Hazard Identification and Risk Assessment (HIRA)

for Renewables

RE-Safety Department

Page 1 of 30
 Doc No: RE/HIRA/001
Hazard Identification and Risk
Revision: 0.0
Assessment (HIRA)
Date: 24.11.2023

Name Signature
Approved by Mohit Bhargava, ED(Renewable), CEO (NTPC REL) NGEL
Reviewed by Soumya Kanti Chowdhuri, GM (PM & SD) NTPC REL
Prepared by Prabhat Kumar Ranjan, Sr. Manager (RE-Safety)

Page 2 of 30
Contents

1. Preface ......................................................................................................................................................... 4

2. Brief on Hazard Identification and Risk Assessment (HIRA) ........................................................................ 5

3. Five steps for HIRA ..................................................................................................................................... 6

4. Hazards in Solar power plants ...................................................................................................................... 8

4.1 Specific hazards from solar ................................................................................................................... 8

4.2 Generic Hazards for Solar at ground level ............................................................................................. 8
4.3 Generic Hazards for floating Solar ........................................................................................................ 8
5. Hazards in Wind power plants ...................................................................................................................... 9

5.1 Specific hazards from land-based wind power ....................................................................................... 9

5.2 Generic Hazards from wind power ........................................................................................................ 9
6. HIRA for identified Hazards in Solar .......................................................................................................... 10

7. HIRA for identified Hazards in Wind ......................................................................................................... 13

Annexture -1: Operational Control Procedures (OCPs) ........................................................................................... 15

OCP - 01 Ladder ................................................................................................................................................... 15
OCP - 02 Scaffolding ............................................................................................................................................ 17
OCP - 03 Work at Heights ..................................................................................................................................... 19
OCP - 04 Lifting gears Crane/Hydra ...................................................................................................................... 20
OCP - 05 Electrical Works ..................................................................................................................................... 23
OCP - 06 Hot Work (Arc Welding) ........................................................................................................................ 26
Annexture -2 : Common procedure for electrical isolation ...................................................................................... 27

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1. Preface
NTPC – Renewables gives utmost importance to Safety, Health and Environment (SHE) in all its activities.
This commitment is reinforced by choosing “Safety” as one of the core values. One of the principles of our
safety policy is:

“Our activities carry various hazards; however, all hazards can be identified”.

Company firmly believes that “All accidents are preventable” and promotes safe working environment
striving for “ZERO INCIDENTS” at work. Safe work results in
1. High Productivity

2. Positive work environment

3. Improved bottom lines

4. Better satisfaction to stakeholders

To translate the safety policy into standard practices with “ZERO INCIDENTS” outcome, a need was felt for
identification of possible hazards, assessment of associated risks and their mitigation measures. NTPC
renewables covers solar, wind, hydrogen and Hydrogen derived chemicals. All these domain pose specific
hazards and therefore requires appropriate mitigation measures.
This HIRA document is being prepared to serve as a reference document for RE-sites. This will guide for
identification of hazards, assessment of associated risks and their control measures to execute the jobs
SAFELY. The Operation Control Procedures (OCPs) for working with ladders, scaffoldings, Hydra, Welding,
etc. have been indicated for ready reference.
HIRA for Hydrogen working shall be added in the next revision in April 2024.
Sites may further augment this document as per site specific additional hazards.

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2. Brief on Hazard Identification and Risk Assessment (HIRA)

Hazard Identification and Risk Analysis (HIRA) is a collective term that encompasses all activities involved
in identifying hazards and evaluating risk at facilities, throughout their life cycle, to make certain that risks
to employees, the public, equipment or the environment are consistently controlled.

Globally all safety Management Systems considers Hazard Identification and Risk Analysis (HIRA) as corner
stone to establish a sound safety system. Moreover, industries are required to carry out HIRA for their
different activities and operations as per statutory requirements. Considering importance of HIRA, the
Bureau of Indian Standards has brought out a complete standard titled “Hazard Identification and Risk
Analysis – Code of Practice” IS 15656:2006.

Relevant definitions are given below:

a) Hazard: Source or situation with potential for harm, something that can cause body injury,
occupationalillness, damage of property etc.

b) Risk: Risk is the chance or probability that a person or property will be harmed if exposed to a hazard.
It also includes possibilities of adverse health effect to personnel.

c) Risk Assessment: A systematic and structured process whereby hazards present in workplace, or arising
from workplace activity, are identified, risks are evaluated.

Few others relevant definitions are given below:

Risk Mitigation : Risk mitigation is defined as the process of reducing risk exposure and minimizing the
likelihood of an incident.

Competent person: As per OSHA, the Competent person is someone who is capable of recognizing and
solving hazards in a workplace.

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3. Five steps for HIRA
Renewables construction and operation workers are exposed to risk when they do a job. To minimize
this, they should be more informed about various risk resulting from different hazards. A simplified
five-step hazard and risk assessment along with control measures is given below.

1. Identification of a Hazard.
2. Identification of associated Risk.
3. Control of the risk, which Includes:
1. Elimination / Substitution.
2. Engineering barrier.
3. Administration controls.
4. Personal protection equipment.
4. Documentation of the HIRA process.
5. Monitoring and review of the HIRA process.

Step 1- Identification of hazard:

Extensive deliberation with different NTPC sites, and consultations with experts resulted in
identification of 12 hazards in solar area and 20 hazards in wind area. These are specified in section 4
and 5.

Step 2- Identification of associated Risk:

The associated risk of identified 32 hazards are mentioned in section 6 and 7, respectively for solar and
wind.

Step 3- Control of the risk:

The control measures of the identified hazards are mentioned in section 6 and 7. The assessment of
individual risk is not performed separately but included while specifying control measures. The last
column of the table in section 6 and 7 specify the controlled risk rating which is also an outcome of
risk assessment.

Step 4- Documentation of the HIRA process:

Identification of hazard, associated risk, control measures and frequency are formalized in November
2023, which is part of this document.

A well accepted methodology for risk assessment is indicated in subsequent section which is adopted
for our process.

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Risk Index Matrix:

Risk Level
Probability of Accident(O)
1 2 3 4 5
Rare Remote Occasional Frequent Almost
Certain
5 Catastrophic M M H H H
Accident(S)

4 Major M M M H H
Severity of

3 Moderate L M M M H

2 Minor L M M M M

1 Negligible L L L M M

Low Risk No additional risk control measures may be needed. However, frequent review may be needed to
Acceptable
OxS ≤ 3 ensure that the risk level assigned is accurate and does not increase over time.
Green colour
A careful evaluation of the hazards should be carried out to ensure that the risk level is reduced
Medium Risk Moderately acceptable to as low as reasonably practicable within a defined time period. Interim risk control measures,
4 ≥ OxS≤ 12 such as administrative controls, may be implemented. Management attention is required.
Yellow colour
High Risk Alternate arrangements to be made.
Not acceptable
15 ≥OxS≤ 25
Red colour

Table 1: Probability/Likelihood of Accident Table 2: Severity of Accident/injury

Probability/ Rating Description Consequence Rating Description

Likelihood
Catastrophic 5 Fatality, fatal diseases or multiple major
Not expected to occur but injuries
Rare 1 Serious injuries or life-threatening
still possible
occupational disease (includes amputations,
Major 4
major fractures, multiple injuries,
Not likely to occur under occupational cancer, acute poisoning)
Remote 2
normal circumstances Injury requiring medical treatment or ill-
Moderate 3 health leading to disability (includes
Possible or known to
Occasional 3 lacerations, burns, sprains, minor fractures,
occur dermatitis, deafness and work-related upper
Injury or ill-health requiring first-aid only
Minor 2 (includes minor cuts and bruises, irritation,
Frequent 4 Common occurrence
ill-health with temporary discomfort)
Continual or repeating Not likely to cause injury or ill-health.
Almost Certain 5 experience Negligible 1

Step 5- Monitoring and review of HIRA:

The review of all identified hazards, associated risks, control measures and frequency of occurrence
etc will be done every six months or whenever any incident happens.

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4. Hazards in Solar power plants
4.1 Specific hazards from solar

There are specific hazards typical to a solar plant, as mentioned below:

a. Solar module panel glare
b. Snake and insect bite
c. Back injury from lifting and working with solar panel
d. Fire from stored packing materials, dry grass after grass cutting

4.2 Generic Hazards for Solar at ground level

1. Physical hazards
a. Trip and fall
b. Cut and bruises

2. Electrical hazards
a. Flash over and burn injury
b. Electrocution

3. Hazards arising out of hot weather

a. Heat strokes
b. Sun burn
c. Dehydration
4. Fire Hazards
a. Fire in electrical equipment

4.3 Generic Hazards for floating Solar

1. Drowning

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5. Hazards in Wind power plants
5.1 Specific hazards from land-based wind power

There are specific hazards typical to a land-based wind plant as mentioned below:

a. Fall from height.

b. Snake bite

5.2 Generic Hazards from wind power

1. Physical hazards
a. Trip and fall
b. Cut and bruises

2. Electrical hazards
a. Flash over and burn injury
b. Electrocution

3. Hazards arising out of hot weather

a. Heat strokes
b. Sun burn
c. Dehydration

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 6. HIRA for identified Hazards in Solar

A total of 12 hazards are identified for Solar area, as in Section 4. In following sections, HIRA and risk
mitigation has been worked out and guidelines have been suggested for effective mitigation.

SL Hazard Probability Severity

Associated Risk Control measures OxS Risk Level
No. identified (O) (S)

Solar module Vision problem

4.1a Use of sun glasses. 1 2 2 Low
panel glare Eye irritation

1. Spraying of Carbolic acid

2. Use of all required PPEs and
Snake bite Gumboots mandatory to all
Physical Injury/
4.1b workers engaged in grass 1 4 4 Medium
Insect bite fatality
cutting.
3. Chemical Weeding at regular
interval

1. Use of proper posture of body

Physical injury 2. Use of proper PPE
Back injury
like cut,
4.1c from lifting 3. poster for awareness during 1 2 2 Low
bruises,
solar panel lifting of heavy weight.
Fracture
4. Organize Awareness lecture.

1. Deployment of Trained
Fire due to
personnel.
stored packing Burn injury
4.1d materials, Dry Properties 2. Arrangement portable fire 1 2 2 Low
Grass after damage extinguisher.
grass cutting.
3. Use of required PPEs.

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SL Hazard Probability Severity
Associated Risk Control measures Risk Level
No. identified (O) (S) OxS
1. Regular inspection of work
area for different in elevation,
temporary obstruction,
Physical injury illumination, wet or slippery
4.2.1 a Trip and Fall 1 4 4 Medium
fatality surfaces.
2. Regular training
3. Use of appropriate PPE such as
Safety shoes, Safety helmet.
1. Use of hand gloves, safety
Cut and shoes, safety helmet.
4.2.1 b Physical injury 2 3 6 Medium
bruises 2. Posters for awareness.
3. Regular training

 Equipment 1. Permit to work to be obtained.

4.2.2a Flashover damage 2. Competent person for job. 1 5 5 Medium
 Burn injury 3. Use of Arc flash suit.

1. Competent person for the Job

Electrical shock
2. SOP should be followed.
4.2.2b Electrocution could result into 1 5 5 Medium
3. Permit to work to be
Fatality
obtained.

1. If possible, use cold water for

sprinkling generously to
 Unconscious lower body temperature
Heat strokes ness 2. Wear light weight cloths
4.2.3a 1 2 2 Low
 Nausea while working in hot weather.
 Headache 3. Victim to be shifted
immediately to nearest
hospital.

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SL Hazard Probability Severity
identified Associated Risk Control measures Risk Level
No. (O) (S) OxS

Skin peeling,
Sun burn Tenderness, 1. Drink more water.
4.2.3 b premature skin 2. Sun screen 2 1 2 Low
aging and skin 3. Full Cover the skin.
cancer.

 Diarrhea
1. Drink more water.
4.2.3c Dehydration  Vomiting 1 2 2 Low
2. Use of ORS (Oral Rehydration
 Fatigue
Solution)

1. Checking and preventing looseness

Fire in of contacts.
Physical injury
4.2.4a electrical 2. Selection and use of fire 1 2 2 Low
Property damage
equipment extinguisher to take timely action
and avoid secondary damage.

Use of lifebuoy to prevent from

4.3.1 Drowning Fall in water 1 2 2 Low
drowning.

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 7. HIRA for identified Hazards in Wind

A total of 09 hazards are identified for wind area, as in Section 5. In following sections, HIRA and risk
mitigation has been worked out and guidelines have been suggested for effective mitigation.

SL Hazard Associated Probability Severity

Control measures Risk Level
No. identified Risk (O) (S) OxS

1. Use of Work at height permit.

2. Use of fall protection PPEs,
Fall from Physical Horizontal & vertical lifelines, Full
5.1a height. injury body harness, Retractable fall 2 3 6 Medium
Fatality arrester.
3. Barricading the area below the work
activity.

1. Spraying of Carbolic acid

Physical 2. Use of all required PPEs and
5.1b Snake bite injury Gumboots mandatory to all workers 1 2 2 Low
Fatality engaged in grass cutting.
3. Chemical Weeding at regular interval

1. Regular inspection of work area for

different in elevation, temporary
Trip and Physical obstruction, illumination, wet or
5.2.1a Fall injury / slippery surfaces. 1 2 2 Low
fatality 2. Regular training
3. Use of appropriate PPE such as Safety
shoes, Safety helmet.
1. Use of hand gloves, safety shoes,
Cut and Physical safety helmet.
5.2.1b 1 2 2 Low
bruises injury 2. Posters for awareness.
3. Regular training.
Equipment 1. Permit to work to be obtained.
5.2.2
Flashover damage and 2. Competent person for job. 2 3 6 Medium
a
Burn injury 3. Use of Arc flash suit.

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SL Hazard Probability Severity
Associated Risk Control measures Risk Level
No. identified (O) (S) OxS
Electrical shock
1. Competent person for the Job.
Electrocuti could result
5.2.2b 2. SOP should be followed. 1 3 3 Medium
on into
3. Permit to work to be obtained.
Fatality
1. If possible, use cold water for
sprinkling generously to lower
 Unconscious
Heat body temperature
strokes ness
5.2.3a 2. Wear light weight cloths while 1 2 2 Low
 Nausea
working in hot weather.
 Headache
3. Victim to be shifted immediately
to nearest hospital.
Skin peeling,
Tenderness, 1. Drink more water.
5.2.3b Sun burn premature skin 2. Sun screen 1 2 2 Low
aging and skin 3. Full Cover the skin.
cancer.

 Diarrhea
Dehydrati 1. Drink more water.
5.2.3c  Vomiting 1 2 2 Low
on 2. Use of ORS (Oral Rehydration
 Fatigue
Solution)

Page 14 of 30
 Annexture -1: Operational Control Procedures (OCPs)
In following sections, six relevent OCPs for RE are mentioned which are formalized in NTPC’s yellow
book for safety (Electrical Mechanical hand book).These are for use of ladder, scaffolding, work at
heights, Lifting gears, electrical works and arc welding.
OCP - 01 Ladder
Ladders are gradually replaced by scaffolds, platforms, and trestles over the years. Today even in the
latest machinery, hydraulic ladders, scissors ladders, fork ladders are used extensively. However,
ladders are still being used by workers. Some of the common hazards are due to overreach, slip, electric
conductance, falls from ladders etc.

Sl. PROCEDURAL STEP YES/ REMARK

NO NO (IF ANY)
Before using any ladder check:
1. If there are any visible defects i.e. bends, dents, cracks and
completeness of components.
2. Suitability for work i.e. height according to work area, area of
placing i.e. in vicinity of electrical lines, on uneven surfaces,
1 slippery floor & stability of landing area etc.
3. Placement of feet with full contact on ground and also check if they
are free from dug soil, loose soil and oil/grease.
4. Check all ladders used in a scaffold system Once a week

The options for securing a ladder are as follows:

1. Tie the ladder to a suitable point, making sure both top and bottom
stiles are tied.
2
2. Where it is not possible to tie at top one person should hold the
ladder.

You should only use ladders or stepladders:

1. Built ladders not more than 6 M and rung spacing not more than
300mm.
2. Where they will not be struck by vehicles, by protecting them with
suitable barriers or cones.
3. Where they will not be pushed over by other hazards such as doors
or windows, by securing doors (not fire exits) and windows where
3 possible. If this is not possible, have a person standing guard at a
doorway, or inform workers not to open windows until they are told
to do so.
4. Where pedestrians are prevented from walking under them or near
them, by using barriers, cones or as a last resort, a person standing
guard at the base. The stiles of some ladders or the 1 in 4 rule (1 unit
out for every 4 units up).
5. Don’t use the top three rungs of a ladder.

Page 15 of 30
Sl. PROCEDURAL STEP YES/ REMARK
NO NO (IF ANY)
Do’s and Don’ts while using the ladders:
1. Avoid overreaching and not maintaining three points of contact i.e.
two hands and one foot or two foot and one hand should always
4 in contact with the ladder.
2. Avoid multiple persons accessing the same ladder at same time.
3. Avoid overloading it, the person and anything they are taking up
should not exceed the highest load stated on the ladder
Avoid makeshift arrangements at ladders i.e. placing wooden planks,
5
metal pieces below the ladder footings
Avoid side loading when working on stepladders such as side-on drilling at
6 walls, door. Steps of the ladder should face the work activity.

7 Avoid carrying material while ascending or descending the ladder

8 Avoid using metallic ladders in the vicinity of electrical lines
9 Avoid combining or jointing two individual ladders to access heights
10 Avoid using ladder as walk way or working platform.
Avoid accessing the ladder with shoes having the soles hanging off, have
11 long or dangling laces, or be thick with mud or other slippery contaminants
like grease, waste oil etc.
Avoid trying to move / relocate any ladder while user is at ladder.
Ladders used for access should project at least 1 m above the landing point
12
and be tied. Alternatively, a safe and secure handhold should be available.

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 OCP - 02 Scaffolding

A scaffold includes any temporary structure, on which or from which person perform work. All those
works that cannot be carried out conveniently from ground floor or with the use of ladders need
scaffold. Accidents happen either due to collapse of the scaffold or fall of working personnel from
scaffold besides the above, principal hazards are:
a) Slippage of unsecured ladders.
b) Use of unsuitable or faulty material.
c) Inadequate support of scaffold board, irregular platform width.
d) Omission of guard rails or toe boards.
e) Overloading of platforms.
As per SP: 2001, the design of scaffolding needs the same skill and attention as the design of any
permanent structure. The erector/agency shall ascertain from the manufacturer the safe load it can
carry. The scaffold shall be checked before use.
Sl. REMARK (IF
PROCEDURAL STEPS YES/ NO
NO ANY)
A scaffold shall only be constructed, taken down and substantially altered
1
by competent person/ trained workman.
Materials for construction of scaffolds shall be strong, free from defects and
2
shall be sufficient for the intended load.
Scaffolds shall be provided with safe means of access such as stairs, ladders,
3
and ramps.
Every scaffold shall be maintained in order, and once checked and
4 inspected, every part shall remain fixed or secured and on no account shall
any element be detached
1. At no time shall a scaffold be overloaded.

5 2. The load on the scaffold shall be evenly distributed as far as is

practicable, and in any case shall be so distributed as to avoid any
dangerous disturbance of the equilibrium.
1. Do not use ladders and make shift devices on top of scaffold to increase
the height.
6 2. While setting planks on platforms, it should overlap one foot on bearers
and should arrest properly. The planks of scaffold should overhang not
less than 6" on either ends but not more than 12".

Page 17 of 30
Sl. REMARK
PROCEDURAL STEPS YES/ NO
NO (IF ANY)
Before erecting scaffolds near any electrical lines or near exposed electrical
equipment, electrical supervisor must be consulted to determine what
7
special precautions are to be taken and also great care should be taken for
not making use of plant process pipelines / equipment for support purpose
All structures and appliances used as supports for working platforms shall be
8 of sound construction, have a firm footing and be adequately strutted and
braced to make them stable.
No working platform shall be used until its construction is completed and
the necessary safeguards properly fixed. Every working platform from
9
which a person is liable to fall a distance of more than 2m shall either be
closely boarded.
Planked or plated, or consist of open metal work. Every working platform
10 shall be of sound construction, adequate strength and free from patent
defect and shall be at least 60 cm in width.
Width of working platforms and gangways for passage of persons only shall
11 be at least 600mm and for gangways for passage of material at least 650
mm.
Every person using it shall be wearing a safety harness, which shall be
properly maintained. A notice in English and the local language shall be
12 displayed prominently: -“Every person riding on a suspended platform shall
wear a safety harness properly attached to an independent lifeline or an
appropriate anchorage.”
13 Each scaffold shall be inspected by a responsible person: - once every
7 days;
1. Before use.

2. After amendment. or

3. After exposure to weather conditions likely to affect its Stability.

14 A comprehensive checklist for inspection shall be, maintained for

recording the deficiencies, rectification measures, names of persons
responsible for taking action, proposed due date and completion dates.

15 Personnel shall watch for over-head clearance when making a scaffold.

casters shall be pinned. Locking Pins are in place at each joint.

Page 18 of 30
 OCP - 03 Work at Heights
Significant hazards are associated at working at height. Fall of Person and material are amongst the
severe most of them. Working at height may also lead to giddiness that might pave way for an
untoward incidence. Advance Planning before taking up works at heights can effectively safeguard
most of our interests.

Sl.
PROCEDURAL STEPS YES/ NO REMARK(IF ANY)
NO
Elevated work place:
1. A work place more than 2 m above the floor or ground shall be protected
on all open sides by guard – rails and toe boards complying with the
requirements of Sl. No. 2 of this operational control procedure.
2. Elevated work place will be provided with safe means of access and
1
egress.
3. Where necessary, persons employed at elevated work place or other
work place from where they might fall more than 2 m shall be protected
by means of adequate catch nets, sheets or platforms or be secured by
safety belts with the life line properly attached.
Use of Ladders
1. Ladder shall not be used as work platform.
2. Ladders shall be of good construction with no missing or defective rungs,
2 of sound material and of adequate strength for its intended use.
3. Ladder shall be erected on level and firm ground at an angle not
exceeding 75 deg or a 4 (heights) : 1 (base ) ratio.
4. Ladder to be secured at top when impracticable, firmly secured at base
Use of Safety Nets
1. When impracticable to provide adequate guardrails or platform access,
safety nets will be erected.
2. If guardrails, platforms and nets are impracticable, safety harnesses shall
be used to prevent injury due to fall of persons.
3. Safety nets if removed from access or movement of material shall be
3 replaced as early as possible.
4. Suitable and sufficient anchorage fittings shall be provided for safety
harnesses.
5. Safety nets and harnesses will be inspected and maintained.
6. Each person provided with harness shall wear it and keep it attached to
a rescue anchorage while working from a place where a fall of 1.5m or
more is possible.

Page 19 of 30
 OCP - 04 Lifting gears Crane/Hydra
There are Many hazards associated with lifting appliances and lifting gears such as fall of material,
injury to workmen working on the appliances and obstruction to movements.

Sl. REMARK (IF

PROCEDURAL STEPS YES/ NO
NO ANY)

General
1. Lifting appliances shall be installed under the supervision of a
competent person.
2. No structural alternation or repair shall be made on any part of
the lifting appliances that affects the safety without the
permission of the competent person.
3. Every lifting appliance being operated outdoors should have a
cabin for the protection of the operator against weather. All
panes should be intact to stop rainwater.
4. The maximum safe working load (SWL) shall be marked on the
1 lifting appliance.
5. No crane, hoist, winch or other lifting appliance, shall, except for
testing purposes, be loaded beyond the SWL.
6. Operators shall not leave lifting appliances unattended with
power on or with a load suspended.
7. During hoisting operations, effective precautions shall be taken
to prevent any person from standing or passing under the load
8. Lifting appliances (other than cranes, crabs and winches) shall be
tested and thoroughly examined by a competent person after
erection and thereafter tested every 5 years and inspected every
12 months.

Page 20 of 30
 REMARK (IF
Sl. NO PROCEDURAL STEPS YES/ NO
ANY)

Cranes
1. Every crane shall be tested and thoroughly examined by a
competent person after erection at site before put to use.
2. Every crane shall be fitted with:
a. Angle indicator
b. Plate inside the cabin showing safe working load at
2 various radius of operations (Load Chart).
c. Limit switches for boom and hoist Boom light, swing horn,
flashing beacon.
d. Safe Working Load (SWL) prominently painted on the
crane body.
e. ASLI (Actual Safe Load Indicator) or LMI (Load Mean
Indicator) which will be shown weather lifting load is
within the limit of SWL or not. (if possible)
Cranes shall not be used for the following operations:
1. To pull out fixed objects;
2. To drag objects or move vehicles or to lift an object with a
slanting pull whether out of radius or sideways reach.
3. To lift material during bad weather which likely to endanger its
stability.
4. To do lifting operations close proximity to electric power lines.
3 5. Swing area of the crane shall be barricaded and no one will enter
the area when the crane is in operation.
6. When more than one crane is required to lift or lower one load
i.e. Tandem Lifting.
7. Arrangements shall be such that none of the cranes will at any
time be loaded beyond its SWL or be rendered unstable in the
hoisting or lowering of the load. and
8. A competent person shall be specially appointed to co-ordinate
the operation of the cranes working together.

Page 21 of 30
Sl. REMARK
PROCEDURAL STEPS YES/ NO
NO. (IF ANY)
Test and examination shall be carried out by a registered examiner
when :
1. after each installation (or re-installation).
4
2. after major alternation.
3. after alteration of height of travel.
4. at intervals not exceeding 6 months.
Lifting gear used in connection with cranes and lifting appliances
1. A competent person shall inspect all lifting gear before they are
put in use.
2. Manufacturers shall issue a test certificate.
3. When not in use, ropes, chains and accessories shall be stored
under cover in clean, dry, well-ventilated places where they are
protected against corrosion or other damage.
4. Slings that show evidence of cuts, excessive wear, distortion or
other dangerous defects shall be withdrawn from use.
5. Wire rope slings shall be kept well lubricated.
5
6. Sharp bends of loads shall be padded by semicircular metallic
pipe pieces or rubber pads etc.
7. When multiple slings are used, load shall be equally distributed.
8. Where double or multiple slings are used, the upper ends of the
slings shall be connected by means of a shackle or a ring and not
be put separately into a lifting hook.
9. Eye splices and loops of wire ropes shall be provided with
thimbles.
10. Hooks shall be provided with a spring-loaded safety latch to
prevent the load from slipping.
11. Slings shall be colour coded periodically.

Records
1. Test and inspection certificates.
2. Details and License of operator.

Page 22 of 30
 OCP - 05 Electrical Works
Electrical Works call for attentiveness and knowledge of the work in addition to adoption of proper
Permit to-work system. It involves working at heights working under live sections of electric networks
and in close proximity of high voltages. The workers must be briefed about the minimum safe working
clearances that must be maintained from all live parts. Rubber gloves and Safety Shoes (Electrical
Grade) must be used at all times. All equipment must be earthed securely before commencement of
work.

Sl.
PROCEDURAL STEPS YES/ NO REMARK(IF ANY)
NO
All works on existing electrical installation to be carried out under Permit
1
To- Work
Only authorized and licensed electricians shall be allowed to work,
2 helpers will be restricted to only carry tools, materials and assist in
holding ladders and such like tasks.
General:
1. Only industrial type electrical fittings shall be used.
2. No loose connections shall be permitted which are the prime
factors in electrical fires.
3
3. Electricians will use rubber hand gloves while working on live
connections and shall stand on rubber mats.
4. Appropriate danger signs shall be installed outside electrical
installations and at DG rooms.
Switchboards:
1. All switchboards shall be free from obstructions and to be
barricaded.
2. Shall be fitted with signs of the supply voltage and DANGER.
3. All distribution boards (DB’s) shall be lockable.
4 4. Proper earthing from more than one earthing pit duly
interconnected shall be provided.
5. All DB’s shall be provided with 30 mA rating ELCB’s.
6. All switchboards and DB’s shall be provided with adequate
protection from rainwater i.e. canopy but not with polythene or
plastic sheets.

Page 23 of 30
Sl. REMARK
PROCEDURAL STEPS YES/ NO
NO. (IF ANY)

Conductors:
1. No bare conductor shall be permitted.
2. All wiring shall be supported on proper insulators and the
insulation of all electric portable cables shall be of heavy-duty
types.
3. Overhead lines shall be carried on wooden support of adequate
strength and at a minimum height of 10’ above ground level and
they should not tie with any conducting materials like binding, GI
wire.
4. Vehicle movement beneath these lines should be restricted by
displaying warning sign board
5. Only heavy-duty conductors shall be laid underground and their
route shall be properly marked by cable markers and also at
Cable lay out display.
6. If plug socket connections are required for connecting cables to
the mains, they shall be:-
a. Properly paired.
5 b. of water proof type.
c. of adequate design.

A single flexible cable shall supply:

1. All flexible cables shall be joined by means of a proper connection
or by appropriate industrial plugs and sockets.
2. Flexible cables shall not be used to lift a portable tool.
3. Only rubber insulated flexible cables shall be used.
Electrical Equipment:
1. Double earthing is must.
2. Control appliances shall not be installed at places where there are
flammable liquids/gases i.e. near to Diesel / Gas cylinder storage
yard.
3. Conductors shall be joined, branched or led into apparatus through
junction boxes, sleeves, bushings, glands or equivalent connecting
devices.
4. Hand lamps shall be equipped with metallic mesh protection for
glass and all current-carrying parts enclosed together with an
insulated handle.

Page 24 of 30
Sl. REMARK
PROCEDURAL STEPS YES/ NO
NO. (IF ANY)
Working Near Overhead Electricity Lines:
1. If possible, shutdown to be obtained from the concerned
authorities in writing.
2. Treat any O/H lines found anywhere as LIVE.
3. Working too close or causing damage to O/H lines is dangerous as
it can lead to flashover, explosion or fire.
7 4. Avoid working and erecting structures (e.g. scaffolding)
unnecessarily directly under the O/H lines.
5. In case of works if there is any doubt on the ground clearance,
voltage, safe working distance or working procedure, contact the
electricity supplier and clear all doubts before commencing work.
6. If there is any vehicle movement beneath the O/H lines a barrier
with safe clearance from O/H lines to be arranged.

Records to be maintained
1. ELCB inspection Report.
2. Electrical Inspection Checklist.
3. Work Permit.

Page 25 of 30
 OCP - 06 Hot Work (Arc Welding)

Sl. REMARK
PROCEDURAL STEPS YES/ NO
NO (IF ANY)
Welding set, cable and electrode should be confirmed to ISI and the same shall
1 be checked at regular interval for any defects.
The primary supply to the welding machine should be given through RCCB of
2 30mA.
Power supply cable should be properly connected through switchboard / isolator
3 by a trained electrician.
The welding machine should be efficiently grounded to protect against any
4 leakage of current
5 Welding cables with lugs should be properly tightened in the secondary terminals

A separate earthing cable should be drawn from the earthing lead of the welding
set to the nearest point of welding, so that current travels the least distance.
6 Open metal wire, strip or rod should not be used for earthing. Earthing should
not be given to pipe rack, column, Instrument supports or vessel containing
inflammable liquid or vapor.
7 Never change the electrode with wet hand or with wet hand gloves.
There are possibilities that gases and fumes produced during welding & cutting
8 may affect the respiratory system.
9 Local exhaust system and good ventilation should be provided at the work place.
10 The person associated with welding job should wear welding helmet.
11 Leather apron, chrome leather hand gloves, helmet, shoes, etc., should be worn.
For overhead welding, cover the ears so that the ear does not come into electrical
12 path.
To avoid over heating due to loose connection, Provide efficient connection of
13 cables by fixing lugs at ends and clamp it properly. All joints should be properly
insulated.
After completion of the job, cable should be arranged in a circular loop. During
14 welding & cutting it should not come in contact with sparks.
All flammable materials to be removed in the affected areas and at lower levels.
After completion of work, check if there is a any smoldering or burning around
15
or below.

Obtain PTW from SO/ SSI for welding on / inside any pressure vessels containing
16 or contained flammable/ explosive material.

Page 26 of 30
 Annexture -2 : Common procedure for electrical isolation
1. Required common precautions during isolation and normalisation:
1. Electrical Safety shoes, Hand Gloves of proper Voltage Rating, Helmet.
2. Working exclusively by trained and authorized person only.
3. Display of Shock treatment chart.
4. Ensure availability of insulation mat in front of the panel before starting of the job.
5. Ensuring the deployment of appropriate type of Fire extinguishers nearby.
2. ‘Isolation’ procedure of HT breaker:
1. First collect ‘Danger Tag’ for the concerned Drive/ Equipment to be isolated.
2. The Equipment/ Drive Name and Breaker/ Module location (Switchgear Name and
Panel Number) must be mentioned in ’Isolation Slip’/ ’Danger Tag’.
3. Ensure the concerned Breaker is in ‘OFF’ condition by looking at Flag as well as ’OFF’
indication lamp.
4. In case of Module, ensure ’OFF’ indication lamp is glowing.
5. In case of Breaker, make Panel DC ‘OFF’ by opening the upper compartment door and
then close the compartment door properly.
6. Now ‘Selector Handle’ position is to be changed from ‘SERVICE’ to ‘MOVEMENT’
position.
7. Insert the Breaker Rack-out Handle and rotate Anti- clockwise until ‘TEST’ position
Mark is visible.
8. Remove the Rack-out Handle and ‘Selector Handle’ position is to be changed from
‘MOVEMENT’ to ‘TEST’ position.
9. Note down the ‘Castle Key’ number and rotate Anti-clockwise to remove the ‘Castle
Key’.
3. ‘Normalisation’ procedure of HT breaker:
1. Match the Equipment/ Drive Name and Breaker/ Module Number as mentioned in
‘Normalisation Slip’.
2. Ensure Panel DC is in ‘OFF’ condition and check the Breaker is in ‘TEST’ position.
3. Insert the Castle Key in proper manner and rotate Clockwise.
4. Change the ‘Selector Handle’ position from ‘TEST’ to ‘MOVEMENT’ position.
5. Insert the Breaker Rack-in Handle and rotate Clockwise gently until ‘SERVICE’ position
Mark is visible.
6. Make Breaker Panel DC ‘ON’ by opening the upper compartment door and then close
the compartment door properly.
7. Now ‘Selector Handle’ position is to be changed from ‘MOVEMENT’ to ‘SERVICE’
position.
8. Ensure following Indication Lamps are glowing properly:
Page 27 of 30
 a. Breaker OFF
b. Spring Charged
c. Breaker in Service
d. Trip Circuit Healthy
e. Trip Relay Healthy
9. Ensure ‘Gas Pressure Low’ Relay (96) is not in operated condition.
10. N.B. During Breaker Rack-in/ Rack-out if any abnormal jamming is faced, concerned
EMD personnel must be contacted.
11. Always ensure before Breaker Isolation/ Normalization that Floor Insulation Mat is in
position.
12. Only Authorized and Skilled persons should handle the Breaker.
4. ISOLATION PROCEDURE OF LT BREAKER:
1. First collect ‘Danger Tag & Isolation Slip’ for the concerned Drive/ Equipment to be
isolated.
2. The Equipment/ Drive Name and Breaker/ Module location (Switchgear Name and
Panel).
3. Number must be mentioned in ’Isolation Slip’ & ’Danger Tag’.
4. Ensure concerned Breaker is in ‘OFF’ condition by looking at Flag as well as ’OFF’
indication lamp.
5. In case of Module, ensure the ‘OFF’ indication lamp is glowing.
6. Make Panel DC ‘OFF’ from the Upper Compartment.
7. Open the Isolation Cover in front of Middle Compartment by rotating the Knob anti-
clockwise.
8. Now to open the Flap Cover press the Emergency Push Button and simultaneously
rotate the Flap Screw Clockwise using a Screw-Driver.
9. Insert the Breaker Rack-out Handle and lift Upward, first ‘TEST’ position Mark will be
visible. Remove the Handle and reinsert it in the lower groove, on further lifting
upward, ‘ISOLATE’ position Mark will appear.
10. Remove the Rack-out Handle and Close the Flap Cover.
11. Close the Isolation Cover.
12. Remove the Castle Key by rotating it Anti-Clockwise.
5. NORMALISATION PROCEDURE OF LT BREAKER:
1. Match the Equipment/ Drive Name and Breaker/ Module Number as mentioned in
‘Normalisation Slip’.
2. Ensure Panel DC is in ‘OFF’ condition and check the Breaker is in ‘ISOLATE’ position.
3. Insert the Castle Key and rotate Clockwise.
4. Open the Isolation Cover in front of Middle Compartment by rotating the Knob anti-
Page 28 of 30
 clockwise.
5. Now to open the Flap Cover press the Emergency Push Button and simultaneously rotate
the Flap Screw Clockwise using a Screw-Driver.
6. Insert the Breaker Rack-in Handle and push downward, first ‘TEST’ position Mark will be
visible.
7. Remove the Handle and reinsert it in the upper groove, on further pushing downward,
‘SERVICE’ position Mark will appear.
8. Remove the Rack-out Handle and Close the Flap Cover.
9. Close the Isolation Cover.
10. Make Breaker Panel DC ‘ON’ from upper compartment.
11. Ensure Selector Switch (on Upper Compartment) is in ‘NORMAL’ position.
12. Ensure following Indication Lamps are glowing properly:
a. Breaker OFF
b. Spring Charged
c. Trip Relay Healthy
13. During Breaker Rack-in/ Rack-out if any abnormal jamming is faced, concerned EMD
personnel must be contacted.
14. Always ensure before Breaker Isolation/ Normalization that Floor Insulation Mat is in
position.
15. Only Authorized and Skilled persons should handle the Breaker.
6. ISOLATION PROCEDURE OF LT MODULE:
1. First collect ‘Danger Tag & Isolation Slip’ for the concerned Drive/ Equipment to be
isolated.
2. The Equipment/ Drive Name and Module location (Switchgear Name and Panel
Number) must be mentioned in ’Isolation Slip’/ ’Danger Tag’.
3. Ensure concerned module is in ‘OFF’ condition by looking at the ‘OFF’ indication lamp.
4. Make isolator OFF (At the time of module OFF, it makes sound).
5. Open the panel door cover & confirm isolator marking knob is in “0” position.
6. Properly lock the Power fuse with the Fuse Puller and remove the fuses.
7. Remove the control fuses (F106 & NLO).
8. If required remove fuse, F107 for space heater.
9. All power and control fuses are to be kept in safe place.
10. Close the module Cover properly.
11. Place the danger tag.

Page 29 of 30
7. NORMALISATION PROCEDURE OF LT MODULE :
1. First collect ‘Normalization Slip’ for the concerned Drive/ Equipment to be normalized.
2. The Equipment/ Drive Name and Module location (Switchgear Name and Panel
Number) must be mentioned in ’Normalization Slip’.
3. Ensure concerned module is in ‘OFF’ condition.
4. Open the panel door cover & confirm isolator marking knob is in “0” position.
5. Properly lock the Power fuse with the Fuse Puller and insert the fuses one by one.
6. Place the control fuses (F106 & NLO) at the proper fuse base.
7. Place control and space heater fuse.
8. Close the module Cover properly.
9. Make isolator “ON” (At the time of module ON, it makes sound).
10. Match the Equipment/ Drive Name and Breaker/ Module Number as mentioned in
‘Normalization Slip’.
11. Ensure Panel DC is in “OFF” condition and check the Breaker is in ‘ISOLATE’ position.
12. Insert the Castle Key and rotate Clockwise.
13. Open the Isolation Cover in front of Middle Compartment by rotating the Knob anti-
clockwise.
14. Now to open the Flap Cover press the Emergency Push Button and simultaneously
rotate the Flap Screw Clockwise using a Screw-Driver.
15. Insert the Breaker Rack-in Handle and push downward, first ‘TEST’ position Mark will
be visible.
16. Remove the Handle and reinsert it in the upper groove, on further pushing downward,
17. ‘SERVICE’ position Mark will appear.
18. Remove the Rack-out Handle and Close the Flap Cover.
19. Close the Isolation Cover.
20. Make Breaker Panel DC ‘ON’ from upper compartment.
21. Ensure Selector Switch (on Upper Compartment) is in ‘NORMAL’ position.
22. Ensure following Indication Lamps are glowing properly:
1. Breaker OFF
2. Spring Charged
3. Trip Relay Healthy
23. During Breaker Rack-in/ Rack-out if any abnormal jamming is faced, concerned EMD
personnel must be contacted.
24. Always ensure before Breaker Isolation/ Normalisation that Floor Insulation Mat is in
position.

Page 30 of 30