safely by creating a safer work environment and
ensuring that their actions do not harm either themselves or other people.
3. Heads of Departments are responsible for:
a. Ensuring that Engineer-in-charge (EIC) shall spot, report and deal with hazards to help create
safe and incident free workplace.
b. Ensuring training of workers in the area of work and awareness about the hazards of the site
in association with safety department at site.
c. Ensuring that the contractor has deployed safety equipment relevant to its area of operation.
d. Making sure that EIC ensures cordoning of unsafe areas and reports unsafe conditions.
e. Make certain that all co-operate with management and observe rules and procedures which
enable the highest standards of safety to be achieved.
This policy will only be effective with support from all employees and contractors. Accordingly every
employee shall be a signatory to this safety policy and shall be responsible and accountable for safety in
their work area and activities.
C. Policy framework and coordination:
a. Policy framework, review and enablers:
i. Corporate Safety in associations with Corporate functions to prepare and review safety
framework for ensuring"zero incidents".
ii. Corporate Safety to present its analysis on progress of safety framework implementation
and safety culture of the company to senior management periodically.
iii. Corporate Safety is responsible for providing policy/rules/system/procedural enablers
where ever required to implement and adhere to Safety framework.
iv. Corporate Safety shall be responsible for ensuring that safety rules / systems / procedures
are being implemented at all work areas through regular visits, interactions and reviews.
v. Corporate Safety to gather inputs internally and from other leading Organizations and
review Safety framework annually.
vi. Corporate Safety shall prepare a calendar for all reviews and shall ensure adherence to the
schedule.
b. Training:
Director (HR) shall ensure that appropriate training and learning interventions are designed and
implemented.
Corporate Safety department shall come up with detailed requirements (including skill training
and culture building) clearly bringing out the desired objectives, audience and responsibility.
c. Reporting:
All safety officers at site shall functionally report to Corporate Safety department.
d. Communication:
Wider dissemination of Safety policy, rules, safety analysis and best practices shall be the
responsibility of Corporate Safety department in association with Corporate Communication
department.
e. Safety Plan & Provision for Contractors:
i. Contractual provisions shall be reviewed by CC&M in association with OS, Engineering and
PP&M for Corporate packages and provide guidelines to Stations / Projects to implement
the same in site awarded packages.
ii. Safety plan to be submitted by contractor and approved by NTPC prior to commencement
of work at site.
iii. CC&M shall include safety performance assessment in contractor rating system.
iv. CC&M shall devise systems to enable projects/stations for immediate procurement of
quality safety equipment, PPE, etc.
I have read this policy and resolve to comply with the Safety policy of NTPC.
Signed :
Name :
Employee Number :
Designation :
Location :
INDEX
S. No. Topic Page No.
I. Safe practices while working at height. 3
II. Safe practices to prevent electrocution & burns. 12
III. Safe practices to prevent caught in-between

and hit by object. 18
IV. Safe Practices to prevent run over &

road Accident. 25
V. Safe practices to prevent fall of material 28
VI. Safety Instruction Guide: 29
1. General Safety Rules 29
2. Site Safety Rules 30
3. Excavation Safety 31
4. Road Safety 31
5. Fire Safety 32
6. Safety in Gas Cylinders 32
7. Manual Handling of Material 33
8. Safety in Mechanized Material Handling 33
9. Safety Instructions for Sling Man 34
1
10. Safety in Crane Operations 35
11. Electrical Safety 36
12. Safety Instruction for Chain Pulley Block 39
13. Safety in Height work 40
14. Safety in Welding, Gas Cutting & Grinding Work 44
15. Tool Box Meeting & Safety Training 46
16. First Aid 46
17. Good Housekeeping 47
18. Safety in Hand Tools 48
19. Chemical Safety 48
20. Hydra Crane Safety 48
21. Safety during Radiography 50
2
I. SAFE PRACTICES WHILE WORKING AT HEIGHT
1) Scaffolding with proper platform with hand railings and toe-boards must be used to work at height.
A removable ladder / staircase must be provided to reach the work place.
2) Safety nets should be provided also during the dismantling of scaffolding to safeguard the workers
from accidental fall.
3) While carrying out work use of full body safety harness, safety nets, fall arresters, are to be ensured.
4) The condition of the full body safety harness should be examined by competent person once in
every six months and by the user on daily basis.
5) All lifting tools and tackles (such as chain pulley block / D-shackle / ceiling etc.) are to be inspected
as per NTPC / statutory norms.
6) Deployment of safety nets must be ensured outside the structure too, to prevent outside fall. This
can be done by providing cantilever props supporting the safety net.
7) Detachable type of arrangements (chain and hook type) to be provided at all the location where
barricading /hand rail are to be removed temporarily for the purpose of lifting /lowering materials.
8) Persons should not be allowed for height work without full body safety harness. Anchoring of the
Safety Harness with rigid support / life line is to be ensured. Provision of vertical and horizontal life
line for anchoring of safety belt to be ensured.
9) Use of safety nets to be ensured below the working area, where possibility of fall of
person/materials exists. Safety nets are to be provided below the working area as well as at the
periphery of all structures which are under construction.
10) Only well experienced, trained and medically fit workers to be allowed to work at height. Agency
must ensure proper & sufficient equipment as well for height work.
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11) Safety induction training is to be provided to all workers before their deployment for height work.
Refresher training to workmen/supervisor is to be imparted related to risk associated with job.
12) Tampered /damaged full body safety harnesses should not be allowed to be used in any condition.
Regular checking of all PPEs to be ensured.
13) Safety task force / Cross Functional Team members shall review the site on daily basis and
discrepancies shall be highlighted to concern EIC and higher authorities.
14) Proper supervision is to be ensured while working at site. Use of proper PPEs at site is to be
monitored and ensured.
15) Safety posters are to be displayed around work site for safety awareness.
16) In construction sites, Condenser Pit/excavated pit must be properly barricaded & caution board is
to be displayed.
17) Proper coordination between Site Engineer of agency and their Safety officer for day to day
activities is to be ensured. Proper coordination between Line Manager & Safety officer for day to
day activities is to be ensured.
18) All lifting tools & tackles (such as chain pulley block /D-shackle /ceiling etc.) are to be inspected as
per statutory / NTPC norms. All the lifting tools & tackles should be tested and certified by
competent person as per statue.
19) Adequate working platform with hand rails and proper approach must be provided at all the work
places at height. Work platforms used for height works should be fixed / welded firmly to the strong
supports.
20) There should not be any opening at working platform at different elevation. It must be closed /hard
barricaded. Use of safety net to be insured wherever opening is not covered.
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21) The job allocation and its supervision may be done as per their skill from time to time for its
compliance.
22) For removal of grating/railing/other guards, Permit for Floor Opening must be taken from
concerned Engineer-in-Charge / Senior Authorised Person.
23) Awareness program to be conducted for proper usage of personal protective equipments.
24) Safety pep-talks / tool-box talks should be imparted related to risk associated with job before start
of any activity and record of such pep-talks should be maintained.
25) Safety violation wherever observed should be penalized as per NTPC norms.
26) Work should be planned in sequential order to ensure maximum safety at site.
27) One to one walkie talkie communication between supervisor and winch operator may be ensured to
avoid interference.
28) Height works must be carried out only after obtaining the permit for work at height. All the safety
measures envisaged in the Height Work Permit and associated checklist for work at height format
should be strictly ensured. Checklist for Scaffold must be implemented.
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29) Openable type rope grab Fall arrestors and double lanyard type full body harnesses should only be
used in works at height.
30) All the temporary approaches and platforms are to be cross checked by the safety supervisor/area
in-charge of the agencies.
31) Supervisor should be present at such critical works at height to ensure that all safety measures are
followed by the workers.
32) All agencies should deploy qualified and experienced safety officers at their site.
33) All the lifting tools & tackles should be inspected by site engineer of agency on monthly/ regular
basis; record of the same to be maintained. Daily checking of lifting tools & tackles to be ensured by
supervisor/rigger. NTPC engineer to also cross check the status of the tools & tackles.
34) The pulley tied to roof truss with wire rope should have minimum three clamps.
35) Identified signaller to be provided to assist lifting operation and to maintained proper
communication between the workers and winch operator.
36) Boiler lift erection works, proper access arrangement should be made along with the following
measures.
i) Safety nets should be provided at all critical works at height to ensure the safety of the
persons working at height.
ii) Fall arrestors and double lanyard type full body harnesses should be used in works at height.
iii) Daily Safety Pep-talks should be conducted by every agency and record of such pep-talks
should be maintained.
37) The workers deployed for works at height should be particularly trained on usage of fall arrestors,
safety harnesses and measures to be taken at height works.
38) Before commencement of painting of structure at all elevations adequate arrangement like life line,
safety nets with proper PPEs are to be ensured. Effective supervision is also to be ensured.
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39) A survey for detecting of locations where handrails/hard-barricade are not provided or missing on
the edges of the floors as well as openings to be done. It should be followed by immediate actions
to provide the same.
40) There should not be any source of water inside the bunker building. Fire hydrant, should be outside
the bunker floor building and located at the entry to bunker house. MVW fire spray system, if
installed on horizontal portion of bunker conveyor, should be removed. Till the time fire
hydrants/any other water sources are not shifted outside bunker building, bunker floor operators
are to be extra careful for entry of water into coal bunkers from existing fire hydrant/other water
sources. Necessary check list may be prepared for the same
41) Wet cleaning of coal transfer chutes to be avoided or limited to prevent frequent bunker/coal
pipe/coal feeder chokage/blockage during rainy season.
42) Handrails welded to insert plates to be checked for integrity and also to be provided with firm
support at top, bottom and sides.
43) Feeder Gate and Bunker Gate to be closed, and bunker to be checked from top for any
accumulated water in it, before opening the feeder doors for carrying out job on the coal feeder. If it
is difficult to close feeder gate due to coal blockage, first the small inspection doors provided on
the feeder gate should be opened for checking before opening feeder.
44) CCTV Cameras to be provided in the bunker floor building for regular observation of any abnormal
situation. Random surprise visits by concerned officials at least once a month would also help in
taking proper actions in time as this area is very critical for plant operations and not frequented
except by those who are working in this area.
45) While working at height specially with temporary platform (suspended scaffold) agency supervisor/
area in-charge shall monitor the work continuously.
46) A 'Method Statement' describing the erection and dismantling sequences of scaffold to be written
down and strictly followed.
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47) OEM's competent representative may be called during every overhaul at the time of scaffolding
erection and dismantling for physical inspection of the scaffold for its stability and to ensure safety.
48) Overloading of the scaffolding platform should strictly be controlled through constant supervision
during erection and dismantling of scaffold system inside the boiler.
49) It should be ensured that adequate and experienced workforce and supervisors are deployed by
the agency in erection/dismantling of scaffold system.
50) As per OEM recommendation, inspection, maintenance and painting of Quick Erecting Scaffold
(QES) system should invariably be carried out once in every year and proper record to be
maintained.
51) Safety training and daily safety inspection should be ensured during unit overhauling.
52) Proper barricading is required at each floor towards scaffolding to restrict entry of person, when
scaffolding is not being used.
53) Safety planning and risk evaluation need to be done before taking up any new activity.
54) T h ere should be defined route for going up and coming down during the height work and this has
to be explained to all concerned.
55) Public address system to be restored for effective communication at various locations of
construction work.
56) CCTV coverage at different locations of site and its close monitoring at the control room to be
ensured.
57) Working hours shall be followed as specified in the statute. If late night work carried out on any day,
it is to be ensured that the late night working team / workers to be given sufficient rest and may be
called for duty on next day in the afternoon.
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58) To carry out work at height proper supporting arrangement of men & material movement is to be
ensured.
59) Devices like cherry picker or hydraulic scissors lift with platform & safe barricading may be used for
lifting and reaching height.
60) Provide 14 mm diameter Polyamide rope as vertical life line to anchor rope grab fall arrester
suitable for running on this rope while moving on vertical ladders for climbing up / down. A 14 mm
diameter Polypropylene rope or 8 mm diameter wire rope with three U-bolts connectors at each
end to tie the wire rope to a fixed support must only be used as horizontal life line.
61) Area wise proper records are to be maintained for all workers working at site & that should be
ensured by the supervisor of associates.
62) While working all opening should be barricaded effectively and may be used as and when required.
63) Proper functioning of Dust Suppressing and Dust Extraction System should be ensured for visibility
and proper area lighting should be carried out in CHP area.
64) Security persons should also be provided with required PPEs in case if they required visiting the
construction site.
65) Housekeeping must be done on daily basis. As in this case falling directly on the material has
increased the injury.
66) Sufficient numbers of pipes are to be welded with CW-duct during duct laying work so that it can be
used as hand railing while moving on top of the duct.
67) Periodic inspection of support and platforms of the walkway is to be done.
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68) Encasement of CW duct should be done across the CW Duct instead of, along with the duct.This will
reduce the walking distance on bare/non-encased CW Duct.
69) Galvanized MS grating is to be used in walkway/ access along with hand railing.
70) A schedule of safety awareness training and Pep-Talk to be prepared by EIC and to be adhered to.
71) A cross-functional team consisting of a representative from the various departments may be
constituted to assess the healthiness of the CHP structures with particular attention to seal plates,
deck sheets, and conveyor gallery walkways. A comprehensive program giving high priority may be
made to replace all such components which have degraded with components of adequate
design/specifications and strength to provide intended long service.
72) Periodical inspections by such cross-functional team may be undertaken to avoid deterioration of
healthiness of structure/ components.
73) Housekeeping tools should be as per work condition and safety for users. Safety Supervisor/ Area
Supervisor to ensure the adequacy and proper method of use of the same by the workers. Shovel
with long handle should be used for cleaning and collection of coal dust/slurry before disposal by
shovel at restricted areas. The brooms should be provided with long handles so that housekeeping
person is not tempted to enter restricted areas (like below of conveyor over the seal plate).
74) A system of recording feedback about defects from housekeeping staff to be put in place to
liquidate the same and avoid developing site conditions to avoid repetition of incidents of this
nature.
75) Winch operator is only authorised to operate the winch machine.
76) Guided rope must be ensured for lifting /shifting material by gang leader at the site.
77) To strengthen the safety measure in construction area inter-agency safety audit/ inspection may be
implemented for better safety improvement. Agency maintaining safe working condition may be
suitably encouraged. Engineer In-Charge in consultation with Safety officer to ensure the
implementation of the recommendation/suggested in an audit report in time bound manner. The
exception of the audit may be reviewed by project head in daily meeting.
78) Occupational Health Check-up for all construction workers on a periodical basis to be ensured by
the respective agencies.
79) There should be dedicated gang while dismantling or erecting the mini crane.
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80) When the machine is assembled, place the counter weights before fitting the motor unit to avoid
the imbalance and toppling of the machine.
81) While dismantling the machine, the counter weights should be removed only after removing the
motor unit and boom assembly to maintain the stability.
82) Usage of building tower hoist in place of mini crane to be explored to prevent frequent dismantling
of mini crane and fixing at different floors of the same building.
83) Location of winch machine should be fixed in such a manner that its signalling for operation can be
done conveniently and safely.
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II. SAFE PRACTICES TO PREVENT ELECTROCUTION AND BURNS
1) A fencing arrangement may be provided to restrict the movement of any person beyond the OHE
isolation zone in track hopper.
2) The length of isolation of OHE in track hopper may be extended so as to cover one full rake distance
on either side of the Track hopper.
3) Before placement of Boxn wagon at track hopper for manual unloading of coal, the agency should
deploy labors by allotting them token, so that only specified labors will do the unloading work in the
specifically assigned wagon.
4) Supervision during manual coal unloading may be increased. In addition to supervisor one
executive has to be deputed in especially during night shift.
5) OHE within track hopper should not be charged until all the BOXN wagons as well as unloading
labors are removed from Track hopper.
6) Indicating lamps (RED & GREEN COLOUR) may be provided at both sides of Track Hopper to
indicate charging status of OHE line.
7) The separate frequency of walkie talkie should be allotted to MGR group
9) Electrical supply to be ensured through ELCB (Electrical Leakage Circuit Breaker) / RCCB for all
hand operated power tools.
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10) All hand-operated power tools must be grounded with proper earthing or must have double
insulated body. Only three pin plugs and boards should be used.
11) Agencies' power distribution board's healthiness should be ensured by their authorized person.
12) Only qualified and designated electricians should be deployed for electrical connection.
13) All electrical grinders, drilling machines, welding machines etc should be examined electrically for
its healthiness by NTPC authorized personnel before using in the plant by any agency during
overhauling jobs.
14) All extension boards should be equipped with ELCB/ RCCB incoming supply to prevent electrical
shock.
15) The guide issued by corporate OS electrical dated 23/10/2013 may be strictly implemented.
16) During overhauling more executives may be deployed for monitoring safety round the clock.
17) Extra precautions regarding safety awareness may be ensured in case new agency is deployed for
overhauling work for a first time at the station.
18) Proper schedule with periodicity for checking process protections (Pull chord, Belt Sway switch,
Zero Speed Switch etc) is to be prepared and must be followed. Records of these checks should be
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19) All Pull Cord Switches and belt sway switches should be numbered; such numbering should be
matched with PLC for proper identification of PCS operation.
20) Defective cameras installed in any area may be replaced for effective monitoring and safe
operation.
21) No maintenance work should be done without proper isolation and PTW.
22) In Coal Handling Plant availability of PA system and siren must be ensured. Any defect in this regard
must be attended with priority.
23) No process protection should be bypassed without the consent of HOD of concerned Department
and records should be kept properly in the register.
24) Illumination and housekeeping at conveyor belts and TPs need to be maintained properly.
25) Walk-down checklist (area-wise) should be prepared and joint walk down by CHP operation,
Maintenance, and Electrical maintenance to be conducted as per pre defined periodicity.
26) Financial Penalty may be imposed on erring contractors as per safety clauses in GCC.
28) Identification i.e. unique uniform/ arm band/ head gear to identify the coal unloading labours may
be envisaged.
29) Display of wagon no. of Boxn wagon rake inside the track hopper may be explored.
30) The labor to start work only when the "go ahead" is given by suitable audio mechanism through the
dedicated siren/ bell/ PA system
31) Such mechanism to include, signals for cleaning the track / wagons when rake movement is going to
start and signals for indicating when it is safe to enter the track/wagons.
32) 24 Volt hand lamp with cage shall only be used for working in confined spaces.
33) Safety Induction Training of the workers to be done before deployment at work.
34) Proper earthing of electrical equipments and portable power hand tools etc. must be ensured.
35) Proper drainage to be ensured in fabrication yard for draining of rain water.
36) For inspection of dewatering pumps during night, at least two manpower should be deployed
considering the area of work and ensuing rain.
37) All efforts to be made to complete the minus level work before the onset of monsoon to avoid
exigencies.
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38) Proper supervision is to be done by agency supervisor to ensure the use of PPEs to all the workers
working during night hours.
39) Thorough checking of control/power cable condition, in the cable trough of all elevator pits may be
done. Ensure the earthing of such cable troughs for all the elevators.
40) Water ingress in the lift pits must be avoided for ensuring dry condition of work.
41) Dewatering of lift pit must be done before sending somebody inside the pit for any maintenance
job.
42) All the electrical installations and connections are to be inspected as per their schedule.
43) A team may be formed for identification and rectification of the electrical hazards on a continuous
basis at the boiler and other areas of project and under periodical checking.
44) RCCBs: All RCCBs are to be ensured with 30mA rating.
45) Earthing: Additional earthing pits are provided in boiler area for strengthening the earthing system.
46) Regular checking of earth resistance is to be conducted at the site as per pre-defined schedule.
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47) Routing of electrical cables in a safe manner and preferably without joints may be ensured.
48) Ensure that no two core cables or lose electric wires are being used.
49) As far as possible, online leak arresting is to be considered only on exigencies.
50) All probable erosion of pipes and bends are to be measured for thickness on regular basis and to be
replaced during opportunity/overhauls.
51) The online leak arresting agency should assess the feasibility before executing the work.
52) Usage of heat resistant full body Equipments (PPEs) is to be ensured by the personnel
inspecting/attending the leakages.
53) The personnel executing the online work should ensure safe access and escape route to the
working area.
54) Ensure a complete isolation of the line before any maintenance work is carried out to arrest the leak
in high pressure line.
55) Safety Slogans & Safety Posters related to electrical safety to be displayed in all vulnerable
locations. Dos & Don'ts to be displayed related to work concerned.
56) Poster depicting electrical hazards and precautions to be displayed in the switchgear room before
commissioning.
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57) Any unnecessary flammable material should not be brought to the site without the knowledge of
NTPC site engineer and Safety personnel.
58) Strict supervision should be ensured while carrying out any critical activity in a confined space/low
ventilated locations.
59) Smoking at the work site should be strictly prohibited.
60) If the work is to be carried out inside the field then electrical isolation of all fields of that particular
pass of ESP must be ensured by. Also all fields of that particular pass should be disconnected &
grounded. Electrical isolation of Emitting Electrode Rapping Motors (EERM), Collecting Electrode
Rapping Motor (CERM) & Hopper heaters to be ensured before entering inside the field.
61) Manual discharge rod should be properly tightened with earthing clamp.
62) Inlet & outlet gates of concerned ESP pass to be closed or all ID/ FD fans to be switched off before
entering inside the ESP pass.
63) All concerned to adhere to the work permit and take proper isolation from the concerned
departments before undertaking any work in the under commissioning / Commissioned units.
64) Agency to ensure that their workers carrying out the electrical work must use the electrical safety
shoes and electrical hand gloves before starting the work.
65) Safety interlocking keys are provided in the system which needs to be ensured before the start of
work.
66) The person should be skilled with relevant experience for inside inspection of any ESP fields.
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III. SAFE PRACTICES TO PREVENT CAUGHT IN BETWEEN AND HIT BY OBJECT
1) All rotating and moving parts of machine must be guarded.
2) Once the equipment is commissioned, no work will be carried out on that equipment without
obtaining a valid Permit to Work.
3) Proper guidance and training are to be given to the worker for using safe approach & not adopting
the shortcuts.
4) All necessary tools tackles and lifting equipment required to perform a job are to be provided.
5) Effective supervision must be ensured while working for box type duct by putting enough
temporary support to hold the duct in a vertical position for safe working.
6) All contractors' workers including supervisors entering the plant are to be briefed about safety
practices by a representative of Engineer In charge.
7) Workers deployed in Conveyor galleries should be briefed about the emergency stop/pull chord
facilities for use in case of emergency.
8) While issuing work permit the risk involved should be properly analyzed by the permit issuing and
receiving personnel and proper isolations/ conditions should be ensured and recorded in the
permit.
9) While civil work permits are being issued for operational areas, the scope of work should be
properly described. The separate permit should be taken if any work is to be done in the close
vicinity of the running equipment and proper isolation and supervision should be agreed and
recorded in the PTW.
10) After issuance of PTW, issuing authority to apprise of the risks associated with the job to the
recipient of the PTW before handing over the printed copy to the recipient.
11) If work has to be carried out on unguarded/unfenced machinery in motion, another person well
acquainted with emergency procedures is to be deployed and he shall keep watch on the person at
work and hold himself close to and ready to operate a stop device.
12) A committee to be formed at station level to identify all the missing guards and insufficient guard of
coupling, pulley, conveyor drive, conveyor tail pulley, toe guard hand railing etc. The committee
will put its report to station head. A time bound action plan to be prepared to rectify all the defects.
All the guards must be such that it prevents ingress of body parts.
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13) Safety instructions to be displayed in such language which is understood by all. Plant safety
department along with HOD of the concerned department may identify the locations for safety
display boards.
14) A committee at station level may identify adequacy of hooters in CHP area. Based on the
committee report, extra hooters if required, may be installed. Hooters may be interlocked with
starting of any conveyor drive.
15) Healthiness of conveyor belt protection system like pull chord switches, emergency Push buttons
are to be checked at a regular interval and protocols to be maintained. This checking schedule to be
made a part of Preventive Maintenance schedule in SAP.
16) Any anomaly / malfunctioning of pull chord protection of conveyor belt is to be recorded in the
control room log book and to be brought in the notice of Head of CHP within 24 hours.
17) Safety precautions should be followed.
18) Nobody should work on or near the conveyor belt, which is being started.
19) Guards on moving parts of machine should fit properly and all safety interlocks must be operational.
20) In batching plant, partition walls made of the steel structure are to be strengthened to withstand
the differential load of aggregate.
21) In batching plant, material (sand & aggregate) fill level of each bin must be maintained to avoid level
difference between adjacent bins to avoid differential pressure on the partition wall, if in any case
violation of fill level been observed, must be regularized by emptying filled bin before operation or
maintenance work.
22) Fully mechanized batching plant operation may be preferred. If manpower deployment is
necessary, it should be done under the supervision of site-in-charge or responsible engineer.
23) There should be no manual removal of debris when the batching plant is operational.
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24) Periodical joint inspection of batching plant and ancillaries may be done.
25) Illumination of batching plant area must be adequate.
27) At the beginning of work, the foundation of batching plant and partition walls are to be secured
properly in view of the storage of aggregate.
28) Additional permissive push button should be added in the circuit of Side Arm Charger operation
(similar to loaded rake side) in Wagon Tippler.
29) Before each operation of Side Arm Charger, wagon tippler operator should get clearance from
both Traffic Points Man (TPMs) and unloading labor through walkie-talkie.
30) Operating instructions should be made for each activity with responsibility for effective supervision.
31) No worker shall be allowed to continue the following morning shift after he has completed his night
duty.
32) The entire wagon tippler area should be cleared for easy and obstruction free movement of
personnel working in the area.
33) Installation of CCTV should be explored to ensure visibility to wagon tippler control room regarding
the movement of men engaged in the coal wagon unloading process.
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34) Some operations in wagon tippler area, such as adjustment of couplings of wagons require strength
and quick movements. So, it is suitable to engage the younger workforce. However, retired Railway
personnel may be engaged only for jobs requiring railway experience.
35) Wagon Tippler control room operating console should be near to the front glass panels so that the
operator can view the entire area during operation
36) PA systems in WT control room should be near to the operating console.

37) Checklist of the trial run of machine and equipment during its commissioning should be made with
coordination of O&M.
38) Experience persons should be deputed at tail end and head end of the conveyor system during the
trial of conveyor belt during its commissioning.
39) Public addressing system to be installed for effective communication prior to any commissioning
activity of the conveyor system.
40) Persons engaged for housekeeping work while cleaning coal from conveyor belt should be trained
regularly, about the associated hazards.
41) Close and effective supervision by the agency of works performed at night needs to be ensured.
42) While carrying out any job of wagon doors in BOBR wagons from inside (cleaning or maintenance),
the work should be supervised by foreman of agency
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44) Any work inside BOBR wagon doors to be started after ensuring that total air is drained from the air
cylinder of the wagon & air source is completely isolated so that the door flaps will not get operated
even after an inadvertant command.
45) While operating pneumatic doors of BOBR wagons, each time audible warning is to be given for
alertness of working persons.
46) Standing in between the door flaps of BOBR wagons for coal cleaning purpose should be strictly
avoided & use of long-handled poking roads is to be ensured for the safety of the personnel.
47) Job instruction boards, pertaining to wagon maintenance work, may be put at work location while
carrying out maintenance/cleaning of wagon doors.
48) Implementation of proper safety induction training program for workers working in batching plant
may be ensured.
49) In batching plant, manhole gate of mixing drum should be under lock & key condition and any work
inside the drum should be carried out after taking PTW from the operator, which ensures complete
power off of the system during such type of job.
50) Permissive switch should be away from manhole of mixing drum of batching plant so that in any
case this switch could not be engaged inadvertently by worker while working inside for cleaning of
mixing drum.
51) Necessary modification of manhole gate of batching plant must be made to avoid accidental
closure of same without the intervention of the labor working inside.
52) Any maintenance work of batching plant should be carried out under the supervision of an
experienced supervisor.
53) Use of right tool for the right job to be strictly ensured. Chamfering machines/ needle grinder
should be used for edge preparation/polishing work of boiler tubes instead of angle grinding
machines, especially for overhead position. Under no circumstance, the wheel guards of the
grinding machines should be removed to make it suitable for the work.
54) Works which can be done at ground level should be completed at ground before lifting to minimise
the work at height.
55) Method statements/Job Safety Analysis should be reviewed and resubmitted by the working
agencies for all project activities.
56) Adequate number of safety personnel should be deployed by agencies for strict supervision, safety
surveillance and safety culture enhancement in both principal and subcontracting agencies. Sub-
agencies must deploy additional safety personnel / safety supervisors for effective safety
monitoring.
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57) Ambulance to be made available at project site near first aid center/site dispensary facilitating
effective interim treatment and quick transportation of patient to nearby hospital, if required.
58) In case of serious injuries to the workers at site, it should be ensured that the injured person is
shifted to nearest hospital after due first aid at site or by accompanying the first aid/nursing staff in
the ambulance on the way to the hospital.
59) Large size containers with heavy materials should have adequate dimensions to ensure stability
while being stored and during its transportation.
60) Holes on the conveyor belt for fixing the belt puller must be made only by using punches.
61) As the punches for conveyor belt get blunt easily there should be sufficient stock of belt punches for
making holes for fixing the belt puller.
62) The conveyor belt puller to be pulled with the help of winches of suitable capacity.
63) For work of joining of conveyor belt, a board may be placed near work area describing - job,
executing agency, permit no, name of the contracting supervisor, duration of permit, name of the
NTPC area in charge, name of the NTPC-EIC.
64) During conveyor belt pulling and joining works, 'no entry' board is to be placed between the belt
and winch, so that nobody enters the area.
65) Work instruction for "conveyor belt laying / replacement" to be followed. Work instruction for
"lifting & lowering of take up load" to be followed in totality.
66) As far as possible, the person who is holding the guide rope of load during its lifting should stand
outside of the material lifting/lowering zone.
67) In case of abnormality observed during lifting operation, concerned site supervisor is to be involved
in decision making and working group should strictly follow the same.
68) Proper supervision by the Agency must be ensured for lifting / erection of heavy material.
69) During tandem operation, chain pulley blocks of adequate capacity should be used and Safe
Working Load (SWL) of each lifting equipment should be more than the total weight of the load.
70) PTW should be implemented before lifting of heavy material / height work in construction / erection
works.
71) It is suggested to give basic knowledge of chain pulley blocks regarding their number of falls and
capacity to all concerned for the safe use.
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72) Qualified and experienced rigger and lifting gang should be used for erection work.
73) Special Pep talk / tool box talk to/ should be given by the Site Supervisor / Engineer before erection
of such high risk job / lifting of heavy materials.
74) It must be ensured that EOT crane girder is lifted before completing roof of the building by leaving
an access bay.
75) Balance erection works in running plant be properly co-ordinated with Agency, Erection & O&M.
76) The undercutting and vertical cutting for all soils including refilled soil more than 1.5 metres should
be avoided. Only slope or step cutting should be done during excavation.
77) Suitable strutting and shoring should be given to prevent sliding of loose soil.
78) Proper slope should be given to cutting to avoid vehicular movement near the edge area by
providing hard barricading.
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IV. SAFE PRACTICES TO PREVENT RUN OVER & ROAD ACCIDENTS
1) Hydra shall not be used for transporting the material as total clear front view of route is not possible
by virtue of its design.
2) The Hydra should be strictly restricted to the limited use of loading and unloading of material.
3) Talking over cell phone during driving shall be prohibited. Awareness of consequences of talking
over a cell phone while driving is to be increased.
4) An escort with whistle should always accompany the hydra crane to assist him for proper signaling
and alerting others.
5) Details of inspection/examination by a competent person shall be displayed on hydra and other

cranes.
6) Checklist to be prepared and periodical inspection of hydra to be carried out for ensuring the
proper working condition of hydra.
7) No mobile crane is to be allowed to march long distances with hanging load. Penalty may be
imposed for this violations.
8) Exclusive training of mobile crane operators may be imparted.
9) There must be at least two sufficiently long guide ropes attached with the hanging load during its
handling / lifting by crane.
10) Speed Caution Board of 30kmph to be displayed on the road for speed restriction of the vehicle
movement on the road.
11) Gate pass for all workers as well as vehicles entering the project / station should be ensured strictly.
12) Road Safety awareness should be increased amongst all workers engaged in a construction project.
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13) Adequate road safety signage should be installed alongside the roads of site.
14) Separate parking area for two wheeler and four wheelers etc at the suitable location may be
ensured. No vehicles should be allowed to park alongside of road of construction site inside project
area. Prevention of parking of vehicles, trailers etc. on the main roads to be strictly adhered to.
15) Construction workers participation in Safety committee should be ensured by all agencies. Their
suggestions should be implemented.
16) Vehicle parking area and repair area should be at designated locations to avoid road accidents.
18) No one is allowed to drive / operate a vehicle / crane without proper driving licence suitable for
vehicle / crane he drive/ operate.
20) Any roadside breakdown of vehicle must be attended only after placing a barricade around the
vehicle.
21) Improvement in Housekeeping inside the entire plant premises needs top attention. Scrap and
other useful material should not be kept lying all around and these material should be kept in their
designated places.
22) Safety rules, safety display boards are to be installed in all critical areas in local language.
23) Efforts to be made for barricading the running units from construction area.
24) All hydra crane, heavy vehicles and jeep drivers etc. should be counselled and formal training on all
safety aspects including parking, defensive driving may be imparted by agency.
25) All hydras cranes to be fitted with wheel guards, sensors and back horns and necessary precautions
to be adhered as per checklist. Possibility for use of new generation cranes such as TRX 1250 or
equivalent cranes with modified features may be explored.
26) Before planning for shifting of any heavy structure /heavy material a detailed plan survey of the
route map to be carried out and shifting to be done during non-rush hours of traffic congestion.
EIC, agency & safety department to ensure the proper planning & safe execution of job.
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27) Personnel involved in the shifting work should invariably be wearing fluorescent jackets for better
visibility to the operators.
28) Ensure fitness certificates and healthiness of all construction equipment and vehicle in
service at site.
29) The under construction drains alongside the roads should be properly barricaded.
30) Thorough fare for movement of ambulance and emergency vehicle around units under construction
need to be ensured.
31) Documentation regarding pep talks safety induction training of workers needs to be maintained.
Safety awareness video film at gates or any other convenient location to be displayed covering
all work areas.
32) Road Safety campaign is to be carried out on a regular basis.
33) All roads are to be kept clean and unnecessary stones, rubbishes and sands are to be removed from
the work areas specially from the areas where excavation and earth related works are being
carried out.
34) It should be ensured that during movement of the tractor trolley in the work area, no one should be
allowed to sit/ stand on the trolley.
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V. SAFE PRACTICES TO PREVENT FALL OF MATERIAL
1) Only agencies having relevant experience are to be deputed for work. The persons deployed must
have exposure to the relevant work.
2) The work needs to be done under experienced contractor's supervision and presence to ensure
implementation of proper instructions related to work.
3) Proper communication channels need to be maintained for no distortion in communication w.r.t

execution of work in part or full at any stage.
4) Before the start of any gas cutting work on any equipment, it should be ensured that both sides of
the cutting surface are exposed to atmospheric pressure. For this, the drain valve / Manhole etc. to
be kept open and the pipeline drained.
5) During work in water box of condenser, manhole / drain is to be provided between water box and
the CW butterfly valve in the Inlet/Outlet pipe.
6) A system circular to be issued for the strict supervision at the site to all concerned.
7) Supervision from contracting agency must strengthen.
8) The area below the height work shall always be barricaded.
9) No person shall be allowed to enter into the area where barricading has been done below
for height work.
10) Proper arrangement shall be provided for keeping loose materials secure to prevent their
fall from height.
11) Safety Instruction must be displayed at work locations and training on safety is to be provided to
make work place safe from fall of material from height.
12) Any injured person should be given first aid by medically trained first aider before moving to
hospital and ambulance with necessary facilities should be used for transporting the victim.
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VI. SAFETY INSTRUCTION GUIDE
1. General Safety Rules
1. Work with the spirit of safety and imbibe safety measures in your work procedures.
2. Always be cautious while working.
3. Obtain all the required & necessary information/ guidelines prior to commencement of the work.
4. Utilize the safety equipments at the work place effectively.
5. Ensure the safety of the work place before commencing the work.
6. Do not use shortcuts or be impatient while working.
7. Follow the safety rules implemented by the company. Do not flout or ignore them.
8. Do not enter hazardous places or places marked with caution tape without permission
9. Keep away from electrical hazard areas and do not handle electrical equipments carelessly.
10. Do not wear loose clothing while working on machinery.
11. Work cautiously in hot areas.
12. Sleeping is strictly prohibited while at work. It may lead to an accident.
13. Consult the supervisor in case of any difficulty.
14. Learn from the minor mishaps and treat the causes so that they are not repeated in future.
15. Warn / intimate your fellow workers of any possible danger. Keep the electrical equipment away
from water contact.
16. All the safety equipment protects you from any unforeseen accident.
17. Lifting weights beyond one’s physical capacity may lead to accidents like muscular stress / rupture
or crushed toes & fingers.
18. Red tag or red tape means ‘Danger’.
19. Do not jump over the pits.
20. Ladders are useful at work but equally dangerous when handled incorrectly.
21. Do not overlook the safety instructions.
22. Be attentive in your work to prevent accidents.
23. The correct use of equipment and tools helps in completion of work while protecting you and your
co-workers.
24. Emphasize on the maintenance and up keep of cylinders.
25. Always be alert while passing by goods / material that is heaped / piled / stacked improperly.
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2. Site Safety Rules
1. Hazardous areas should all be marked with caution signs.
2. All the roads leading to work site should be kept free from obstructions.
3. Never work alone at unfamiliar sites. Know about the site from your supervisor.
4. Cover the manholes and other openings in the floor / ground properly.
5. Get the hand rails fixed immediately after the platforms and staircases / ladders are constructed /
erected.
6. Make-shift handrails should be fixed on make-shift platforms. Also, ensure that all walkways are free
from obstructions and there should be adequate head clearance to avoid any head collision.
7. Everyday, in a planned manner, the supervisor should brief all the workers about the various work
sites and work related hazards.
8. All the hazardous places should be marked with caution / warning signs in regional / vernacular
language.
9. All the work sites should be properly illuminated.
10. Electrical equipment should be handled with caution and safety.
11. Do not handle welding jobs without gloves and screen.
12. Always wear gloves and goggles while gas cutting.
13. Do not stand in the area where the material is being lifted by a winch or a crane.
14. Do not leave the work related tools / equipment in the work area after the completion of work.
15. Do not tamper with any safety equipment.
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3. Excavation Safety
1. Commence excavation only after obtaining the official permit.
2. Inspect the excavation site in advance for the presence of any gas pipeline, electrical line, etc. If so,
tag the same for all to follow.
3. Use proper tools that are in good condition for excavation.
4. If excavation tools are faulty or damaged, replace immediately.
5. The excavated soil / trash should be stacked much away from the edge of pits and ensure to get the
same removed at the earliest.
6. Arrange for ladders to get into the pit while excavating.
7. All excavated pits should be properly barricaded to prevent anyone from falling
8. Arrange for proper lighting at the excavation site at night and put a ‘Caution’ signage
9. Arrange for proper dewatering of excavated pit.
4. Road Safety
1. Always walk on footpaths so that the vehicles coming from the front are visible.
2. Before crossing the road, stop and look to the right and then left. Cross only when the road is clear.
3. Always look for potholes and slippery surfaces while walking.
4. Follow the traffic instructions and signals.
5. Wear a safety helmet while driving a two-wheeler.
6. Follow the prescribed speed limits and maintain a safe distance from other vehicles.
7. Do not overtake on turns.
8. Do not expose your hand or head outside the window while driving or sitting in a vehicle.
9. Do not drive when drunk. Do not smoke while driving.
10. Mind the headlight and turning signals while driving at night.
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5. Fire Safety
1. Site fires are caused mainly due to welding and gas cutting.
2. Ensure that there is no flammable material in the vicinity of welding or gas cutting work.
3. Use suitable safety equipment while carrying out the works mentioned above.
4. Use Earth Leakage Circuit Breaker (ELCB 30mA) for electrical boards & welding machines.
5. Use suitable fire extinguisher according to requirement.
6. Obtain hot work permits for works like welding, gas cutting and any other work that could produce flames.
7. Familiarize yourself with all type of fire extinguishers at work site.
6. Safety in Gas Cylinders

1. Always keep the gas cylinders tied in an upright position.
2. Always use a trolley to carry them from one place to another.
3. Do not drag or lift cylinders by holding their valves.
4. Keep the cylinders away from any source of fire.
5. Check the cylinder for any kind of gas leakage before using the same.
6. Lift the cylinder in a cage to carry it to a higher place.
7. Select the regulator carefully and inspect after installing it to a cylinder.
8. Switch off the regulator after use and store the cylinder in a safe place.
9. Do not drop the cylinder while storing or unloading it. It may force the valve to burst open.
10. Store the filled and empty cylinders separately and use a chalk to mark them for ‘filled’ or ‘empty’.
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7. Manual Handling of Material
1. Do not lift the material beyond your physical capability.
2. Do not delay in seeking assistance when the material is heavier.
3. Ensure that the material to be lifted / carried does not have rust or sharp / pointed edges.
4. While lifting material, bend your knees and take support of your legs / feet and not your back.
5. Take breaks intermittently to relax your muscles while lifting material.
8. Safety in Mechanized Material Handling

1. Inspect the entire load handling equipment like sling, wire rope, chain and other lifting equipment
thoroughly before using them.
2. Lift only one material at a time. Maintain the balance while lifting.
3. Only a trained rigger should be engaged in setting up sling or rope.
4. The presence of supervisor is mandatory during lifting of load / material.
5. Either the supervisor or trained rigger should ensure that correct sling & U-clamps are being used.
6. The area around the lifting should be cordoned with a caution tape or a rope.
7. Do not let anybody cross under the suspended load.
8. Do not use a hammer or any other metallic object to tighten the sling.
9. Always inspect the lifting machine for its brakes, limit switches and other emergency safety controls.
10. Lift the material slowly and not with a jerk.
11. The material to be lifted should be of at least 10 % lesser weight than the rated capacity.
12. Do not use the load chain as sling. Never let the chain get twisted.
13. Do not stack or keep the material on walkways.
14. Secure the sling on hook properly to prevent it from slipping.
15. Use guide ropes to prevent the heavy / long material from swinging precariously.
16. Use hand gloves while working.
17. Emphasize on proper housekeeping of the work site.
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9. Safety Instructions for Sling Man
1. Sling man should guide the crane operator.
2. Sling man should not stock faulty slings at work place.
Such slings should be discarded.
3. Sling man should only use the sling and chain that have been quality inspected and certified.
4. Sling man along with the crane operator should have complete knowledge of signaling code.
5. Sling man should have a good estimation of material load so as not to exceed the safe working load
(SWL) of the crane.
6. Sling man should select the most suitable sling in terms of type and length to go with the actual load
being lifted by the crane.
7. Sling man should ensure that the sling and chain have not been shortened by knotting.
8. Sling man should ensure that the hook of the crane is always positioned above the load. He should
also ensure that the rope is suspended vertically so that the load does not swing while lifting.
9. Sling man should ensure that the rope and chains being used to lift the load do not vary in length to
prevent any imbalance of load.
10. Sling man should signal the crane operator from a safe distance and should ensure that no one else
is standing close to the load during the lift process.
11. Before transferring the load, the load should be kept lifted to a height of 200- 300 mm for sometime
and the sling man should inspect the tensile strength of slings and that the load, has been secured
well. He should ensure that the load would not fall during transfer.
12. While transferring the load, sling man should ensure that the route is free from obstructions /
obstacles. He should possibly move with the crane or else he should stand at a distance from where
his signals are clear to the crane operator.
13. Sling man should ensure that the load should not be carried from above or near the area where
people are working.
14. Before lowering the load, the sling man should check the ground underneath for electrical wires /
cables, gas / steam pipe lines and also that the load is not kept on any temporary platform.
15. While stacking the load in pile, sling man should ensure that the load is not kept on a slope or wet
surface to prevent from falling down. While lifting heavy loads, sling man should ensure that the
sling has secured the load from all four sides and that there is no risk of slipping or popping.
16. While lifting the load, sling man is prohibited from the following:
(a) Use of faulty/ uninspected sling, chain or any other equipment to lift loads.
(b) Bolting of broken chain end or use of sling with loose ends.
(c) Adjustment of sling or chain with the help of hammer, etc. to balance the load.
(d) Standing near the hanging load that is in an unbalanced or unstable state.
(e) Thrusting feet, hand or body under the load.
(f) Use of bolt in place of pin on D-shackle.
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10. Safety in Crane Operations
1. Crane operator should ensure that all the systems and cabin of crane are clean & tidy.
2. The operator should ensure that the work area is sufficiently illuminated. If illumination is
inadequate, he should report the same to the supervisor.
3. After repairs are carried out on the crane, work should be resumed only when the operator has
examined the crane thoroughly.
4. Cleansing and lubricating material should not be kept carelessly. All unwanted items should be
removed from the crane immediately.
5. Whenever the operator steps out of the crane, all the controls should be put to neutral. The main
switch should be switched off and the cabin door locked.
6. If the crane catches fire, the main supply should be cut immediately and efforts should be made to
douse the fire with the help of suitable fire extinguisher. Simultaneously, the emergency phone
number should be informed either by self or through the co-workers.
7. In case of a power failure during crane operation, the operator should put all the controls to neutral.
8. In case of long travel, the crane should be operated at a safe distance from the nearby machines and
material.
9. The crane operator should understand & verse himself well with the signaling code before lifting
any load. The signals should be followed only from the authorized personnel.
10. Crane operator should be aware of the SWL of the crane. No load should ever be dragged by a
crane.
11. If the crane operator notices any defect in the wire rope or any electric spark near the wire rope, he
should shut down the crane immediately. The crane should then be operated only after proper
inspection and rectification by qualified personnel.
12. Unauthorized personnel should never be allowed to step on the crane.
13. Flammable material should not be kept inside the crane cabin.
14. Crane operator should never attempt to repair any system or electrical equipment of the crane.
15. Cleaning and inspection of the crane should never be done when in “ON” state.
16. Tools & other objects should never be left carelessly on the crane platform or trolley.
17. Crane should never be operated in case of defect in safety systems like limit switch, electrical
contractors, brakes, electrical panel, etc.
18. Cabin should never be evacuated with hoist lever in ‘ON’ state.
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11. Electrical Safety
Electrical is a highly versatile form of energy but only when used properly. Failure to take suitable
precautions in its use, however, creates conditions, which result in bodily injury or property damage
or both. Control of electrical hazards is neither difficult nor expensive, but ignoring or neglecting
them may lead to serious accidents.
Injuries due to Electricity

A. Electric shock
The flow of electricity through human body may lead to electric shock. Electric pressure, resistance
of human body against electricity and duration of flow is important. Electric shock is more fatal
when there is a direct contact with A.C. supply because the body sticks to the AC supply for longer
duration. The normal functioning of nerves, tissues and muscles can get impaired if electricity flows
through them. Electric flow through heart can lose one’s balance due to shock and fall from height.
The shock may shove the person away with a force leading to an injury.
B. Burning
Body parts can get burnt when they come under high voltage area.
Body parts can also get burnt due to short circuit.
Short circuit can lead to fire that can cause burning.
C. Dos
• Let only a qualified & trained personnel handle electrical repairs.
• All the electrical lines should be considered energized till their shut down is ascertained.
• One should ascertain that the cable is free from cuts & twists and that the insulation is not
damaged.
• Check for any loose pins in the socket.
• Ensure that the supply can be shut off easily.
• Use only such switches that have clear marks ‘ON’& ‘OFF’ and are of correct amperage.
• Check the voltage & amperage regularly and ensure that the values are appropriate.
• Get all the equipment, circuit breakers, etc. checked by a qualified & competent person from
time to time.
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• While using portable electrical equipment ensure that it is earthed properly, there is no leakage
of current, cable is connected well to the plug through the rubber covering and that the cable is
not under tension.
• Use work permit to work in combustible environment.
• Identify & eliminate the electrical hazards.
• Switch off the mains if there is any short circuit or fire.
• First aid procedures should be known to everybody.
D. Don’ts
• Do not leave unsafe, temporary joints or naked wires.
 • Do not work with wet electrical equipments.
 • Do not repair the electric lines on instincts. Repair only when there is complete information.
 • Do not tamper fuses as they provide safety.
 • Do not repair the blown fuse till the actual defect is identified and rectified.
 • Do not operate any switch till the outcome is known.
 • Do not let any electrical point get overloaded.
 • Do not pour water on electric fire. Use dry sand, carbon dioxide gas or dry chemical powder to
extinguish fire.
 • Do not let any material / goods accumulate near the main switches.
 • Do not stand close to or take support of a high rise building during thunder storms.
 • Do not be careless. Adopt safety procedures.
E. In case of physical injury
In case of an accident due to electric shock, provide artificial respiration to the patient and consult a
doctor immediately. Do not let people crowd around the patient. He needs fresh air. In case of
burns, keep the affected area cool with water.
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Checklist for Electrical Works
The following points should be checked and complied with before start of work involving electrical
power supply.
Sl. No. Points to be checked

1 Electrical equipment /tools are in sound condition and inspected /tested for its healthiness
2 Body earthing is provided to machine / electrical hand tool
3 The Switches / Fuses/ Plug top used are of appropriate rating.
4 The power cable is having three cores in case of single phase and four cores in case of
3 phase supply.
5 The joints in power cables are properly insulated
6 For Welding cable, job earth and joints are proper
7 Electrical machine/tools cables are free from obstruction, contact with water and hot
sparks
8 ELCB is provided in the supply system
9 Use of 24 volts hand lamp in confined space /vessel
10 Permit to work has been taken
11 Proper access and illumination are available to switch boards and work location
12 Safety tags are provided
13 Engagement of experienced and authorised workers for doing the work
14 Workers are briefed on safety precautions to be taken
15 Use of Helmet, Shoes, Gloves , Face shield and Safety belt (height work) by worker
16 Worker is not exposed to rain and not standing on wet /water logged location
17 Second person is available with the engaged worker
18 Agency supervisor deployed
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12. Safety Instructions for Chain Pulley Block
1. Always inspect the chain, hook, pulley & lubrication before lifting any load. Do not use in case of any
discrepancy.
2. Before suspending the chain block, always inspect the place for strength, suspension method and
the load lifting method.
3. Check the Safe Working Load (SWL) of the chain pulley block. Do not use a chain pulley block that
does not have the SWL marked on it.
4. Never exceed the SWL of the chain pulley block under any circumstances.
5. Never use the chain pulley block in shifting the load from one place to other.
6. Maintain the chain sling and block properly so they do not get rusted.
7. Get the chain pulley block examined by the authorized personnel at least once a year.
8. Never tie a knot to the load chain or hand chain while using the same.
9. Never drag a load with pulley block. Ensure that the hook of the pulley block is right over the centre
of gravity to prevent slippage of the load.
10. Provide rubber support to the wire rope if the chain pulley block has to be suspended through it.
This will prevent any damage to the wire rope.
11. Presence of safety latch in the hook opening of chain pulley block is a must.
12. If the latch is missing then the open end of the hook should be secured suitably after suspending the
material to prevent its slippage.
13. Before lifting the load, always ensure the following Safety Check List:
i. Method of suspension.
ii. Method of anchoring the sling & D-shackle.
iii. SWL of the chain pulley block.
iv. Maintenance of the chain pulley block.
v. Inspection of the place of anchoring / lifting.
14. Never lift a person using chain pulley block.
15. Never wrap the load chain around the load.
16. Only authorized personnel should operate chain pulley block.
17. Use maximum possible number or clamps for suspending chain pulley block.
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13. Safety in Height Work
1. Supervisor should ensure before the start of work that all the workers have adequate PPEs like
Helmets, Safety Shoes, Safety Harness, Fall Arresters, etc. Working at heights without PPEs is
strictly prohibited.
2. Supervisor should ensure before the start of work that all the safety harness is free from any defect
like cuts, poor strength etc. In case the safety harness is improper, replace it immediately with a
suitable one from the store. Examine the following in a safety harness: stitching, rope (lanyard),
hooks, anchoring belt, etc.
3. Access route should be pre-defined for ascending & descending while working at heights. Use only
designated route for movement. Do not use short cuts under any circumstances.
4. The workers should inspect the work site at higher elevations thoroughly for belt anchoring point,
material storage space, access routes, condition of tools, etc.
5. Before the start of work, the workers should understand all the work related safety instructions from
their supervisor and follow accordingly.
6. The hook of safety harness should be anchored above the shoulder height to a strong point and
jerked briskly to ensure safety in strength.
7. To go from one column to the other at heights, first a rope should be tied over the channel and then
the belt should be hooked on to it. Cross while in sitting position.
8. While working at heights, it is the responsibility of the supervisor to be present all the time and to
continuously supervise all the height related work.
9. Before the start of work, foremost, the workers & supervisor should inspect the safety of the
working platform like the width of the platform, the support, platform erecting method, load
withstanding capacity, etc. Use it when assured of its safety.
10. The area beneath the height where the work is to be carried out should be barricaded with a caution
tape.
11. It is the responsibility of the supervisor to monitor all the activities of the workers at height. He
should immediately stop the workers from doing any unsafe activity & inform about the safe work
procedures.
12. Unskilled & untrained workers are prohibited from working at height.
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13. Only physically fit workers should be engaged to work at heights. Workers should be medically
examined before sending them for height work.
14. Supervisor should ensure the availability of adequate illumination at height and the access routes.
15. Unwell workers are not allowed to work at height.
16. To prevent fire due to sparks generated from different activities like welding, gas cutting, g r i n d i n g
etc., the worksite should be kept clean at height. Remove all flammable material.
17. Workers should possibly keep both their hands free while ascending to be able to hold the side rails.
18. Always carry the tools to a height in a tool kit.
19. Loose clothing is strictly prohibited while working at height.
20. Baskets meant for working at height should be inspected regularly and should be used only after
inspection by the competent authority.
21. After the completion of work at height, remove the scrap generated immediately.
22. Throwing of material / things from height is strictly prohibited.
23. Supervisor & workers should always work with patience & grace, when at a height. Do not work in a
hurry.
24. Height Work permit has to be used when working at height of more than 3 meters.
Ladders & Platform:
1. Inspect the ladders before use and do not use defective ladders.
2. Ensure before commencement of the work that the ladder is secured properly.
3. If the lower part is unstable then it should be held by other co-workers.
4. Do not use ladders to block the doors.
5. Do not place the ladders on uneven or fragile surface.
6. Ladder should be arranged so that its upper part extends at least one meter above the landing
surface.
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7. In an excavated area, ensure that the ladder is secured properly.
8. Do not stand in between the ladders.
9. Do not carry any material while ascending or descending the ladder.
10. Only one person at a time should climb the ladder.
11. Use wooden ladders instead of metal ladders near electrical installations.
12. Before starting work, inspect whether the platform boards have been erected properly at right
places.
13. Inspect whether the scaffolding platform boards have been provided on all open sides of platforms
more than 4 feet in height.
14. Do not exceed the load bearing capacity of the scaffolding.
15. Immediately repair the defects in a scaffold, if any.
16. Do not use the scaffolding during a storm or strong winds.
17. Maintain safe distance between scaffolding & electric wires so that people do not hit the cables.
18. Always maintain three point contacts while ascending or descending the ladder.
19. Apply the four to one rule: ladder should be one foot from the wall for every four feet of height.
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Checklist for Working at Height
The following points should be checked and compiled with before start of work at height.
Sl. No. Points to be checked

1. Work area below is temporarily cordoned / barricaded.
2. Openings in Walkways and platforms (if any) are properly barricaded.
3. The scaffold erected has iron pipes and clamps in good condition.
4. Diagonal / lateral bracings pipes are provided to ensure stability
5. Planks / sheets as temporary platform are tied properly using binding wires
6. Metallic Planks / sheets used in temporary platforms are in good condition
7. Temporary platforms are having side railing and toe guards.
8. Working platforms and walkways are free from oily and greasy surface.
9. Access ladder is provided to reach the work location.
10. Wooden bellies and wooden planks are not used as scaffold
11. The slings / pulley blocks / ropes being used are tested for fitness and certificates are
available
12. Portable electrical equipments are checked for healthiness including earthling /fibre body
13. Proper illumination available at work location.

14. Workers are wearing Helmet, Shoe, Safety belt
15. For anchoring of Safety Belt at height, rigid support / life line is provided.
16. Fall arrestors are provided to workers at height in good condition.
17. Safety nets are provided below the work location.
18. Workers having height experience with physical fitness are only engaged for work at
height.
19. Workers are briefed on Safety Precautions to be taken (Dos /Don’ts)
20. Lone workers are not allowed at height, at uneven, narrow and confined space. Extra care
in taken in such cases.
21. Supervisory staff of agency is available during the work
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14. Safety in Welding, Gas Cutting & Grinding Work
1. Wear proper PPEs like gloves, goggles, screen, etc before starting activities like welding, Gas
cutting & grinding.
2. Welding machine should be properly earthed.
3. Use correct type of electrode for welding.
4. Ensure before welding that there is no combustible material. Remove if possible; if not then cover it
properly.
5. Check the quality of cable before welding. Connect the cable properly.
6. Never use oil or gas pipeline as earth for welding. Cable connection should be secured tight.
7. Welding holder should be of good quality. Damaged holders should not be used.
8. Welding should not be done during rain or wet body condition due to perspiration.
9. Wear safety harness while welding at height. Make proper arrangements to prevent fire hazard
from the welding spatters falling from height.
10. Do not lay the welding cable connection on passages. It may get damaged by plying vehicles.
11. Work permit should be obtained for welding, wherever necessary.
12. Welding, gas cutting & grinding should not be carried out in closed rooms. If it is necessary then
take adequate safety measures & the work should be carried out under the supervision of Shift
in-charge.
13. Do not shift the welding machine when it is being operated.
14. Shut off the welding machine after the completion of the work. Do not leave the machine in 'ON'
condition.
15. Remove the welding electrode stubs from the work site.
16. Before the welding of the drums of oil or any other combustible material, ensure that the cover or lid
is open. Oil or gas pipelines should be clean & suitable for welding. Ensure the same things while
gas cutting.
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18. Ensure that the tip / nozzle of the gas torch is free from dirt / dust. Clean regularly.
19. Hose connection should be of good quality. There should be no cuts in the pipe.
20. Gas cylinders should be lifted and never rolled to carry.
21. Remove any combustible material around the working area or cover it suitably
22. Always keep the cylinders covered with wet gunny bags / jute bags so that in case of leakage, the
gas never comes in contact with sparks / spatters.
23. Keep the cylinders at a suitable place after gas cutting. Do not leave the gas cutting set in operating
condition. Always shut the cylinders off before leaving.
24. Never apply oil or grease to the oxygen hose pipe joints. Keep the cylinders away from contact with
electric current.
25. Check the earthing of the grinding machine. The wheel used should be of correct size.
26. Use suitable PPEs like gloves, apron, goggles, guard, etc.
27. Check the quality of the grinding wheel. Secure it firmly on the machine.
28. Prevent the possibility of fire hazard due to the sparks generated during grinding.
29. Never leave the gas cutting torch in a confined space. Remove it immediately after completion of
work.
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15. Tool Box Meeting and Safety Trainings
1. Organise a workshop before the start of work that talks about work hazards and the various safe
working procedures.
2. Discuss the problems with your respective departments.
3. Ask questions.
4. Come out with solutions to your problems.
5. All the new workers should have their induction from the safety department, before starting work.
6. It is the responsibility of the sub contractors to make their workers aware of the nature of work & the
safe working procedures.
16. First Aid
Condition Symptoms Treatment

Unconsciousness If a person doesn't Immediately inform your department for
respond help, after examining the person
Injury / bleeding External injury /wound, Make the person sit, try to stop the bleeding, clean
excessive bleeding the wound, dress up the wound with bandages.
Inform your department for further assistance.
Burn Redness or swelling Immerse the affected area under cold water for
15 minutes, do not apply any medicine by yourself,
inform your department immediately.
Electric shock Fainting Recline the person, inform your department if there
is bleeding,
Eye ailment Irritation of eyes, tears Do not touch eyes with dirty hands, rinse
in eyes, redness of eyes the eyes with clean water
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17. Good Housekeeping
1. Adopt Japanese 5-S technique
5S MEANING DEFINITION
SEIRI Sort Going through all the tools, materials, etc., in the plant and
work area And keeping only essential items. Everything
else is stored or discarded
SEITON Set in order Tools and equipment should be kept where they will be used.
For everything there should be a place and everything
should be in its place.
SEISO Shine Cleaning of the workplace. Maintaining cleanliness

should be part of the daily work.
SEIKETSU Standardize Standardized work practices or operating in a consistent and

standardized fashion. Everyone knows exactly what his or
her responsibilities are.
SHITSUKE Sustain Maintaining and reviewing standards. Maintain the focus on
this new way of operating, and do not allow a gradual decline
back to the old ways of operating.
2. Keep the workplace clean.

3. Keep stairs & walkways clean.
4. Do not allow water to stagnate.
5. Do not obstruct the area around electrical distribution boards, winch machines, welding machines
etc. by stacking material.
6. Do not obstruct walkways and ensure that no part of the material falls on walkways.
7. Do not keep combustible material in open containers.
8. To prevent slippage, clean the oil, grease or any other fluid on the floors.
9. Remove metal pieces, wooden pieces, bags, paper etc after the completion of Work & dispose off
at a designated place.
10. Welding cable should be routed separately from the power cables and should
11. Not be laid on ground.
12. Storage of the PPEs should be done carefully to prevent them from getting damaged.
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18. Safety in Hand Tools
1. Ensure that hand tools are in proper working condition before putting them to use.
2. Use the right spanner for bolting / unbolting of nuts.
3. Ensure that the hands are free from oil, grease, etc. while working with hand tools.
4. Do not use a file with a loose or no handle.
5. Use suitable tools for different activities.
6. Do not use hammers with loose / broken handle or the ones with mushroom head.
7. Ensure that the handle & case of the hammer are not slippery.
8. Keep the small tools tied with a rope while working at a height to prevent them from falling down.
9. Handle hacksaws with great caution. The blade should neither be too tight nor loose.
10. Keep the tools in the right place and in the right order after the work is over.
19. Chemical Safety

1. Consider all the chemicals hazardous and do not touch the chemical vapours.
2. If the properties of any chemical are not known, consult the supervisor before its use.
3. Always wear PPEs like gloves, apron, face mask, goggles, etc. while dealing with chemicals.
4. In case of spillage of any chemical like petrol, diesel, paint, thinner, etc. change the clothes
immediately and wash the affected area with plenty of water.
5. Do not keep and empty chemical container or drum at a hot place.
6. Never apply gas cutting / welding on a chemical / oil drum. Work under the supervision of the
supervisor if required.
7. Store all the empty drums of paint, diesel, polyethylene, thinner, etc. properly in the store.
20. Hydra Crane Safety

1. There must be 2 helpers appointed. Helpers must be 2-3 m distance away from hydra.
2. Helper must use florescent jacket and a whistle.
3. Operator must have heavy vehicle license.
4. Reverse horn to be ensured in all hydra cranes.
5. All brakes including parking brake must be checked before use of crane.
6. Operator must lift the material slowly without jerk.
7. Tyre air pressure should be checked before use.
8. Guard must be provided in both side of the wheel and weight.
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9. All hooks must have latches.
10. Limit switch must be checked in intervals to ensure safety. Sling should be maintained properly and
inspected regularly.
11. Never draw weight from angle.
12. Get the following components checked before starting the job, for areas for damage, improperly
installed or missing parts as per the manufacturer’s manual :
I. Electrical components, wiring and electrical cables
II. Hydraulic power unit, reservoir, hoses, fittings, cylinders and manifolds.
III. Tyres and wheels
IV. Trailer lights and reflectors
V. Parking brake, and electric braking system (including the breakaway system)
VI. Drive wheel and motor
13. Follow safety measures during operations to ensure that the health and safety of self or others is not
at risk.
14. Talking over cell phone during driving shall be prohibited. Awareness of consequences of talking
over a cell phone while driving is to be increased.
15. An escort with whistle should always accompany the hydra crane to assist him for proper signalling
and alerting others.
16. Details of inspection/examination by a competent person shall be displayed on hydra and other
cranes.
17. Checklist to be prepared and periodical inspection of hydra to be carried out for ensuring the
proper working condition of hydra.
18. Exclusive training of mobile crane operators may be imparted.
19. There must be at least two sufficiently long guide ropes attached with the hanging load during its
handling / lifting by crane.
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21. Safety during radiography
Radiography in enclosures :
1. Unauthorized entry into the radiography zone should be prohibited.
2. A warning lamp must be provided at the entrance. A radiation zone monitor must be installed at a
suitable location near the entrance to indicate the radiation level in the exposure hall.
3. Wherever possible the radiation beam should be directed towards areas of minimum occupancy
and must not be pointed towards doors, windows, and control panel.
4. While carrying out the radiography in open top enclosures, it shall be ensured that the red warning
lamps on the four corners of the hall are switched on.
Open field radiography :
1. The radiography work must be carried out only under the supervision and guidance of the
Radiography safety site in charge.
2. All operation should be planned in advance and executed in minimum possible time.
3. Radiography camera should be moved to the site along with radiation survey meter.
4. As far as possible, field radiography should be carried out when there is minimum occupancy. The
area around the field radiography site should be cordoned off so that the radiation at the cordon off
area does not exceed the permissible level for members of public.
5. Radiation warning symbol in English and in local languages must be displayed at cordon off
distance. Red warning lights must be displayed during night along the cordon off at the point of
entry.
6. The concerned radiographer must be available at the site very near to the cordoned area
throughout the exposure. Entry of unauthorized person into these cordoned areas during
exposures should be strictly prohibited.
7. After termination of each exposure, it is to be ensured that the source is safely retrieved back into
the camera.
8. Proper collimators should be used to limit the radiation beam to the job to be radio graphed.
Training :
1. Radiographers shall complete a radiation safety program conducted by Bhaba Atomic Research
Centre (BARC), Trombay and shall be certified. Certificate shall be renewed every three years.
2. Updation of requirements shall be done from the following websites :
i. BARC : http://barc.ernet.in
ii. Department of Atomic Energy : http://dae.gov.in
iii. Atomic Energy Regulation Board : http://aerb.gov.in
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3. Radiographers and employees working in the vicinity of a radiation source shall keep track of :
i. The potential effects of radiation exposure.
ii. Procedures, precaution, and /or protective equipment required to minimize the potential for
health effects and emergency response procedures
iii. Radiation regulations and license conditions.
Handling and Storage:
1. Radiographers shall wear dosimeter badges when operating the source. Operator exposure shall
not exceed 2.0 rem in 1 year.
2. The source shall be stored in a locked, sealed lead box and shall be placed in a locked storage
room/pit and the radiation hazard sign shall be displayed as below.
Transport :
1. Sources shall be transported in a separate vehicle and never in a passenger vehicle, shall never be
left in unattended vehicles or taken home.
2. A copy of the permit and shipping form shall be in plain view on the dash or on the seat near the
driver when transporting the source.
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Testing, Operation and Maintenance :
1. Sources shall be leak tested by a professional service group at least every other year, or as per BARC
Regulation. Test results shall be maintained on file where the source is stored.
2. If leaks or contamination are detected, check that the carry shield is properly in place. If the
contamination/ leak source cannot be determined, the source must be removed from service and
repaired by a qualified BARC approved repair service agency before it is used again.
3. Contractors use the camera; develop the film and give to NTPC Limited for final interpretation. In
case of Hospital, it is done by the qualified NTPC radiographer
4. Sources are locked by BARC and which are never to be tempered with; Refilling and disposal of
sources are to be done by BARC only
5. Maintained records shall include :
i. Application for requisition/refilling of source
ii. Authorization for sanction from BARC
iii. Certificate for Authorization for competent Radiographers
iv. Badges being sent to BARC monthly for exposure monitoring
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OUR MISSION
Provide Reliable Power and
Related Solutions in an Economical,
Efficient and Environment friendly manner,
driven by Innovation and Agility
CORE VALUES - ICOMIT
Integrity
Customer Focus
Organisational Pride
Mutual Respect & Trust
Innovation & Learning
Total Quality & Safety
Corporate Safety Department

NTPC Limited, Engineering Office Complex, A-8A, Sector-24, Noida

2018210-Safety Tips Booklet

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2018210-Safety Tips Booklet

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IP S S A F E T Y TIPS SAFE

A F E T Y TIPS SAFETY T FETY TIPS SAFETY TIP

dkS'ky fd'kksj 'kekZ dsUnzh; dk;kZy;/Corporate Centre

I am confident that this document shall be useful for everybody.

With Best Wishes

(Kaushal Kishore Sharma)

Corporate Identification Number L40101DL1975GOI007966

I. Safe practices while working at height. 3

II. Safe practices to prevent electrocution & burns. 12

III. Safe practices to prevent caught in-between

IV. Safe Practices to prevent run over &

V. Safe practices to prevent fall of material 28

VI. Safety Instruction Guide: 29

1. General Safety Rules 29

2. Site Safety Rules 30

6. Safety in Gas Cylinders 32

7. Manual Handling of Material 33

8. Safety in Mechanized Material Handling 33

9. Safety Instructions for Sling Man 34

11. Electrical Safety 36

12. Safety Instruction for Chain Pulley Block 39

13. Safety in Height work 40

14. Safety in Welding, Gas Cutting & Grinding Work 44

15. Tool Box Meeting & Safety Training 46

16. First Aid 46

17. Good Housekeeping 47

18. Safety in Hand Tools 48

19. Chemical Safety 48

20. Hydra Crane Safety 48

21. Safety during Radiography 50

67) Periodic inspection of support and platforms of the walkway is to be done.

75) Winch operator is only authorised to operate the winch machine.

36) PA systems in WT control room should be near to the operating console.

5) Details of inspection/examination by a competent person shall be displayed on hydra and other

8) Exclusive training of mobile crane operators may be imparted.

32) Road Safety campaign is to be carried out on a regular basis.

3) Proper communication channels need to be maintained for no distortion in communication w.r.t

7) Supervision from contracting agency must strengthen.

8) The area below the height work shall always be barricaded.

9. All the work sites should be properly illuminated.

10. Electrical equipment should be handled with caution and safety.

11. Do not handle welding jobs without gloves and screen.

12. Always wear gloves and goggles while gas cutting.

15. Do not tamper with any safety equipment.

3. Use proper tools that are in good condition for excavation.

4. If excavation tools are faulty or damaged, replace immediately.

6. Arrange for ladders to get into the pit while excavating.

9. Arrange for proper dewatering of excavated pit.

3. Always look for potholes and slippery surfaces while walking.

4. Follow the traffic instructions and signals.

5. Wear a safety helmet while driving a two-wheeler.

7. Do not overtake on turns.

9. Do not drive when drunk. Do not smoke while driving.

5. Use suitable fire extinguisher according to requirement.

7. Familiarize yourself with all type of fire extinguishers at work site.

6. Safety in Gas Cylinders

2. Always use a trolley to carry them from one place to another.

3. Do not drag or lift cylinders by holding their valves.

4. Keep the cylinders away from any source of fire.

6. Lift the cylinder in a cage to carry it to a higher place.

7. Select the regulator carefully and inspect after installing it to a cylinder.

2. Do not delay in seeking assistance when the material is heavier.

5. Take breaks intermittently to relax your muscles while lifting material.

8. Safety in Mechanized Material Handling