STANDARD OPERATING PROCEDURE (SOP)

Tata Steel, Meramandali

SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 1 of 11

Step Details of Activity Associated safety Responsibility Safe process (tools & Equipment, PPEs, Remarks / Reference
No (WHAT) Hazards/ Env. Impacts/ (WHO) Training etc.) (HOW) (Document &Records)
Quality Requirements
SAFETY: 1.Safety induction training must be given to
a) Unaware of the TSM incharge and contractor’s worker before
hazards of steel starting thejob & to be documented.
2.Ensure that all employees are trained on the
plant. relevantSOP and record to be maintained.
b) Unaware of the use 3.Ensure all the employees are trained on the
General Awareness ofPPEs workpermit system.
c) Unaware of Tata Shift in charge/ 4.Use following PPEs of TSM specified
1. steelsafety Concerned standardsduring job.
engineer/ • Safety helmet
standards. • Safety shoe
supervisor

P
d) Associated hazard • Safety goggles
tothe activities. • Fluorescent jacket

ENVIRONMENT: S O • Nose mask

5.All contractor workers’ PPE to be check by
TSM/Vendor supervisor during TOOLBOX

a) Dust Emission from

the RMHS Plant
l i d TALK.
6.Ensure daily tool box talk meeting at site in

a
eachshift.
7.Start the job only after getting the work permit
QUALITY:
V
a)Condition of Tools
&Equipment
(dulyfilled up & signed) and after completing tool
box in each shift-E Permit also allowed
8.Ensure that all the tools & equipment are as
perstandard
b)Condition of workers
PPE

O P
Prepared BY Checked By
1.Get Permit for Hot Work.

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024

V SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 2 of 11

Pre Job 2. Before starting the work, ensure the

Preparation Shift in workplace should be cleaned and free from
2. 1.Identify hazards. SAFETY: charge/ any slippery & flammable material like oil,
2.Take Hot workPermit 1.Slip,Trip,Fall Concerned wood, paper and cotton waste.
to Work 2.Electrical Shock engineer/ 3.Ensure Welding machine, Grinding
3.Deliver Toolbox talk 3.Arc radiation supervisor Machining &
regarding SOP Gas cylinders & cable (both welding, gas
4.Fire
5.Burn injury during cutting for good condition, properly. Also
Fabrication Work. ensure welding earth cable properly
earthed connection Lugs to be provided,
and ELCB to be connected.
4.Check PPES compliance for specific
work.
5.Toolbox talk about workplace and process
ENVIRONMENT:
•
•
Dust Emission
Air contamination due to
O P hazards / SOP.
Allow to work only experienced person.
4.Work should be done under strict
Spread of metallic toxic
fumes during welding.

d S supervision.
6.Mandatory PPE's must be used.
QUALITY:
Use proper tools and
a l i 7.Take necessary work permit by filling six
directional hazards.
8.If Work place is in height, use Elect.

V
approved PPE’s.
Hoisting equipment or pully rope for shifting
of welding machine and cable.
9.Use proper & certified tools tackles& sling
for lifting of material at height
10. Keep fire extinguisher available near
the hot work area & Fire blanket to prevent
falling spatters on other equipment or area.

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024

V
Printed on - 07-Mar-2024 SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 3 of 11

3. Area
Material lifting and Engineer/ 1. If Work place is in height, use Elect. Hoisting
shifting to joblocation SAFETY: Supervisor/ equipment orpully rope for shifting of welding
• Injury due to manual Sr. machine and cable.
shifting Technician 2.Use proper & certified tools tackles& sling
• Fall of material from for lifting ofmaterial at height.
height during lifting
can lead serious
accident
• Failure of Lifting
tools tackles during
work

EVIRONMENT: N/A
O P
QUALITY: N/A

d S
a l i
V

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024

V SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 4 of 11

Step Details of Associated safety Hazards/ Env. Responsibility Safe process (tools & Equipment, PPEs, Remarks / Reference
No Activity (WHAT) Impacts/ Quality Requirements (WHO) Training etc.) (HOW) (Document &
Records)
4. SAFETY: Shift in charge/ FOR WELDING MACHINE.
• Trip Concerned 1 Use all common PPEs like safety shoes, helmet,
• Electric shock engineer/ goggles, Leather hand gloves, nose mask, Jacket
• Burn injury supervisor & welding apron etc.
Connection and • Fire catching and spread of fire 2.Ensure body earthing of machine
Working of due to loose/weak Cable 2. Ensure welding machine equipped with proper
WeldingMachine. rated (30mA) RCCB &VRD.
• Exposure of heat causing heat
stroke. 3.Only trained person should allow to do elect.
• Connection.
4.Always use industrial socket equipped with

O P proper rating MCCB for plug in welding machine

with standard connector.
5.Use connection power cable of proper rating as

d S per machine specification.

6.power source should be as per rating of

ENVIRONMENT:
a l i welding machine.
7.Welding cable should be in good condition &
cable joint should be properly tight with lug.
• Dust Emission

QUALITY:
•
V
Use standard cable and all
8. Keep welding electrodes dry with proper Oven
Heating of Electrodes.
9. Remove any type of combustible material from
within 5 meters of the workplace
electrical equipment. 10. Keep fire bucket and extinguisher always
Cable must not bedamaged.

P
near at the working place.
• Use nose mask during the welding work.

Prepared BY Checked By
S
Review By
O
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
i d
Name & Designation- Mr. Sistu Bruhaspati
Head, RMHS/RMPP
l
Signature with Date:14.02.2024 Signature with Date:14.02.2024 a
Signature with Date:14.02.2024

V
Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024 SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 5 of 11

Step Details of Activity Associated safety Hazards/ Responsibilit Safe process (tools & Equipment, PPEs, Training Remarks / Reference
No (WHAT) Env. Impacts/ Quality y etc.) (HOW) (Document &
Requirements (WHO) Records)
5. Safety: FOR CUTTING SET
1. Lack of knowledge/training Supervisor/ 1. 1 Use all common PPEs like safety shoes, helmet,
aboutuse of oxy/fuel gas Skilled goggles, Leather hand gloves, nose mask, Jacket &
equipment. welding apron etc
2. Backfire of Torch cause
workmen
Connection and
2.Oxygen and LPG cylinder should be placed at least
seriousburn injury.
Working Gas 3. Bad condition of hoses &
distance of 3mtr.
cutting set. regulators cause serious 3.Only trained person should allow to gas cutting
injury. workwho well trained for-
4. Catching fire due to • The safe use of equipment.
carelesshandling of lighted • The precaution to be taken.
blow pipe.
5.Fire in hoses due to leakage or
splatter from work piece.
O P • The use of Fire extinguisher
• The means of escape, raising the fire alarm
andcall the Fire brigade
6.Explosion due to contact of oil/
Grease with oxygen

d S 4. Flash back arrester should be fitted in both

Torch andcylinder end.

ENVIRONMENT:
a l i 5. Ensure the fire extinguisher is in operable
condition.
6.Remove all inflammable materials from site to
• Dust Emission

QUALITY: V
• Use standard cable and all
avoid fire.
7. Prevent leakage from equipment. Check and
tight properlyjoints before light up the blow pipe.
electrical equipment. 8.Turn the gas supply off when not in use.
Cable must not bedamaged 9.Never allow oil/grease to come in contact with
oxygenvalves or cylinder fittings.

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024

V
Printed on - 07-Mar-2024 SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 6 of 11

Step Details of Associated safety Hazards/ Env. Responsibility Safe process (tools & Equipment, PPEs, Remarks / Reference
No Activity (WHAT) Impacts/ Quality Requirements (WHO) Training etc.) (HOW) (Document &
Records)
6. SAFETY: Shift in charge/ 1.Only trained person should allow to do
1. Electric shock by machine body . Concerned elect. Connection.
2..Fire in cable due to over engineer/ 2. Use connection power cable of proper
heating/short circuit supervisor rating as per machine specification.
Grinder 3. Health hazard during grinding work 3. Should be used proper rating of power
connection & due to Exposure of metallic source as per load with facility of MCCB.
grinding work 4.Burn injury by splatter, hot slags, 4. Power cable should be tightly jointed
hot metal chips during grinding . with proper insulation Use ISI marked
5.Injury due to hit by broken wheel. power cables and PPEs etc of reputed make
6.Fire hazard due to deposition of fire 6. Use leather hand gloves and shock proof
catching materials nearby

O P shoes during grinding work.

7. Use proper PPE’S, goggles / face shield
Environment:1. Throwing of used
/damaged grinding wheel part any

d S to protect face and eyes from hot flying

particles.

i
where a.Use proper wheel as per specific work

a l
2. Dust /fumes emission during
grinding of rusted /dusty item
(Never cutting by grinding wheel or grinding
work by cutting wheel)

V
Quality: Low quality equipment and
grinding wheel
ensure Proper mounting of wheel and
wheel guard.
c. Handle carefully and don’t run
continuous for long time.
d. doesn’t use expired /cracked/ badly worn
grinding.

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024

V
Printed on - 07-Mar-2024 SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 7 of 11

Step Details of Associated safety Responsibility Safe process (tools & Equipment, PPEs, Training etc.) Remarks / Reference
No Activity (WHAT) Hazards/ Env. (WHO) (HOW) (Document &Records)
Impacts/ Quality
Requirements
5. POST SAFETY: Area InCharge/ 1. Ensure that no person is working or in contact with anypart
COMPLITING OF
JOB
1. Lack of co- Area engineer/ of equipment.
1. Cancellation of ordination Supervisor 2. Ensure that all Manpower, tools, Tackles and foreign
Permit and between materials removed from working area & nearby area.
Restoration of multiple 3. Close work permit, get electrical shut down permit
Equipment. agencies for cancelled.
restoration. After resume power take trial.
2. Injury
/Equipment
damage due to
foreign material
left inside/in

O P
S
touch with any
moving
equipment.
Malfunctioning of

l i d
system.

V a

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024

V SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 8 of 11

Responsibility Remarks / Reference

Step Details of Associated safety Safe process (tools & Equipment, PPEs, Training etc.) (Document &
No Activity (WHAT) Hazards/ Env. Impacts/ (WHO) (HOW) Records)
Quality Requirements
SAFETY: Site safety personnel responsibility:
6. Emergency a) Fire Supervisor 1.Must ensure 100% employees gone throughfirefighting
preparedness b) Physical injury of and all training.
any workmen 2.Fire extinguishers must be in defined locations
employees of
during execution
the contractor 3.Must ensure for periodical audits of Firefightingdevices.
c) Road Accident
4.Must ensure to take corrective actions if found anyfaults
during inspection.
5.Must ensure for emergency siren/ hooter atunloading
EVIRONMENT:NA
point.
QUALITY:
1.The operational
O P
6.Must ensure emergency contact numbers display at
critical areas.
condition of Fire
extinguisher

d S Area working personnel responsibility:

1.The working personnel must ensure all emergency
2. Expiry date of the first
aid item

a l i preparedness equipment in place.

2.All workmen must follow the company procedure and
rules at work.

V 3.SOPs and Work instructions must be in place.

Emergency plan for example:
Workman1: can blow emergency siren
Workman2: call to first aider/ immediatesupervisor.
Workman3: Follow the necessary actions to bringthe
control on situation.
Needs to bring the situation under control.
If the location is at a little interior, keep a person as aguide,
who will escort the agencies to the exact same spot.
O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024

V SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 9 of 11

Mandatory PPE’s required for this job execution (double tick PPEs are mandatory for all)

List of
PPE’s

Safety Safety Shoe Safety Florescent Ear Plug Co Detector Dust Mask Positive
Helmet Goggles Jacket Isolation Lock
Leather hand
gloves

During Pre- Start-up

Job activity.
X

O P X X

During on Job

d S X X

a l i Any Other PPE

[Please Mention]

List of PPE’s
Full Body
Hardness
V Gas Welding Eye
Glass
Welding Eye Shield Fire Protection Shin Guard
Jacket
During Pre-Start-up Job X X X X
Activity
During on Job

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024 Printed on - 07-Mar-2024

V SOP Valid Till - 27-Feb-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/M/RMHS/RMPP/SOP-067 Effective Date 14.02.2024 REV. No. 00
SOP DESCRIPTION General Fabrication and Erection (Welding, Gas SECTION RMPP
Welding, Grinding, Material Shifting)
DEPARTMENT RMPP PAGE Page 10 of 11

O P
d S
a l i
V

O P
Prepared BY Checked By

d S
Review By
Name & Designation- Mr.K.S.Kaushik
Manager, RMHS/RMPP
Signature with Date:14.02.2024
Name & Designation- Mr. Anil Kumar Rout
Area Manager, RMHS/RMPP
Signature with Date:14.02.2024
Head, RMHS/RMPP

a i
Name & Designation- Mr. Sistu Bruhaspati

l
Signature with Date:14.02.2024

Printed By -Debasis Nayak(911964) Print valid till - 17-Mar-2024

V
Printed on - 07-Mar-2024 SOP Valid Till - 27-Feb-2025