Project Repot Safety

A
PROJECT REPORT
ON
EVOLUTION OF SAFETY AND

HEALTH STATUS IN NUCLEAR
POWER PLANT
Carried out for Partial fulfillment
OF
ADVANCE DIPLOMA IN INDUSTRIAL SAFETY

Carried out at
RAJASTHAN ATOMIC POWER PLANT

2006 - 2007
UNDER ELECTIVE PAPER VIII
(SAFETY IN CONSTRUCTION INDUSTRY)
SUBMITTED BY
SANDEEP SURANA
CONDUCTED BY
CENTRAL LABOUR INSTITUTE,
GOVERNMENT OF INDIA,
MINISTRY OF LABOUR
SION, MUMBAI 400022.
-i-
CERTIFICATE
This is to certify that MR.SANDEEP SURANA , a
student of Advance Diploma in Industrial Safety
(2006-2007)
being
conducted
by
Central
Labour
Institute ,Govt. of India, Ministry of labour, Sion,

Mumbai,
has
EVOLUTION
OF
prepared
his
SAFETY
AND
project
report
HEALTH
on
STATUS
IN
NUCLEAR POWER PLANT , at Rawatbhata , (via) Kota,

Rajasthan, under my guidance. The work is under the
elective Subject Safety in Construction Industry.
(A.K. BHATTACHARYA)
Dy.DIRECTOR I/C (SAFETY DIVN.)
AND
PRINCIPAL, CLI, SION MUMBAI
MUMBAI
DATE
- ii -
I acknowledge my whole hearted thanks to Shri C.P.Jhamb, Site Director RAPP for
providing me an opportunity to improve my knowledge in the field of safety mainly in
Nuclear Power plant Construction through project work at RAPP site.
I am highly grateful to Shri P.K Sharda, (C.S) & Shri V.K Jain, (O.S), and Industrial
safety section of RAPP site for their valuable support and co-operation.
I am extremely thankful to Shri A.K. BHATTACHARYA, Dy.Director In - charge,
Central Labour Institute, Mumbai for their most valuable guidance & co-operation
extended to me in carrying out this project work & grateful to them for giving me his
valuable time & knowledge from their expertise.
Finally I extend my thanks for the co-operation given to me by all section heads,
dept. heads, engineers, supervisors, workers and other employees for RAPP while
carrying out field work, observation & other information provided and are related to
this project work.
I would be failing in my duties if I would not be grateful to all the officers and staff of
the Central Labour Institute, who proved as a source of information and inspiration to
me while carrying out my project work.
Mumbai :
Date
SANDEEP SURANA
SUBMISSION
- iii -
I SANDEEP SURANA , a student of Central Labour Institute ,

for the course Advance Diploma In Industrial Safety during the
year 2006 2007 , humbly submit that , I have completed ,
from time to time , project work as described in this report and
study from 23rd October, 2006 to 22nd December, 2006.
This report, I have prepared by my own skill and have not
copied anywhere as per instructions and guidance of Shri. A.K.
Bhattachaya, Dy.
Director I/C .Principal,
Central Labour
Institute, Sion, Mumbai.

I have not copied the report or its appreciable part from any
other literature in contravention with academic ethics.
Mumbai :
Date
SANDEEP SURANA
INTERNAL EXAMINER
EXTERNAL EXAMINER
PREFACE
- iv -
This project report has been prepared in partial fulfillment of

the requirement of the Advance Diploma in Industrial Safety
conducted by CLI ,Sion , Mumbai 400 022.
The topic of the project report Evolution of Safety and
Health Status in Nuclear Power Plant at Rajasthan Site.
Accident Data has been collected from the RAPP-5&6 site for
past 3 years and study work carried out as per guidelines
proved by Central Labour Institute, Sion, Mumbai 400 022.
After all the detailed analysis an attempt is made to suggest
ways and means for improvement in safety status of nuclear
construction site.
Observations noted down accordingly recommendations are
given/suggested to follow safe system of work to reduce
accidents in future with a thought.
ZERO ACCIDENTS, BELIEVE IT, ACHIEVE IT
INDEX
CHAPT
CONTENTS
-v-
PAGE
ER
1
2
3
4
NOS.
INTRODUCTION
OBJECTIVES & METHODOLOGY
ABOUT THE RAPP-5&6 SITE
ACCIDENT DATA COLLECTION,
1-4
5-7
8-11
12-48
ANALYSIS AND CASE STUDIES

5
5.1
5.2
SAFETY MANAGEMENT SYSTEMS

HAZARD IDENTIFICATION
DISCUSSION ON GENERAL ASPECTS
5.3
5.4
RELATED TO NUCLEAR SAFETY .

SECTIONAL PROCEDURES
DUTIES AND RESPONSIBILITES OF
68-77
78-89
5.5
VARIOUS FUNCTIONARIES.
APPLICATION OF ACTS/RULES FOR
90-114
5.6
SAFETY .
EMERGENCY PREPAREDNESS AND
115-133
PROCEDURES
FINDINGS AND RECOMMENDATIONS
REFERENCES
ANNEXURES
134-151
152
153-157
6
7
8
- vi -
49-133
49-54
55-67
CHAPTER - 1
INTRODUCTION
Industrial development is the indicator of growth and prosperity on any country with
the rapid technological development, potential hazard arising from various
dangerous operations carried out in these industries is also increased hence the
number of major accident have also occurred and have had a major impact on
surrounding communities.
Safety guidelines are basically a management tool to have an effectiveness of the
safety program on a periodical basis, this is an useful technique for industrial
management where by they can obtain a systematic appraisal of the effectiveness of
safety management system.
Study of Evolution of Safety and Health Status in Nuclear Power Plant is carried
out at Rajasthan Site , as Project work for partial fulfillment of Advance Diploma in
Industrial Safety for the year 2006- 2007 being done at Central Labour Institute, Sion
(Mumbai).
I hope that it will be found useful by the management, employees & contractors to
establish and develop a good Safety, Health & Environment programme to achieve
ultimate goal of production with 100 % Safety and clean Environment .
I am thankful to Shri A.K. Bhattacharya (Dy.Director/Principal) Central Labour
Institute Mumbai, under whose guidance it is possible to bring out the project report
and also I, wish to thank industrial safety section and management of RAPP Site, for
their valuable support and cooperation.
I want to dedicate this project work to poor worker who is directly exposed to
hazards and in the absence of work force especially in India, it would not be possible
to achieve remarkable industrial development of the country.
-1-
SCOPE
Although the scope of Safety Management in Nuclear Power Plant Construction is
very wide. To concentrate on specific topics with in this project, following topics were
selected.
(A) Management Aspects.
Following elements were selected under this headings.
1
Health & Safety Policy.
Safety & Health Organization.
3
4
5
6
7
8
Accident Reporting, Investigation And Analysis.

Safety Inspection.
Safety Education and Training.
First Aid.
Occupational Health Centre.
General working condition.
Hazard Identification and Control.
(B)
Technical aspects
Under this heading following elements were selected.

1
Safe operating Procedures.
Work permit system.
Personal protective equipment.
Fire protection.
Emergency Preparedness.
Lifting Machines & Tackle.
Mobile Equipment and Vehicular traffic.
Access.
On site Gas Cylinder Storage area.
-2-
SAFETY POLICY OF RAPP 5&6

a)
The safety policy of Rajasthan Atomic Power Project- 5&6 is an expression of

the firm commitment of the management and the employees of RAPP 5-6
towards safety in all respects.
b)
The management of RAPP 5-6 has moral, social and legal obligation to
proven hazards which may lead to injuries or Occupational diseases to the
personal working at this site and impart training and knowledge about safe
working practices.
c)
The management of RAPP -5-6 firmly believes in the motto Production

must but safety first. The management considers it as its responsibility to
ensure that high standards for safety are maintained within the plant as well
as in the surrounding areas.
d)
There shall be a well-defined safety organization with well-defined powers.

Safety section shall advise and assist the management in prevention of
personal injuries and maintaining a safe working environment.
e)
Section heads and section in charge shall be responsible for maintaining safe
working conditions and practices in their areas of jurisdiction.
f)
Engineers and supervisors shall ensure that all workers, including the workers
of the contractors, working under them are provide safe working environment,
shall adhere to safe working practices and use necessary personal protective
equipment while working.
g)
All the employees of RAPP 5-6 shall make their sincere contribution for the
cause of their safety of their fellow employees. It is their responsibility to work
safely and set examples for others to follow.
h)
The contractor / sub contractors shall be responsible for the safety of their
employees.
-3-
SAFETY GOAL
Zero accident and zero injury through safe habits and safe environment.
The management and employees of RAPP 5-6 are firmly committed towards
achieving this goal.
Project Management of Rajasthan Atomic Power Project- 5&6, has moral, social and
legal obligation to prevent hazards to create safe working environment and guard
against all possible hazards and risks. Management of RAPP 5&6 is committed to
achieve its ultimate goal PROGRESS WITH SAFETY by adopting and
promulgating the safety policy as described below.
ABOUT NPCIL
Nuclear Power Corporation of India Limited (NPCIL) is a public sector enterprise,
wholly owned by the Government of India, under the administrative control of the
Department of Atomic Energy (DAE). It has been registered in September 1987 as a
Public Limited Company under the Companies Act 1956, with the objective of
undertaking the design, construction, operation and maintenance of the nuclear
power stations for the generation of the electricity in the pursuance of the schemes
and programmers of the government of India under the provisions of the Atomic
energy act.
NPCILS MISSION
The mission of NPCIL is to develop nuclear power technology and to produce, to
develop nuclear power technology and to produce nuclear power as a safe
environmentally Benin and economically viable source of electrical energy to meet
the increasing electricity needs of the country. Present nuclear power capacity of
NPCIL is 3690 Mwe. With the projects under construction at Kaiga 3-4 (2x220Mwe),
Kudankulam 1-2(2x1000Mwe) and RAPP5-6 (2x220Mwe), a total nuclear power
capacity of 6570 Mwe is planned to be achieved by December 2008 progressively.
-4-
CHAPTER - 2
OBJECTIVES & METHODOLOGY
Details of methodology adopted for carrying out the project study in principles of
safety in nuclear construction at Rajasthan Atomic Power Project-5&6 are given
below.
1. Applicable codes of standards, regulatory requirements and all safe
operating procedures were studied.
2.
Collected the following information and evaluated with the applicable

codes of standards and regulatory requirements.
3.
(A)
Safety policy and Safety manual.
(B)
Safe operating Procedures.
(C)
Emergency Preparedness Plan.
(D)
Fire emergency plan.
Collected the following data.

(A)
Brief description of the accidents in the past three years.
(B)
Accident statistics analysis of last three years.
(C)
Details of medical examination of all employees.
(D)
Record of testing and examination of all lifting machines and lifting

tackles.
(E)
Details of various training programmes being conducted.
(F)
Details of various safety promotional activities like National safety day

celebration, safety competition etc.
4. Studied all the minutes of meeting of Apex safety committee, safety fire
protection committee meeting, and sectional safety committee meeting.
5. Through inspection of the project was conducted to verify and supplement the
details on physical project conditions, work procedure followed by the workers
and identification of hazards.
-5-
OBJECTIVES:
To assess compliance of regulatory requirement and to identify deviations from

laid down procedures and standards.
To critically evaluate the effectiveness of the safety managements programmes.
To identify the fire, safety and health hazard and evaluate the effectiveness of the
procedures for controlling them.
To find out the deficiencies and efficiencies of the present work cultures,
procedures, practices and management system towards safety.
To recommend the various safety measures to be taken to improve the overall

safety performance of the project.
BASIC SAFETY PRINCIPLES AND OBJECTIVES:

DAE SAFETY PRINCIPLES/GUIDELINES:
Safety principles of DAE has been guided by the following statement by Dr. Bhabha,
which was in relation to radiation safety: Radioactive materials and sources of
radiations should be handled in the Atomic Energy Establishments, in a
manner which not only ensures that no harm can come to workers in the
establishment or any one else; but also in an exemplary manner, so as to set a
standard which other organizations in the country may be asked to emulate.
Similarly DAE industrial safety principles, policies, programmes and practices shall
be such as to be worth emulating by others.
The management of Rajasthan Atomic Power Project 5& 6 by adhering to the DAE
guidelines and other statutory requirements shall provide a safe working
environment for all those who enter or work in RAPP 5&6 and will contribute to the
health and welfare of its employees, through the programmes of industrial safety.
RAPP 5& 6 SAFETY PRINCIPLES:
It is recognized that any industrial activity involves potential hazard, but has firm
belief that with appropriate action all personal injuries can be avoided.
It is essential to train every employee so that;
i)
He works safely
ii)
He understands that it is to his advantage to work safely.

-6-
He must co-operate in working safely and behave in disciplined manner.

It is feasible to limit the property losses due to fire through its preventive measures.
Safety audits and inspections shall form an important part in RAPP 5&6 safety
programmes.
Comply with the provisions of central and state legislations, regulations, and rules
laid down by AERB and other statutory bodies.
SAFETY OBJECTIVES:
From the ideals set for the safety standards by Dr. Homi Bhabha guidelines
provided by the industrial health and safety policy of NPC. The RAPP 5& 6
management sets the following
Objectives for its safety policy.
Identification and elimination of risks before personal injury incidents and losses
occur.
Application of systematic safety training programmes to improve both managerial
and employees competence and safety consciousness.
Reduction of incidents which may result in injury, damage to machines, plant and
materials etc.
Consideration of safety matters in all activities so as to ensure safe working
conditions.
Comply with legal requirements of Central and State Governments, AERB,
Directorate of Health & Safety Group and other statutory bodies.
SAFETY AUDIT:
RAPP 5&6 management has firm belief that safety audit is essential and important
tool to ensure that entire RAPP 5-6 organization is in good shape.
Internal audits are carried out by internal audit team headed by CE (Mech) of RAPP
5&6. External audits are carried out by NPC Head quarter- Industrial Safety Group
and by AERB Inspectors.
-7-
CHAPTER 3
ABOUT THE RAJASTHAN ATOMIC POWER PROJECT -5&6 SITE.
Rajasthan Atomic Power Project unit 5&6 is situated at Rawatbhata, which is 70 km
from Kota (Distt. Chittoregarh). It is situated on the bank of river Chambal near
Rana Pratap Sagar Dam. It is third Nuclear Power Project of Twin Units of 220 Mwe
capacity at rawatbhata.It is eighth nuclear project in India.Rawatbhata is a nuclear
city of 6 units of nuclear power and a Heavy Water plant. Electricity from the project
will be distributed to rajasthan, U.P., Delhi, Haryana, Madhya Pradesh, Chandigarh,
J&K, (Northern Grid).
Natural Uranium (U238) is being used as fuel. Heavy water is being used as a
moderator and coolant. It is ideal site for the construction and operation of nuclear
projects because of its rocky soil, low density of population and availability of
resources. It is situated on the valley of Aravali hills.
Plant Layout :The main plant buildings are accommodated in approx 6000 m2 area (300 m x 200
m). Main plant building consists of two reactor buildings of 49 M out side diameter
situated at 83 M center to center distance. for each Reactor unit, Reactor Auxiliary
Building (including Emergency Control Room), Turbine Building, Diesel Generator
Building, Induced Draft Cooling Tower and Natural Draft Cooling tower have been
provided on a unitized basis where as the other building / structures such as Spent
Fuel Building, Service Building Annex, Control Building, Stack, Stack Monitoring
Room, Fire Water Pump Hose, Condenser Cooling Water Pump House, D 2O
Evaporation & Clean up Buildings, D 2O
Upgrading Plant and Switch Yard are
common to the two units.

Power Generation Process :The Reactor is of pressurized heavy water type using heavy water moderator, heavy
water coolant and natural uranium dioxide as fuel. The heat generated in the reactor
-8-
core is removed by heavy water coolant, recirculated through the core. The coolant
passes around the fuel elements and temperature is raised from 240
C at a
pressure of 87 Kg / cm2 to 293 0 C.

The coolant from the reactor channels flows to a common header known as reactor
outlet header the hot coolant is then carried from the out let header to steam
generators.
The heat energy from hot coolant (pressurized heavy water) is
transferred to light water in four steam generators to produce steam and the steam is
than directed to turbine via combined isolating and emergency stop (CIES) and
governor valves.
A maximum flow of 1330 Te/ hr of saturated steam with 0.26 % moisture content
from the steam generator to the HP Turbine is delivered at a pressure of 39.297 Kg /
cm2 (g) and a temperature of 249.66 0 C .
The HP Turbine consisting of 5 impulse stages. Steam after expanding through HP
Turbine is taken to Moisture Separator Reheater (MSR) at a pressure of 4.933
kg/cm2 (g) and a wetness of 11.0 %, where the steam is dried and reheated in two
stages i.e. in bled steam reheater and live steam reheater. From MSR the steam is
directed to a double flow LP Turbine through hot reheated pipes and LP Interceptor
Emergency and Governor valve at a pressure of 4.631 kg/cm 2 and a temperature of
232.9
C for further expansion, after which the steam condenses in a surface type
condenser.
The generator is directly coupled to the turbine, the excitation is provided by the
static Excitation System. The Hydrogen gas filled in the generator casing for cooling
the rotor of the generator. The maximum out put at the turbo generator terminals is
fixed at 235 Mw
Nuclear Power Corporation at present is having 3690 Mwe generating capacity, (3%)
of the total power generation in India.
The above generation is from the following stations:
1. RAPS 1-2 Decommissioning under progress (Unit - 1) &
1X150 Mwe (Unit
- 2).
-9-
2. RAPS 3-4 2X220Mwe.

3. NAPS 1-2 2X220Mwe.
4. MAPS 1-2 2X170Mwe.
5. KAPS 1-2 2X220Mwe.
6. KAIGA1-2 2X220Mwe.
7. TAPS 1-2 2X180Mwe.
8. TAPS 3-4 -2X540Mwe.
The following projects are under construction:
1.
RAPP 5&6-2x220Mwe,at Rawatbhata (Rajasthan).
2.
Kaiga3&4-2x220Mwe at Kaiga near Karwar (Karnataka state).
3.
KKNPP-2x1000Mwe at Kudankulam near kanyakumari (Tamilnadu state).
The industrial safety aspect of the operating plants and construction projects are
under department of Atomic Energy, which is regulated & inspected under the
preview of Atomic Energy Regulatory Board.
Independent Directorate of Health and Safety Environment and public awareness
exists in the headquarter of NPCIL, Whose director reports to CMD NPCIL. All
project sites stations, have industrial safety organization set up. The head of IS&F
directly reports to the head of the unit.
Overall Industrial safety and fire performance of NPCIL is very good and comparable
to international standards.
- 10 -
ORGANISATION CHART OF SAFETY SECTION, RAPP-5&6
Project Director
Head (IS&F)
Fire Protection Engg.

Safety Officer
Safety Officer
Safety Inspector
Safety Supervisor
- 11 -
Safety Inspector
CHAPTER 4
ACCIDENT DATA COLLECTION . ANALYSIS
&
CASE STUDIES
As per IS 3786 1983 lays guidelines for accident statistics and analysis, Accident
Rate ,Severity Rate, Incidence Rate , are major factors , which are to be considered
during accident statistics and analysis.
IMPORTANT DEFINATINOS AS PER IS 3786 OF 1983
ACCIDENT: An unintended occurrence arising out of and in the course of
employment of a person resulting in injury.
DAYS OF DISABLEMENT (MAN-DAYS LOST): In the case of disablement of a
temporary nature, the number of days on which the injured person was partially
disables, In the case of death or disablement of a permanent nature whether it be
partial or total disablement, man day lost means the charges in days of earning
capacity lost due to such permanent disability of death. In other cases, the day on
which the injury occurred or the day the injured person returned to work are not to
be included or man days lost; but all intervening calendar days (including Sunday
or ;days off ,or days of Plant shut down) are to be included. If after resumption of
work, the person injured is again disabled for any reason arising out of the injury
which caused his earlier disablement, the period of such subsequent disablement
also to be included in the man days lost.
MAN HOURS
WORKED: The total number of employees hours worked by all employees working
in the industrial premise. It includes managerial, supervisory, and professional,
technical, clerical and other workers including contractors labour.
LOSS TIME ACCIDENT (LTA): is an accident, which extends beyond the day of the
shift.
- 12 -
FORMULAE USED
Frequency Rate (as per IS 3786-1983)
Frequency Rate is one of the most important measures to know and judge the safety
performance of the industry. Frequency Rate (F.R.) is calculated as given below.
No. of Lost Time Accident (reportable)
Frequency Rate (F.R.) = Man hours Worked
= X 106
Severity Rate (as per IS 3786-1983)

Severity Rate is a measure to know the seriousness of the injuries. Severity Rate
(S.R) is calculated as given below:
Severity Rate (S.R.) =
No. of days lost due to reportable injury

Man hours Worked
= X 106
Incidence Rate (as per IS 3786 1983)

Incidence Rate is the ratio of number of injuries to the number of persons during the
period under review. It is expressed as the number of injuries per 1000 persons
employed. Incidence Rate (I.R.) is calculated as given below:
Reportable lost time Injury =

Incidence Rate (I.R.)
No. reportable loss time injury

= X 103
Average No. of Persons Employed
- 13 -
TABLE -1 ANALYSIS OF ACCIDENTS FOR THE YEAR - 2003

S.NO.
Category
Avg. No. of
Employees
Man
Hours
Worked
(in 1000)
2003
359400
Reportable
Injury
Man days
Lost
2003
01
2003
14
1.
Departmental
2003
150
2.
Employees
Contractor
2099
7437712
04
6108
3.
Employees
Combined
2249
7797112
05
6122
(Including 01 Fatal)
TABLE -2 INJURY RATES
S.NO.
Category
Departmental
Frequency
Rate
2003
2.78
Severity
Rate
2003
38.95
Injury
Rate
2003
0.108
Incidence
Rate
2003
6.66
Avg. Days
Charged
2003
14.00
1.
2.
Employees
Contractor
0.53
821.22
0.435
1.90
1527
3.
Employees
Combined
0.64
785.16
0.502
2.22
1225.00
Longest Accident Free Period: 324 days (11.08.2002 to 02.07.03)

TABLE - 3 ANALYSIS OF ACCIDENT AGENCYWISE 2003
Minor
Injury
2003
Serious
Total
Injury
2003
2003
01
01
01
01
00
01
Man
Day Lost
2003
45
21
14
1.
2.
3.
IS
Code
(B-1)
2062
2111
2421
4.
224
Electrical Installation
01
01
42
5.
213
Means of
01
01
6000
04
05
6122
S.NO.
Agency
Machine
Cranes
Floors
01
Transportation
Total
01
TABLE - 4 ANALYSIS OF ACCIDENT TYPEWISE 2003
- 14 -
S.NO.
1.
IS
Code
(B-5)
102
Type of Accident
Fall of persons on the
2.
124
same level
Struck by moving
3.
13
4.
5.
Minor
Injury
2003
01
00
Serious
Total
Injury
2003
2003
00
01
Man
Day Lost
2003
14
01
01
6000
objects
Caught in / between
01
01
45
16
Contact with electrical
01
01
42
115
current
Follow of objects
01
01
21
04
05
6122
during handing
Total
01
TABLE - 5 ANALYSIS OF ACCIDENT LOCATION OF INJURY WISE 2003
1.
2.
3.
IS
Code
(B-5)
455
432
445
4.
447
Fingers
5.
431
Back
Total
S.NO.
1.
2.
3.
Location of Injury
Ankle
Chest
Wrist
Minor
Injury
2003
01
Serious
Total
Injury
2003
2003
01
01
01
01
01
Man
Day Lost
2003
14
6000
21
01
01
45
00
01
01
42
01
04
05
6122
Environmental release:
Chlorine discharge to water body/day (kg)
: NA
Concentration of out fall (PPM)
: NA
Safety Surveillance:
(a)
Number of work permits cleared.
: 570
(b)
Number of safety related deficiencies raised.
: 88
(c)
Number of material handing equipment Inspected and tested: 12
(d)
Number of housekeeping Inspections carried out.
: 06
(e)
Illumination survey.
: 02
Enforcement Measures.
- 15 -
4.
5.
6.
(a)
Number of persons detected, who were not using required PPEs : 91
(b)
Number of defective equipment detected without safety provision: 42
(c)
Number of Electrical equipment without safety provision.
Fire safety and First Aid.

(a)
Number of fire incidents reported.
: 00
(b)
Number of fire drills conducted.
: 02
(c)
Number of persons trained in fire safety.
: 312
(d)
Number of persons trained in First-aid.
: 54
(e)
Number of fire safety inspections carried out.
: 06
Safety Promotion Activities.

(a)
Number of new posters displayed / replaced.
: 271
(b)
Number of safety competitions conducted.
: 08
(c)
Number of housekeeping competitions conducted.
: 01
(d)
Number of safety seminars conducted.
: 02
(e)
Number of video films on safety shown.
: 44
Safety Training.
(a)
Number of training programme conducted.
: 1,191
(Including tool box and safety induction training)

(b)
7.
Engineer
: 50
Supervisors
: 47
Technicians and helpers
: 17
Contractors.
: 7872
Any other information.

(a)
(b)
8.
Number of persons covered.
Medical Examination.
(i)
For height passes.
: 581
(ii)
For occupational health.
: 201
Details of Safety Audit/Internal Safety Audit.
: 03
Safety Committee Meetings.

(a)
Sectional Safety Committee Meeting.
- 16 -
: 24
: 30
9.
(b)
Apex Safety Committee Meeting.
: 04
(c)
Fire Protection Committee Meeting.
: 02
Details of Green Site Development.
: 171Nos trees
Planted
10.
Safety Award and Achievements.
11.
Emergency Drills.
: Nil
(i)
Fire Emergency Drill
: 03
(ii)
H2S Emergency Drill.
: 02
(iii)
Radiation Emergency Drill
: 02
TABLE - 6 ANALYSIS OF ACCIDENT FOR THE YEAR - 2004

S.NO.
Category
1.
Avg. No. of
Employees
2004
Departmental
221
Man Hours
worked (in 1000)
2004
531000
Reportable
Injury
2004
00
Man days
Lost
2004
00
2.
Employees
Contractor
3571
12164721
05
6044
3.
Employees
Combined
3792
12695712
05
6044
(Including 01 Fatal)
TABLE - 7 INJURY RATES
Departmenta
Frequency
Rate
2004
00
Severit
y Rate
2004
00
Injury
Rate
2004
00
2.
l Employees
Contractor
0.41
496.8
0.203
1.40
1209
3.
Employees
Combined
0.39
476.0
0.185
1.32
1209
S.NO.
Category
1.
Incidence Avg. Days

Rate
Charged
2004
2004
00
00
Longest Accident Free Period: 155 days. (04.01.2004 to 05.06.2004)

TABLE - 8 ANALYSIS OF ACCIDENT AGENCYWISE 2004
S.NO.
IS
Code
(B-1)
Agency
Minor
Injury
2004
- 17 -
Serious
Total
Injury
2004
2004
Man
Day Lost
2004
1.
2.
3.
2511
2134
239
Roof
Concrete miller
Shuttering panel
00
00
00
01
01
01
01
01
01
6000
20
07
4.
231
Explosives
01
00
01
10
5.
239
Unloading of MS rods
01
00
01
07
Total
02
03
05
6044

IS
Code
(B-5)
101
Fall of persons from
Minor
Injury
2004
00
2.
3.
131
115
height
Caught in an object
Fall of object during
00
01
01
00
01
01
20
07
4.
181
handling
Explosion
01
00
01
10
5.
133
Caught between
01
00
01
07
moving objects
Total
03
02
05
6044
S.NO.
1.
Agency
Serious
Total
Injury
2004
2004
01
01
Man
Day Lost
2004
6000
TABLE - 10 ANALYSIS OF ACCIDENT LOCATIN OF INJURY WISE 2004

S.NO.
1.
2.
3.
IS
Code
(B-7)
417
449
Minor
Injury
2004
Head
00
Upper limb unspecified
00
447
locations
Finger
01
00
01
07
Location of Injury
Man
Day Lost
2004
6000
20
4.
447
Finger
01
00
01
10
5.
454
Leg(lower leg)
01
00
01
07
03
02
05
6044
Total
1.
Serious
Total
Injury
2004
2004
01
01
01
01
Chlorine discharge to water body/day (kg.)
- 18 -
: NA
Concentration of out fall (PPM.)
: NA
Safety Promotional activity among general public: Environment day celebrated

on 5th June
2.
3.
4.
5.
6.
2004. Competition were also organized for employees.
(a)
: 1106
(b)
: 659
(c)
Number of material handling equipment inspected and tested. : 119
(d)
Number of housekeeping Inspections carried out.
: 13
(e)
: 04
(a)
(b)
Number of defective equipment detected without safety provision. : 66
(c)
Number of pending SRDs .
: 05
(d)
Number of SRDs implemented
: 654

(a)
: 00
(b)
: 06
(c)
: 529
(d)
: 30
(e)
: 20

(a)
: 555
(b)
: 12
(c)
Number of housekeeping competitions conducted.
: 01
(d)
: 01
(e)
: 72
Safety Training.
(a)
(b)

Engineer
: 1459
: 23
- 19 -
7.
Supervisors
: 73
: 107
Contractors.
: 19666
8.
(a)
(i)
For height passes.
: 533

(a)
: 70
(b)
: 04
(c)
: 02
TABLE - 11 ANALYSIS OF ACCIDENT FOR THE YEAR 2005

S.NO.
Category
1.
Avg. No. of
Employees
2005
Departmental
336
Man Hours
worked (in 1000)
2005
807000
Reportable
Injury
2005
00
Man days
Lost
2005
00
2.
Employees
Contractor
4113
13298257
07
18133
3.
Employees
Combined
4449
14105257
07
18133
*(Including 03 Fatal)
TABLE - 12 INJURY RATES
S.NO.
Category
1.
Departmenta
2.
l Employees
Contractor
Employees
3.
Combined
Frequency
Rate
2005
Severit
y Rate
2005
Injury
Rate
2005
Incidence Avg. Days

Rate
Charged
2005
2005
00
00
00
00
00
0.53
1363.5
0.72
1.70
2590.5
0.50
1285.5
0.64
1.57
2590.5
TABLE 13 ANALYSIS OF ACCIDENT AGENCYWISE 2005
- 20 -
IS
Code
(B-1)
229
Others equipment not
2.
3.
252
2134
else where classified

Open cast mixing
Hydra
4.
229
Doka shuttering
5.
2214
Gas cylinder
6.
2192
Mech conveyor
S.NO.
1.
Minor
Injury
2005
01
Agency
Serious
Injury
2005
2005
01
Man
Day Lost
2005
15
01
01
01
01
22
6000
02
02
6080
01
16
01
01
6000
05
07
18133
01
Total
02
Total

S.NO.
1.
IS
Code
(B-5)
114
Type of Accident
Minor
Injury
2005
01
ladders , piles of
133
(except flying or falling
4.
123
objects.)
Striking against
114
moving objects.
Collapse one of the
solider of doka
5.
6.
01
15
01
01
22
01
01
6000
02
02
6080
01
16
01
01
6000
05
07
18133
goods etc.
Caught between
moving objects
3.
Man
Day Lost
2005
Collapse of building
walls ,scaffolds
2.
Serious
Total
Injury
2005
2005
115
shuttering.
Fall of object during
101
handling.
Fall of persons from
01
height
Total
02
TABLE - 15 ANALYSIS OF ACCIDENT LOCATIN OF INJURY WISE 2005
- 21 -
1.
2.
3.
IS
Code
(B-7)
432
446
417
Chest
Hand
Head
4.
432
Chest
5.
433
Abdomen
6.
434
Pelvis
7.
42
Neck
8.
444
Fore arm
9.
432
Chest
10.
454
Lower leg
11.
411
Skull brain
S.NO.
Location of Injury
Minor
Injury
2005
01
02
Man
Day Lost
2005
15
22
6000
01
01
6000
01
01
80
01
16
01
01
6000
05
07
18133
01
Total
1.
Serious
Total
Injury
2005
2005
01
01
01
01
01
Chlorine discharge to water body/day (kg.)
: NA
Concentration of out fall (PPM.)
: NA
Safety Promotional activity among general public: Environment day celebrated

on 5th June 2005. Competition were also organized for employees
2.
3.
(a)
: 703
(b)
: 452
(c)
Number of material handling equipment inspected and tested. : 348
(d)
Number of housekeeping Inspections carried out.: 20
(e)
: 04
(a)
(b)
Number of defective equipment detected without safety provision. : 28
- 22 -
4.
5.
6.
7.
8.
(c)
Number of Electrical equipment without safety provision.
(d)
Number of pending SRDs .
: 25
(e)
Number of SRDs implemented
: 337

(a)
: 00
(b)
: 07
(c)
: 1237
(d)
: 230
(e)
: 49

(a)
: 190
(b)
: 12
(c)
Number of housekeeping competitions conducted. : 03
(d)
: 02
(e)
: 17
Safety Training.
(a)
(b)
: 1806
Engineer
: 125
Supervisors
: 101
: 20
Contractors.
: 27550

(a)
(i)
For height passes.
: 1340

(a)
: 79
(b)
: 04
(c)
: 02
- 23 -
: 28
FATAL ACCIDENT INVESTIGATION DATA
Fatal Accident Report RAPP-5&6, July-2003
1. Date & time of accident
: 3rd July, 2003, 0815 hrs.
Place of incidence
: Turbine Building Unit-6 area
Details of deceased
: Shri Laxman Ray, Aged 27 years, Fitter of sub

contractor of M/s HCC
2. Details of the incident
On 02/07/2003 at about 1930 hrs. a trolley loaded with reinforcement bars meant for
Control Building-6 was dispatched by rebar yard. As it was observed that
another trailer was being unloaded in that area, this trolley was parked with
blockade of
stones near Turbine Building-6 area. It was planned to shift the
- 24 -
material to the
required area i.e. control Building (CB) area adjacent to RAB- 6 on
03/07/2003.
On 03/07/2003, at about 0805 hrs. four workers of M/s S.C.Biswas, sub contractor of
M/s HCC namely Shri Dular Dastidar, Fitter, Shri Amarlal, Khalasi, Shri
Mukesh
Yadav, Fitter and Shri Laxman Ray, Fitter were instructed by their
supervisor Shri Ganen Sarkar to take the steel material from the trolley with
help of CB Tower Crane. Workers reached and saw that trolley was at TB-6
area which was away from the approach of CB tower crane. They discussed
among themselves and decided to take the trolley to the required place by manual
pulling. They thought that it would be easy for them to manually pull the trolley
with material instead of unloading and carrying the steel material for this distance
(Approx. 45m).
At about 0810 hrs. all the four workers started the work. Out of these four
workers, Shri Mukesh removed blockade of stones from rear wheels, Shri
Amarlal removed blockade of stone from left front wheel and blockade of stone
from front right wheel
was removed by Shri Laxman / Shri Dulal. After
removing the blockade, Shri
Laxman Ray (the deceased)
arrangement of the trolley and Shri
held the hooking
Mukesh, Shri Amarlal (at the left front
side) and Shri Dulal (at the right front side)

Pulled the trolley to take it forward. Trolley started moving and subsequently got
accelerated due to downward slope. All of them tried to stop the movement of the
Trolley but could not control. The weight of the trolley was 3500 Kg and weight
of material on it was 1250 Kg. The trolley had no brakes. Seeing this they
shouted for help and simultaneously all of them tried to run away from trolley.
During running Shri Mukesh and Shri Amarlal fell at the left side and Shri Dulal fell at
the right side
of the trolley. Shri Laxman could not escape and got trapped
under the left front wheel of the trolley and was run over by it. He was
seriously injured and was immediately taken to HCC First Aid Centre in a Tata
Sumo and from there to RAPS Hospital in HCC Ambulance. At RAPS Hospital
medical treatment was given but Shri Laxman Ray did not respond to the
treatment and he was declared dead at 0905 hrs. by the Doctor attending him.
- 25 -
3. Root cause of the accident:

1. Inadequate supervision and instructions.
2. The four workers should not have attempted to shift the trolley by physically
pulling it. It should have been shifted using a tractor / truck.
4. Recommendations to prevent such incidents:
1. On the job training should be given to workers about potential hazards involved in
material handling.
2. Adequate supervision is required when a job is done.
3. Before any job is taken up, the procedure to be adopted and hazards involved
should be discussed by the supervisor and the workers concerned (pep talk).
Fatal Accident Report RAPP- 5&6, June-2004

1. Name of the person
: Shri Nagendra Paswan S/o Shri Brahmadev Paswan
Age
: 32 years
Designation
: Khalasi (Helper)
Date and time
: June 12, 2004 at about 2055 hrs.
Place
: Service building Annexe of RAPP-5&6 under

construction
Cause of death
: Fall from 100 MEL to 95 MEL while moving out of work

place
2. Description of accident
On June 12, 2004 at about 0830 hrs. Shri D.K.Gupta, Foreman of M/s Uttam Chand,
sub
contractor
instructed
four
workers
viz.Shri Chandrajit, Carpenter, Prakash,
Carpenter, Harish, Helper and Nagendra Paswan, Helper to carry out shuttering work of
- 26 -
staging in SBA. Foreman informed that the work near grid 4 (N to S) at 100 MEL was
taken up after 1400 hrs. the two carpenters (S/Shri Chandrajit and Prakash), were
involved in fixing of wooden planks during the shuttering work of staging and the two
helpers (S/Shri Harish and Nagendra Paswan) were assisting the carpenters by
shifting / handling and placing the planks in position. All the four persons while
working at 100MEL used the required personal protective equipment like safety
helmets and belts. The Foreman was present outside the building during the job.
At about 2055 hrs. all the four persons have finished their work unhooked their
safety belts and were moving out of the working area for leaving the site. The
four persons were walking on a soffit beam (wooden) of 400 mm width having
projections of embedded parts at three locations in a span of first 6000 mm at
100
MEL. They should travel a distance of about 19000 mm ( 6000 mm straight 7000 mm
after right turn and another 6000 mm after right turn) to come out of the SBA
building Shri Prakash was the first man moving out followed by Chandrajit, Harish
and Nagendra Paswan walking one after another. Shri Prakash, Chandrajit and
Harish could cross the three locations of embedded parts and turned to the right path
for going out Shri Nagendra Paswan, who was the last person, in the process of
crossing the third embedded part projection lost his balance resulting into a fall from
100 MEL to 95 MEL (basement) floor. Shri Gutpa, Foreman who was present
outside the building saw him falling down. He immediately mobilized a crane with a
cage arrangement to lift the victim. The victim was rescued and moved to the HCC
First Aid Centre in a Ambulance located nearby. Shri Mukesh, Duty Compounder
saw the condition of the victim and directed the ambulance to RAPS Hospital. At
2100 hrs. Dr. Shailesh Kumar Duty Medical Officer at RAPS hospital recorded
that Shri Nagendra Paswan was brought dead. He reported that the victim
sustained lacerated head injury of 2 x 1 over occipital area, multiple abrasions on
face and limbs.
3. Observations :
3.1 Shri Nagendra Paswan was imparted with induction training on June 1,
2004 and with toolbox training on June2, 2004. The medical examination
and physical ability test to work at heights was conducted on June 5,
2004. Shri Paswan was qualified to work at height after that.
- 27 -
3.2 The soffit beam, which was used as a working platform is not safe. The width
of the beam was only 400 mm and has no guardrails. This doesnt
qualify as a platform under rule 46 ( 9) (b) of Atomic Energy (Factories)
Rules, 1996.
3.3 There is no practice of certifying the working conditions at a particular
location
before starting a new job.
3.4 There was no pr oper provision for anchoring of safety belts while
working / walking on soffit beam.
3.5 Safety nets were tied at few work spots. The place
where work was under
progress at the time of accident doesnt contain any safety net. Wide gaps wer
e observed within the net at few places and was sagging and sloping, which
is not safe.
3.6 Both the helmet and safety belt were intact. This indicates that safety
belts was unhooked and helmet might not have been on the head of
victim or loosely worn when his head struck the ground.
3.7 The contractor supervisor who was present at the time of accident at
site was
supervising concreting job at SFSB (Spent Fuel Storage Bay),
an adjacent building.
The supervisor designated is a safety steward and possesses only
M.A(History)
degree and has 6 months experience. He was not fully
aware of the jobs being done in SBA area. The committee was informed that
departmental supervision would be provided only when concreting job is
done. Effectively no departmental supervision is available after 2000 hrs.
3.8 On review of Job Hazard Analysis report of m/s HCC noted that hazards
involved while working at heights was identified but no preventive / control
measures were implemented.
3.9 The shuttering work started at 0830 hrs. and was allowed to continue
beyond
2030 hrs.(i.e the scheduled time) upto 2055 hrs. This might have
led the deceased to
hurry in leaving the work site for catching the bus
- 28 -
to home. The job should
not have been allowed to extend beyond 2030
hrs. by the sub contractor foreman.

4. Causes : Unsafe acts and Unsafe conditions :
4.1.
Acts which could have averted the accident :
4.1.1 Had the walking over the soffit beam been prevented.
4.1.2 Had there been proper supervision & instruction to stop the work at
the schedule time.
4.2
Conditions which could have averted the accident :
4.2.1
Had there been a proper walkway of adequate width free from

obstacles, guardrails and provision for lifeline attachment of safety
belt as per provisions of Atomic Energy (Factories) Rules, 1996 and
AERB Safety Guide on Works Contract.
4.2.2 Had there been a safety net along the soffit beam towards the
working / walking area.
4.2.3 Had the working conditions been examined by the Engineer-In-Charge
and declar ed fit for use.
4.2.4 Had there been proper hazard preventive / control measure implemented
as identified by Job Hazard Analysis earlier.
4.2.5
Had there been proper
supervision & instruction to stop the work at
scheduled time
5.
Underlying factors acts and conditions :

5.1
Acts
5.1.1 Knowledge
5.1.1.1 The victim was trained in safety and possesses working knowledge.
5.1.2
Ability
5.1.2.1 The victim was medically and physically examined and certified as
suitable to work at height.
5.1.3
Motivation
- 29 -
5.1.3.1 The job continued upto 2055 hrs and the victim might have been in a
hurry to catch 2100 hrs bus back to home.
5.2
Conditions
5.2.1.1 Proper walkway of adequate width free from obstacles and guard
rails as per provisions of Atomic energy (Factories) Rules, 1996 and
AERB Safety Guide on Works Contract.
5.2.1.2 A suitable pr ovision like running lifeline with anchor ing facility for safety
belt which would also serve as barrier / guard rail along the walkway.
5.2.2 Maintenance
5.2.2.1Maintenance of Safe Working conditions and fall preventive measures
through controlled procedures and instructions.
5.2.3
Actions of others
5.2.3.1 Enforcement of proper hazard preventive / control measures identified in

Job Hazard Analysis
5.2.3.2 Examination
of
conditions
of
walkways/
platforms
and
safety
measures by the Engineer In-Charge and declaring fit for use.

5.2.3.3 Availability
of
required
number
of
departmental
as
well
as
contractors safety personnel as per Chairman, AERB notification dated

July 8,2002.
6.
Recommendations to prevent recurrence :

6.1 Proper walkway of adequate width free from obstacles and guardrails as
per provision of Atomic Energy (Factories) Rules, 1996 and AERB Safety
Guide on Works Contract should always be ensured.
6.2
Conditions
of
walkways/
platforms
and
safety
measures
should be
examined by the Engineer-In-Charge for declaring fit prior to use.

6.3 Suitable pr ovision like running lifeline with anchoring facility for safety belt
should be made available.
- 30 -
6.4
Safe
Working
preventive
conditions
(like
walkways
platforms
etc)
and
fall
measures (like safety belts, guardrails etc) should be
ensured through controlled procedures and pr oper instructions.

6.5 Proper hazard pr eventive / control measures identified in Job Hazard Analysis
should be enforced.
6.6 Project management should ensure the availability of required number of
departmental as well as contractors safety supervisors as per Chairman,
AERB notification dated July 8, 2002 all the time. At present there is a
short fall of one departmental supervisor and 2 contractor (M/s HCC)
super visors which should be made up immediately.
6.7 No worker should work more than 12 hours on a particular day.
Fatal Accident Report RAPP-5&6, July-2005

1. Fact about the accident
Name of the deceased
: Shri Mangal Sharma
Age
: 22 years
Designation
: Helper
Date and time of accident
: 26th July 2005 at 0940 hrs.
Place of accident
: South Station Road near RAB-5
2. Description of accident :
On 26th July 2005, a worker of M/s HCC connecting water hosepipe on

South Station Road near RAB-5 building. One hydra of M/s IOTL (a piping
contractor) as returning back from control building on the Station road and moving
towards RAB-5. The said hydra hit the head of the person who was sitting in the
middle of the road for connecting the water hosepipe. The helmet worn by the
deceased caved in due to impact of the hit. The impact of the hit was so intense that the
deceased was moved two feet away form the location of the work.
- 31 -
The deceased was taken immediately to First Aid Centre and subsequently sent
to RAPS Hospital. He was further referred to Kota Hospital and was declared dead
on reaching Sudha Hospital, Kota.
3. Root cause :
1. Absence of an escort for the hydra movement, who ensures safe movement.
2. Hydra driver was not attentive towards road and did not realize that there could be
somebody in the middle of the road.
4. Recommendations :
1. As per standard road safety requirements, a barricade of nylon or cotton ribbon in
red colour should be installed around the work spot on the road or similar
access where movement is expected.
2. Escort should be provided for each hydra movement for safe movement.
3. Adequate nos. of road safety signs / boards etc. should be displayed along
roadsides.
Fatal Accident Report RAPP-5&6, August-2005
1. Fact about the Accident

: Shri Raman Prasad Shahu
Age
: 22 years
Designation
: Helper
Date & time of accident
: 12/08/2005 at 2150 hrs.
Place of accident
: Reactor Building#6, Inner Containment Wall
2. Description of the Accident
On 12th August 2005, three workers of M/s S.S.Roy, a sub-contractor of M/s

HCC were engaged in deshuttering job on outer face of Inner Containment wall of
RB#6. at 2100 hrs. of the day deshuttering of one of the panels on the outer face of
IC wall was taken over at a height of 121m elv. and three workers were on the
landing mat for this job. The DOKA structure is attached to its shuttering by plates
at six points. Each of the two solider of one unit is fixed with one conical nut to
an embedded bolt of 16mm dia in the containment wall having square thread. It
- 32 -
was reported that when the 6th plate was being removed, one of the soldiers came
out from the bolt along with the cone nut. Two persons including the deceased,
Shri Raman Prasad Shahu who had tied their safety belt to that solider and
standing on the landing mat (placed on the same DOKA structure attached to this
solider) fell down from a height of 121 m elev. to 99 m elev. in the annular space at
about 2150 hrs. The third person who tied his safety belt on the soldier of adjacent
shuttering panel was found hanging after the accident. All the three person were
rescued immediately with the help of tower crane and passenger cage and were
taken to RAPS Hospital by the ambulance.
The doctor at RAPS Hospital declared Shri Raman Prasad as brought dead. The
other two persons having abrasion / fracture were referred to a Hospital at Kota
for further treatment.
3. Root cause of accident :
i) Existing design depends on one single nut which is engaged with the
embedded bolt (of 16mm dia) in the containment wall for holding the soldier.
There is no second protection in this case, though working person are
standing on the landing mat supported on these soldiers.
ii) Inspection of threads of cone and certification for full engagement of the cone
with the embedded bolt was not done.
iii) Safety
belts
were
anchored
on
the
affected
soldier.
Procedure
for
deshuttering as practiced at other sites were not followed here. Anchoring of

safety belt to a stable structure (as done by third worker) was ignored.
iv) Safety net was not provided.
i) QA inspection of the thread of cones and bolts should be carried out
regularly and full engagement of the cone nut with the embedded bolt must be
ensured.
ii) Connect both inner & other shuttering panels by a sling or a chin during all stages
of handling and placement to prevent any inadvertent fall.
- 33 -
iii) Standard procedure for installation and removal of DOKA structure should
be followed at all NPCIL sites.
iv) Anchoring of safety belt to a stable, strong and independent structure must
be ensured and full harness safety belt should be used while working at height.
v) Qualified safety supervisors should be available with all major contractors.
vi) Job Hazard Analysis carried out by the contr actors should be reviewed by
departmental personnel and implementation of JHA recommendations must
be ensured.
vii) Working platform of at least 1 m width along with railings and safety net
should be provided at all works at height.
Fatal Accident Report RAPP-5&6, November-2005

: Shri Ajay Kumar
Age
: 25 years
Designation
: Welder
Date and time of accident : 27th November 2005 at about 0905 hrs.
Place of accident
: EOT Crane Girder at 122.8 m elev. in TB#5
2. Description of accident
On 27th November 2005, a crew of four workers of M/s S.S.Roy, a sub contractor
of M/s HCC was asked by their supervisor to remove the bottom support of
channel welded over the EOT Crane Girder at 122.8 m elev. in TB#5. All the four
workers including the deceased Shri Ajay Kumar accessed the said girder top
using a temporary iron staircase from 116m elev.
- 34 -
All the four workers after reaching the top the girder approached the channel pieces
placed near Grid column B-3. The deceased was last in the line when they were
walking over the girder of the width 0.5 m only. The deceased might have lost
his balance and as he had not anchored his safety belt with available lifeline, he
fell down from the girder top at 122.8m elev. into unloading bay at 100 m elev.
While falling his head struck with a gas cylinder lying on the ground. he was
immediately taken to HCC First Aid Centre at RAPP-5&6 site and from there to
RAPP Hospital where he was declared brought dead.
3. Root cause of the accident:
i) Non- anchoring of safety belt with lifeline available at worksopt.
ii) Removal of the railings before removal of channels and non availability of
safety net below the girder.
iii) Ignorance of safety rules on part of the deceased was observed as he
has been warned and penalized for violating the use of safety belt.
iv) The working area was not engineered for safe operation as the standard
platform of width >1 m was not provided for the job.
i) Railings on the working platform at higher elevation must be provided.
ii) In case it is not feasible to provide railings on the platform, safety net
must be put below the platform.
iii) Contractor worker must be briefed properly about work hazards and requisite
safety precautions. Workers who do not follow safety measure and avoid
use of PPEs should not be allowed to work.
- 35 -
Fatal Accident Report RAPP-5&6, May -2006

Date & Time of accident
: 27/05/2006 at 1645 hrs.
Location
: South Station Road, RAPP-5&6
Fatality
: One
Name of the victim
: Mr. Raju, Beldar S/o Shri Kodar a worker of

M/s New India Builders sub contractor of M/s
HCC Limited
Age / Sex
Address
: 22 years / Male
: Village:- Karanapada P.O:- Kawasha Distt. :Jhabua, (M.P)
2.0 DESCRIPTION OF THE ACCIDENT

On 27/05/2006 at about 1500 Hrs, Shri Bhanwar, Supervisor of M/s New India
Builders a sub contractor of M/s HCC has given instruction to Shri Raju to fill
- 36 -
the trolley, Shri Saitan to clean curb stones and Miss Leela to pour water on curb
stones. Shri Raju started filling the trolley. At about 1630 Hrs. Shri Raju went for
bringing water in a Chhagal. He brought the water & asked Shri Saitan & Miss Leela to
drink water. After drinking water, Shri Saitan & Miss Leela r esumed their work Shri
Raju went under the trolley to hang Chhagal in the lower rear portion of the
trolley. At about 1645 Hrs, while coming out he used lower portion of trolley as
support, causing backward tilting of the trolley. Shri Raju got trapped under the rear
portion of the trolley with his head inside & lower portion of the body out side.
The muck came out of the trolley and fell over the lower portion of the body of Shr
i Raju. He cried for help Shri Saitan, Miss Leela & other workers working in the
vicinity rushed to the accident spot and rescued him.
He was rushed to First Aid Centre RAPP-5&6 in a jeep of M/s EEPL. From First
Aid Centre, RAPP-5&6, he was shifted to RAPS Hospital in Ambulance. After giving
necessary treatment at RAPS Hospital, he was referred to Sudha Hospital Kota. At
Sudha Hospital Kota, he was declared dead.
3.0 ROOT CAUSE OF THE ACCIDENT
1. The trolley was parked without tractor for filling the material.
4.0 OBSERVATIONS
1. Tractor trolley was parked without tractor by the side of cur b stone on South Station
Road.
2. Activity of disposal of muck generated out of fixing of curb stone was in progress.
3. The muck accumulated over a length of 2-3 meters was only dump inside the trolley.
4. The victim was found lying with legs out side the trolley with muck over lower
portion of the body. Small quantity of muck is still available in the trolley.
5. Provision for filling the muck from both sides was available in the trolley.
5.0 RECOMMENDATIONS
1. While loading & unloading, tractor should be kept coupled with the tractor trolley.
2. Loading of tractor trolley from the rear side should be avoided.
- 37 -
ACCIDENT ANALYSIS
Accident Investigation and analysis is one of the means used to prevent
accidents. Accident Investigation and analysis is a defence in depth study
against hazards. Thorough investigation of all accidents which result in lost
time injury to determine contributing circumstances is a must. Accident that do
not result in personal injury (so- called Near Miss Accident) are warning,
they should not be ignored.
For purpose of accident prevention, investigation must be done for fact
finding, not fault-finding, otherwise it may do more harm than good.
Observations :1 All accidents data for the reportable accidents are available & properly
maintained by Industrial Safety section.
- 38 -
2. .All Near-Miss Accidents and accidents which are reported to industrial safety
section are investigated by safety section.
3. The monthly, quarterly and yearly safety performance report are prepared by
industrial safety group. These reports is a part of monthly progress report of
RAPP-5&6, & distributed to all Section Heads & sent to Head Office also.
4. All accident & near miss accidents are classified as per IS-3786-1983.
5. Directorate of Health, Safety, Environment and Public Awareness, NPCIL is
preparing monthly. Monthly, Quarterly & Yearly safety performance reports of
all units of NPCIL & submit these reports to Chairman Cum Managing
Director, NPCIL for appraisal of safety performance of over all NPCIL as well
as individual units of NPCIL. This help in comparing safety performance of
NPCIL units.
6. The accident data & analysis of accidents of last three years is given below:-
Analysis of Accidents for the period from 01.01.2003 to 30.09.2006

Sl.
No.
1.
2.
3.
Period
Average no. of
employees.
Man hours
worked.
Reportable
injuries.
2003
2004
2005
1st Jan. 2006 to

30th Sept.2006
2249
3792
4449
4742
7797112
1269571
2
1410525
7
11038290
05
05
07
02
4.
Fatal accident.
01
01
03
01
5.
Man days lost.
6122
6044
18133
6018
6.
Frequency rate.
0.64
0.39
0.50
0.54
7.
Severity rate.
785.16
476
1285.05
1616.05
8.
Injury index.
0.502
0.185
0.64
0.87
- 39 -
9.
Average days
charged / injury.
1225.00
1209.00
2590.05
1250.00
TABEL - NO - 17
ANALYSIS OF ACCIDENTS FREQUENCY RATE - 2003 TO 2005
FREQUENCY RATE (F.R.)

2003
2.78
0.53
0.64
Departmental Employees
Contractor Employees
Combined
- 40 -
2004
0
0.41
0.39
2005
0
0.53
0.5
TABEL - NO - 18
ANALYSIS OF ACCIDENTS SEVERITY RATE - 2003 TO 2005
SEVERITY RATE (S.R.)

Combined
2003
38.95
821.22
785.16
- 41 -
2004
0
496.8
476
2005
0
1363.5
1285.5
TABEL - NO - 19
ANALYSIS OF ACCIDENTS- INJURY RATE - 2003 TO 2005
INJURY RATE
2003
0.108
0.435
0.502
Combined
- 42 -
2004
0
0.203
0.185
2005
0
0.72
0.64
TABEL - NO - 20
ANALYSIS OF ACCIDENTS-INCIDENCE RATE - 2003 TO 2005
INCIDENCE RATE (I.R.)

2003
6.66
1.9
2.22
Combined
- 43 -
2004
0
1.4
1.32
2005
0
1.7
1.57
TABEL - NO - 21
ANALYSIS OF ACCIDENTS- AGENCY - 2003 TO 2005
IS CODE
2062
2111
2421
224
213
231
2511
2134
239
AGENCY
Machine
Crane
Floor
Electrical installation
Means of Transportation
Explosives
Roof
Concrete Miller
Shuttering Panel
- 44 -
NO. OF ACCIDENTS
1
1
1
1
1
1
1
1
1
239
229
252
2134
229
2214
2192
Unloading of MS rods
Other Equipments
Open Cast mixing
Hydra
Doka shuttering
Gas cylinder
Mech . Conveyor
TOTAL
1
1
1
1
2
1
1
17
TABEL - NO - 22
ANALYSIS OF ACCIDENTS- TYPE - 2003 TO 2005
IS CODE
101
TYPE
Fall of persons from height
NO. OF ACCIDENTS
2
114
Collapse of building walls ,scaffolds ladders , piles of

goods etc.
102
Fall of persons on the same level
124
Struck by moving objects
13
16
115
133
123
131
Caught in / between
Contact with electrical current
Fall of object during handling
Caught between moving objects
Striking against moving objects.
Caught in an object
1
1
3
2
1
1
- 45 -
181
Explosion
1
16
TOTAL
TABEL - NO - 23
ANALYSIS OF ACCIDENTS- - LOCATION OF INJURY - 2003 TO 2005
IS CODE
431
432
455
445
447
446
417
433
454
LOCATION OF INJURY
Back
Chest
Ankle
Wrist
Fingers
Hand
Head
Abdomen
Lower leg
NO. OF ACCIDENTS
1
1
1
1
3
1
3
1
2
- 46 -
411
449
42
1
1
16
Skull brain
Upper limb unspecified locations
Neck
Recommendations :1.
A procedure / system should be introduced for reporting of all near miss and
first aid accidents.
2.
It is to be made mandatory that all accidents / near miss incidents

including first aid injuries be investigated by line management
supervisors
engineers.
The
recommendations
based
on
the
investigation should be implemented at the earliest.

3.
A training programme may be organized for all line supervisors/

on accident investigation.
- 47 -
engineers
CHAPTER 5
SAFETY MANAGEMENT SYSTEMS
5.1 HAZARD IDENTIFICATION
COMMON HAZARDS AND THEIR CONTROL MEASURES AT CONSTRUCTION

SITES:
HAZARDS/ACCIDENTS
- 48 -
1.Trips, Slip
2.Fall from height
3.Fall of materials from height.
4.Fall from same level
4.Electric shock
5 Hit by speeding vehicle.
6 Hit by earth moving equipments
7 Fire.
8 Accidental actuation of tools.
9.Disconnection of pneumatic tools.
10 Dust/ fumes.
11.Handling solvents paints thinner etc.
12 Explosives/ Blasting
13 Heat / Radiation
14 Wrong postures of work etc.
15 Excavation work hazards.
16 Caught in between
CONTROL MEASURES:
TRIPS / SLIPS:
Good house keeping
Removing of unwanted material regularly
All temporary electrical connection should be routed above
or underground.
FALL FROM HEIGHT:
Use of scaffold
Safety belt.
Safety net
Fall arrestor
FALL OF MATERIAL FROM HEIGHT:
Use of safety net.

Safety sheet
Proper slinging
Proper stacking
- 49 -
ground (2meter)
ELECTRICAL SHOCK:
Use of two-core wire.

Use of three-pin plug.
Use of defect free cables portable tools and ELCB
Demarking, warning sign, working procedures.
Permanent panels.
HIT BY SPEEDING VEHICLE:
Observe speed limit.

Authorized entry of vehicle.
Observing traffic rules and signs.
HIT BY EARTH MOVING EQUIPMENTS:
Vehicle with proper condition of parking brake, service brake,

warning
light and horn while reversing.
Trained and licensed driver.
Barricading / flagging the area where such operations is going on.
Observe speed limit to 20Km/hr.

ACCIDENTAL ACTUATION OF TOOLS:
Tools with proper working switch
Trained Operator.
Prevent accidental disconnection of pneumatic tools.
DUST AND FUMES:
Ventilation.
Use of dust masks.
HANDLING OF PAINTS, SOLVENTS THINNERS ETC.
Proper storage
Use of gloves/ barrier cream/ masks
No smoking
Observe hygiene.
EXPLOSIVES:
Authorized storage
Authorized blaster
Keeping record
Lock / key.
HEAT RADIATION:
- 50 -
Face shield, Welding goggles, Gloves

Aprons.
WRONG POSTURE OF WORK:

Right method of material handling
EXCAVATION HAZARDS:
Means for rapid access and egress should be provided. All trenches 120 meter or
more in depth at site shall at all times be supplied with at least one ladder for
every 30 meter along the trench. The ladders shall extend from the bottom of the
trench to at least 1 meter above the surfaces of the ground.
Workers should not be exposed to danger of being buried by excavated material
or collapse of shoring. Measures to prevent dislodgement of loose or unstable
earth, rock or other material from falling into the excavation by proper shoring
shall be ensured.
Persons who are not engaged in excavation work shall be prevented from
approaching excavation work shall be prevented from prevented from
approaching excavation areas by placing warning signs and signals barricades,
etc. near the site of excavation.
Excavation material shall not be dumped with in 1.5 meter of the edges.
An excavated area shall have illumination level of at least 20 lux for night work.
Safety management at construction sites is a challenging job because of its high
accident-prone activities. Going by the statistics, the accident rates at
construction sites are almost 3 4 times more than that in the manufacturing
industry. The main factors responsible for higher risk at construction sites are:
Untrained,
Unskilled,
Uneducated,
mostly
speaking
non-local
temporary manpower.
Long working hours of manpower, working in harsh weather conditions.
- 51 -
language,
Difficulty in wearing Personal Protective Equipments (PPES) due to warm and

humid climatic conditions.
Continuously changing working situations requiring constant alertness of workers
and supervisors.
Keeping in view all the above things in mind and as a proactive approach towards
accident prevention this project on industrial safety is prepared with a view
towards safe work at RAPP 5&6 site, unit 5&6.
Observations :1.
All the hazardous area & hazards may arise during construction phase of
RAPP-5&6 are identified.
2.
The type of accident & types of hazards may arise during the construction
phase of RAPP-5&6 are given below.
IDENTIFICATION OF HAZARDS AT RAPP 5&6 CONSTRUCTION SITE

1.Hazards in excavation.
2.Hazards in blasting.
3.Dust hazard.
4.Noise hazard.
5.Hazards in welding & gas cutting.
6.Hazards in use of portable power tools.
7.Electrical hazard.
8.Fire hazard.
9.Hazard due to failure of centering, shuttering & shoring.
10.Hazard associated with vehicular movement.
11.Hazard in manual & mechanical material handling.
12.Hazard in valve in work at height.
13.Hazard in work in confined space.
14.Hazard in pickling work.
15.Hazard in shot blasting.
16.Other mechanical hazards.
3.
Following steps have been taken to prevent these hazards at
- 52 -
RAPP-5&6 site.
(a) Before starting any new activities job safety analysis / safety procedures
prepared by concerned supervisors / engineers & concurred
by safety officer,
after that work has been started with necessary precaution as mentioned in job
safety analysis / safety procedures.
(b) In addition to point (a) the following works are being controlled by work
permit system.
(1)
Excavation
(2)
Blasting operation.
(3)
Work at height.
(4)
Work in confined space.
(5)
Hot work in fire prone area.
(6)
Removal of guardrails / covering of the floor openings.
(c) A daily checklist system is used at RAPP-5&6 site. In this system each & every
morning before start of work concerned supervisor / engineer visit work site &
fill the checklist before start of job if any deficiency observed by them they write
in the checklist & these deficiency are corrected before starting of job.
Safety officer & staff during daily site visit go through filled checklist & suggest
additional precaution if required.
(d) Although engineering method are used to control of hazards. In addition to this
use of personnel protective equipment is mandatory at RAPP-5&6 site.
(e)
Safety Officer & staff are empowered to stop any job with the consent of
Engineer In - charge if not carried out safely.
4.
Internal safety audit once in six months & external safety audit by AERB
Inspectors (once in year) have been carried out at RAPP-5&6 site and
recommendations of these Safety Audits in being implemented on top priority.
5.
All modification even minor modification are being done at RAPP-5&6 site after
taking approval from the design groups of NPCIL Head Quarter.
6.
The following environmental monitoring equipments available at RAPP-5&6 site

for monitoring the environmental conditions.
- 53 -
a. Direct reading oxygen level monitor.

b. Direct reading explosives gas monitor.
c. Direct reading carbon mono oxide monitor.
d. Digital lux meter.
e. Digital sound level meter.
f. Direct reading H2S monitors.
Recommendations :1.
All steps taken to prevent hazards, which are given in observation No. 3,
should be followed strictly.
2.
Calibration of all monitoring equipment to be carried out time to time &

maintain all monitors in working order all the time.
5.2 -DISCUSSIONS ON GENERAL ASPECTS RELATED TO NUCLEAR SAFETY .

COMMON CONSTRUCTION ACTIVITIES AT RAPP 5& 6
Work at Heights:
- 54 -
Working at Height Including Roof work:

GENERAL PROVISIONS:
1.
It is necessary to guard against danger, where the height of the structure or its
slope exceeds that prescribed by national laws or regulations; preventive
measures should be taken against the fall of workers and tools or other object
or materials.
2.
Elevated work places, including roofs more than 2 meter or as prescribed,

above the floor or the ground should be protected on all open sides by
guardrails and toe boards complying with the relevant national laws and
regulations. Wherever guardrails and toe board cannot be provided; adequate
safety harness should be provided and used.
3.
Elevated workplace including roofs should be provided with safe means of

access and egress such as stairs, ramps or ladders complying with the
relevant national laws and regulations.
4.
If guard rails are not practicable, persons employed at elevated workplaces

including roofs from which they are liable to fall more than 2 meters or as
prescribed should be protected by means of adequate safety nets or safety
sheets or platforms, or be secured by safety harness with lifelines securely
attached.
ROOF WORK:
1. All roof work operations should be preplanned and properly supervised.
2. Workers who are physically and psychologically fit and have the necessary
knowledge and experience of such work should only undertake roof work.
3. Works on roofs should not be carried out in weather conditions that threaten the
safety of the workers.
4. Crawling boards, walkways and roof ladders should be securely fastened to a
firm structure.
- 55 -
5. Roofing brackets should fit the slope of the roof and be securely supported.
6. Where it is necessary for a person to kneel or crouch near the edge of the roof an
intermediate rail should be provided unless other precautions such as the use of
safety harness are taken.
7. On a large roof where work does not have to be carried out at or near the edge, a
simple barrier consisting of crossed scaffold tubes supporting a tubing guardrail
may be provided. Such barriers should be positioned at least 2 meter from the
edge.
8. All covers for the openings in the roof should be of substantial construction and
be secured in the position.
9. Roofs with a pitch of more than 10 should be treated as sloping.
10.For carrying out job on sloping roofs, suitable crawling boards or roof ladders
should be provided and it should be firmly secured in position.
11. During extensive work on the roof, strong barriers or guard rails and toe boards
should be provided to stop a person from falling off from the roof.
12.Where workers are required to work on or near roofs or other places covered with
fragile Material, through which they are liable to fall, they should be Provided with
sufficient suitable roof ladders or crawling boards strong enough, when spanning
across the supports for the roof covering, to support those workers.
13.A minimum of two boards should be provided so that it is not necessary for a
person to stand on a fragile roof to move a board or a ladder, or for any other
reason.
14.To prevent danger, suitable material such as steel wire mesh should be placed in
position before any roof sheeting of asbestos cement or other fragile material is
placed upon it.
- 56 -
15.Purling or other intermediate supports for fragile roofing material should be

sufficiently close together to prevent danger.
16.Where a valley or parapet gutter of a fragile roof is used for access, protection
against falling through the fragile material should be provided by covering the
adjacent fragile material to a minimum distance of 1 meter up the roof.
17.Building with fragile roofs should have a warning notice prominently displayed at
the approaches to the roof.
WORK ON TALL CHIMNEYS:
1. For the erection and repair of tall chimneys approximate scaffolding should be
provided. An adequate catch net should be maintained at a suitable distance
below the scaffold.
2. The scaffold floor should always be at least 65cm below the top of the chimney.
3. Under the working floor of the scaffolding the next lower floor should be left in
position as a catch platform.
4. The distance between the inside edge of the scaffold and the wall of the chimney
should not exceed 20 cm at any point.
5. Catch platforms should be erected over:
(a) The entrances to the chimney;
(b) Passageways and working places where workers could endanger by falling
objects.
6. For climbing tall chimneys, access should be provided by:
a) Stairs or ladders;
b) A columns of iron rungs securely embedded in the chimney wall;
c)
Other appropriate means.
- 57 -
7. When workers use the outside rungs to climb the chimney, a securely fastened
steel core rope looped at the free end and hanging down at least 3 meter should
be provided at the top to help the workers to climb on to the chimney.
8. While work is done on the independent chimneys the area surrounding fencing at
a safe distance should enclose the chimney.
9. Workers employed on the construction, alteration and maintenance, or repair of
tall chimneys should not:
a) Work on the outside with out a safety harness attached by lifeline to a rung,
ring or other secure anchorage;
b) Put tools between the safety harness and the body or the pockets not intended
for the purpose;
c) Haul heavy materials or equipment up and down by hand to or from the work
place of the chimney;
d) Fasten pulleys or scaffolding to reinforcing rings without first verifying their
stability;
e) Work alone;
f)
Climb a chimney that is not provided with securely anchored ladders or rungs.
g) Work on chimneys in use unless the necessary precautions to avoid danger

from smoke and gases have been taken. Work on any chimneys should not
be carried on in high winds, icy conditions, and fog or during electrical storms.
Minimum safety Precautions to be taken during Working at Height
All open sites of a structure above a height of 3.5 meters from which a worker might
fall and openings into which a worker might fall are adequately covered and
barricaded. Providing suitable fencing or railing of one meter provides every opening
in the floor of the building or in a working platform with suitable means to prevent fall
of persons or material.
- 58 -
Where barricades cannot be installed a safety net is being installed closed to the
level at which there is danger of fall. During erection of tall buildings and structures
above 3.5 meters heights, nylon nets are being provided to ensure safety of man if
there is a fall from height in case it is not possible to provide barricades.
Where a secured foot in impracticable safety belts / harness with secured anchorage
points are being provided at the working place as well access to the access path to
the working spot. All persons working at heights above ground or floor and exposed
to the hazard of falling down are using safety belts.
At elevated places, secure access and foothold are provided. Adequate and safe
means of access and egress are provided at all work places for all elevations. Means
of access, potable or fixed ladders ramp or stairway. The use of crosses braces or
framework, as a means of access to a working surface is not permitted.
Scaffolding or staging 3.5 meter above the ground floor are provided with guard rail
properly attached, bolted, braced and secured at least one meter height above the
floor and the platform.
Where the platform is more than 3.5 meter above the ground floor for working
standing on the platform, the width is maintained minimum as 1meter.
SAFETY IN SCAFFOLDINGS:
Every year nearly 100 fatalities and 10,000 injuries occur world over on scaffolds
despite numerous safety regulations aimed to prevent such incidents. If we work on
scaffoldings, we must be able to recognize the hazards associated with the type of
scaffolds we are using, and know what to do when we recognize something that just
isnt safe. There are a number of different scaffolds type, having different rules and
regulations surrounding their assembly, fall protection requirements, and inspections
procedures.
An estimated 2.3 million construction workers, or 65% of the construction industry,
work on the scaffolds frequently. Protecting these workers from scaffolds related
- 59 -
accidents would prevent 4,500 injuries and 75 deaths every year, at a saving for
employers of $90 million in work days not lost. In a recent BLS study, seventy two
percent of workers injured in scaffold accidents attributed to accidents either to the
planking or support giving way, or to the employees slipping or compliance with
Building and Other Construction Workers (Regulation of Employment and Conditions
of Service) act, 1996 and Central Rules, 1998.
TYPES OF SCAFFIOLDS:
There are 30 different types of scaffolds being used in construction industries all over
the world. But the most commonly use scaffolds all over the world are given in the
diagram attached with this portion of course material. In India the use is limited to
few numbers, like welded frame scaffold, bamboo/wooden scaffold, pole scaffold and
mobile scaffold.
SAFE WORKING--WITH SCAFFIOLDS:
Working with scaffolding requires your employees to be attentive to their actions and
the tasks at hand to work safely. There are numerous safety rules and regulations
they should follow. The following rules are generally accepted practices. When
viewing with employees, add any rules that are specific to your operations as well as
common sense rules we have learned through our experiences.
1.DESIGN
Footings
Scaffolding footings or anchorages must be sound and capable of carrying the
maximum load with out setting. Do not use unstable objects such as barrels, boxes,
loose brick or concrete blocks to support scaffolds or planks. Do not erect, move
alter or dismantle.
GUARDRAILS
Guard rails made of lumber must not be less than 50x100mm(or other material
providing equivalent protection). They must also be between 950mm and 1125mm
high, with a midriff of 25x150mm lumber (or other material providing equivalent
protection), and have a minimum 100mm high toe boards on all open sides and ends
on scaffolds more than 3000mm above the ground or floor. Supports must be at
intervals that do not exceed 2000mm. Ramps and walkways 1500mm above lower
- 60 -
levels must have guardrail systems. Where persons are exposed to falling objects
and are required to work or pass under the scaffold, there must be a screen between
the platform and the guardrail. It must extend
along the entire opening and support a down ward or horizontal force of a
minimum70Kgf (35Kgf on single point and two point adjustable suspension
scaffolds). The screens openings should be small enough to prevent Passage of
potential falling objects.
PLANKING
All planking of platforms must be over lapped (minimum of 300mm);or be secured
from movement. Scaffold planks must extend over their end support not less than
150 mm or more than 300mm unless secured or blocked by a guardrail. Planks must
be laid with their edges close together so that platform will be tight with no spaces
greater than 25mm though which tools or fragments of material can fall. Platforms
more than 350mm from the work surfaces must have the guardrail system and/or
employees
must
use
personal
fall
arrestor
system
(for
plastering
and
lathing+450mm). Work areas must be fully planked from the front uprights to the
guardrail supports. All planking must conform to the minimum requirements of IS:
3696(part-II).
ACCESS
An access ladder or equivalent safe access must be provided. Rungs must be a
minimum 200mm wide (internal prefabricated frames) and uniform distance between
rungs not greater than 300mm. Cross braces are not acceptable for scaffold access.
SUPPORT AND STABILITY

Scaffolds and their components must be capable of supporting without failure at
least four times the maximum intended load. Wire, synthetic or fiber rope used for
scaffold suspension must be capable of supporting at least six times the rated load.
The poles, legs or upright of the scaffolds must be plumb and securely braced to
prevent swaying and displacement. Scaffo9lds must be tied back vertically at a
height beginning at four times the scaffold width A then at a maximum every 8-meter.
- 61 -
(Scaffolds 1meter and wider). The horizontal distance of the ties is not to be
exceeded 9 meter.
PLUMB
When the first tier of scaffold has been erected it should be checked for plumb,
alignment and level. Where necessary, adjustments can be made using the screw
jacks. Settlements or slight variations in the fit of the components may require
additional adjustments as tiers are added to the scaffolds tower. Braces should fit
easily if the scaffold tier is level. If braces do not fit easily it is an indication that the
scaffold is out of plumb or out of alignment.
GENERAL
Employees must not work on scaffolds during storms or huge winds. Slippery
conditions on scaffolds must be eliminated before use. Any scaffold, including
accessories such as braces, brackets, trusses, screw legs, ladders, etc. Damaged or
weakened component must be repaired or replaced. Overhead protection must be
provided for employees on a scaffold planking must conform to the minimum
requirements of IS: 3696(part-II). Exposed to overhead hazards. The use of shore or
lean-to- scaffolds is prohibited. Materials being hoisted onto a scaffold must have a
tag line. Tools, scrap materials and debris must not be allowed to accumulate which
may cause a hazard.
2. INSPECTION
Scaffolds materials should be inspected before use for the following:
Damage to structural components
Damage to hooks on manufactured platforms
Split, knots and dry rot in planks
Delaminating in laminated venner lumber planks
Presence of all necessary of all necessary components for the job.
Compatibility of the components.

Structural components, which are bent damaged, or severely rusted, should not be
used. Similarly, platforms with damaged hooks should not be used. Similarly,
platforms with damaged hooks should not be used until properly repaired. Planks
- 62 -
showing damage should be discarded and removed from the site so that they cannot
be used as platform material factors. Generally, running sills longitudinally because
the sill has more contact with the ground will increase the bearing capacity.
3. USE
Base plates:
Base plates and adjustable screw jacks should be used whether the scaffold is
outside on rough ground or indoors on a smooth level surface. Base plates should
be centered on width of sill and nailed securely after the first tier has been erected.
Sills may run either across the width or along the length of the scaffold depending on
great condition & other.
Ties
Scaffolds must be tied in to a structure or otherwise stabilized- in accordance with
manufacturers instructions and the construction regulation- as Erection progresses.
Leaving such items as tie-ins or positive connections until the scaffold is completely
erected will not save time if it results in an accident or an injury. Moreover in most
jurisdictions it is prohibited.
FALL PROTECTION IN SCAFFOLD ERECTION:
Providing practical fall protection for workers erecting and dismantling scaffold and
shoring has been challenging for the construction industry. Workers erecting, using
or dismantling scaffolds must be protected from falling by using guardrails, travel
restraints, fall restricting systems, or fall arrest systems. For fall protection while
workers a scaffold as a work platform, the safest solution is guardrails, provided they
can be erected safely. Workers involved in erecting or dismantling scaffolds face a
different challenge. Erecting guardrails and using fall arrest equipments requires
specialized procedures since normally there is nothing above the erector on which to
anchor the fall protection system. Recognizing that development and innovation
continues in this field we are offering a sampling of fall protection techniques (fall
prevention and fall arrest) in the fig below. These generic examples allow individual
employers, trade groups, unions, and others to adapt the guidelines to their sitespecific needs and to trigger further development.
TRAINING
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Training must be provided by a person qualified in the subject matter and hazards
associated with the scaffoldings being used. Training must be given to employees
performing the work informing them of:
Electrical hazards
Proper scaffold use
Load capacities
Training must be given to employees involved in erecting, dismantling and inspection

by a competent person informing them of:
Hazards
Correct procedures
Loading capacities
We must retain employees because of:
Changes in the worksite
Changes in the equipment
Lack of proficiency.
MOBILE CRANES
The cranes are very widely used in industry for material handling. These are various
types and capacities. Material is handled by a crane along with other accessories
such as ropes, chain, links hooks etc. The safety of lifting operation includes
worthiness of these accessories also. The loads handled by crane are generally
heavy and may be odd in shape. The chances of accidents are more and potential
for injuries is to be severe in nature.
As per statutory provisions and to ensure in safe working, the cranes along with its
accessories are to be periodically tested and examined by a competent person. The
cranes are fitted with interlocks and limit switches. The operator is expected to
ascertain its worthiness at the beginning of the shift. Along with this it is also
necessary to check the working of all the movements and brakes.
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The load lifting capacity of crane or safe working load (SWL) should be prominently
marked on the equipment and necessarily followed. The load lifting capacity of a
mobile jib crane varies with the angle of its boom.
The arrangement of chain or wire rope and pulley is provided for lifting or carrying
load. With this arrangement some swinging of the load is unavoidable. Uncontrolled
violent swing may crush a person working on around or it may strike on material or
equipment and if crane is mobile it may even topple the crane. To avoid this lifting
and carrying operation should be steady and free of jerks. Loads if not tied properly
may fall off with swing in rope. This can cause crushing injury or even fatality. While
the load being moved, it is likely to hurt persons working on the shop floor. The
chances of such type of accidents are more. Since persons engaged in other
production activities may not be aware of Moving objects, they should be warned by
sounding a bell or hooter.
There are various types of cranes depending on the requirements of the job. Mobile
cranes are widely used at the construction site, which are described below:
TERMINOLOGY
It is essential to understand the terminology of mobile cranes that are:
JIB: the jib of mobile crane is the arm that lifts load by using one end (jib
fitting bracket) of the revolving superstructure as a fulcrum.
JIB LENGTH: jib length is a distance from the center of the jib foot pin to the
jib point pin.
JIB ANGLE: it is an angle made between jib centerline and horizontal plane.
OPERATING RADIUS: It is a horizontal distance from the rotating center to

the vertical line on the center of hook.
LIFTING CAPACITY: The maximum mass of the load, which can be loaded
onto a mobile crane (the mass of the hook, grab, bucketed. is also
included).
RATED CAPACITY: The maximum mass of a load can be hitched onto a

hook or grabbed by a bucket etc.
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LIFTING RANGE: It is a vertical distance between the upper and the lower
limit at which the load lifting attachment such as hook, as a grab
bucket, etc can be effectively moved.
BASIC MOTION:
The mobile crane can perform the following basic motions
Hoisting and lowering
Slewing
Jib luffing
Jib telescoping
Traveling (movement)
HOISTING AND LOWERING OF LOAD:
It is the vertical motion of raising and lowering a load by winding and rewinding the
hoisting rope.
SLEWING: it is rotational motion of the superstructure around is center of rotation.
JIB LUFFING: It is changing of the jib angle.
JIB TELESCOPING: It is changing of length of jib i.e. jib extension or jib retraction
TRAVELLING: Movement of the whole mobile crane.
SAFETY DEVICES FOR MOBILE CRANES
Mobile cranes are equipped with safety devices to ensure safe loading conditions.
The safety devices have such functions as sound alarm and automatically stopped
cranes operations when the operations exceeds specified performance levels. Some
safety devices protect the crane against the excessive force, and other prevents the
lifted loads from falling unexpectedly. Mobile crane operators must ensure proper
safety device function operating a crane.
Operators are also required to operate safety devices properly, and keep crane
operations within specified performance guidelines in order to operate cranes safely.
Do not operate mobile cranes when safety devices are malfunctioning or removed.
The following are the safety devices uses in mobile crane operations.
OVER WINDING WARNING & PREVENTIVE DEVICES
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An over winding preventive device and over winding warning device are to prevent
the hoisting wire top from breakage and protect a hook block and a top sheave from
possible damage due to over winding of the hook block.
If the hoisting wire tope is over-winding, the hook blockhead may hit and destroy the
jib, or the hoisting wire rope may be broken and drop the suspended load. To prevent
these accidents,
The mobile crane is equipped with such safety devices as to sound the alarm or as
to stop the machine automatically when the hook block is hoisted to the upper limit
and pushes the weight, which is connected, to the limit switch. The device which
sounds an alarm is called over winding alarm device and that which halts hoisting
operations by automatic power shut off is referred to a over winding preventive
device. These safety devices must be adjusted in accordance with legislative
requirement to operate usually and effectively. The clearance between the top of the
hook block and the lower of the sheave set on the jib tip must be periodically
adjusted according to the following descriptions so that the hook block may not strike
the sheave.
The over winding alarm device must be activated when the clearance stated above
is equal to 1.5 times rated lifting speed (m/s) and
The over winding preventive device must stop hoisting operation when the clearance
stated above is equal to 0.25 meters or more (0.05meters or more in case of a
directly acting type).
OVERLOAD PREVENTIVE DEVICE
The rated load of a mobile crane is specified according to its jib length and jib angle
(operating radius) and the extended width of outriggers and working range. With in
the rated load range the mobile crane has a large moment of stability on its counter
weights side as compared with an over turning movement on its load side. When
load acting on the Crane is going to exceed the rated load during jib lowering; a
magnitude of overturning moment approaches that of movement of Stability, and this
may result in the overturning of the crane. The mobile crane must therefore be
equipped with an over load Preventive device which sound an alarm and
automatically stops load hoisting. Jib lowering and jib extending when the
Overturning moment reaches the moment of stability.
The overload preventive device is in short, a safety device that prevents overturning
and resultant failure when a crane is loaded exceeding its rated capacity.
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5.3 - SECTIONAL PROCEDURE/PRINCIPLES ADOPTED AT RAPP5&6

SAFETY RELATED DATA
GENERAL
Under section 86 and 86A of the Factories Act, and AE (Factories) rules No. 86,
accidents and dangerous occurrences etc. are to be reported in the prescribed
Performa. Safety data needs to be collected and compiled to arrive at the trends in
the safety activities.
DATA ORIGIN
DGM (P&IR), RAPP-5&6 will submit a monthly summary indicating section wise staff
position, regarding RAPP-5&6 employees.
DM (IR) should submit a monthly
summary of contract manpower to ENC (F&IS).

Respective section heads will submit form ISF-8 to the safety section. This data
pertains to the contractor's employees, employed in the respective section.
Safety Section shall work out:
a)
Frequency rate.
b)
Severity rate.
c)
Incidence rate.
d)
Injury Index
e)
Industrial Accident Index, etc.
f)
For both Departmental and Contractor's employees.
DATA BASE:
RAPP-5&6 Safety Section shall maintain accident and loss statistics on
a) Monthly/ quarterly / yearly basis,
b) Summary of losses,
Based on accident and summary loss data, following analysis shall be done:
c) Accident analysis - Section wise
d) Accident analysis - Age group wise
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e) Accident analysis - Body part wise

f) Accident analysis - Agency wise (as applicable)
g) Accident analysis - Cause wise
h) Accident analysis - Place wise.
Accident data base management
Industrial Safety Section shall submit data base management for
accidents/dangerous occurrences to AERB on quarterly basis in the format of SHE
Report.
Yearly Summary of financial year
The ENC (F&IS) shall compile the data in the above-mentioned manner.
The ENC (F&IS) will send the copies of the Quarterly/ yearly report to.
a) Chairman, SARCOP, AERB,
b) Director (HSE & PA), NPC,
c) Chief Engineer, Industrial Safety Group, NPC,
1.SAFETY ADVICE NOTE PROCEDURE
GENERAL
Section 7-A of the factories act gives General duties of the occupier. On behalf of
the Project Director, who is the occupier under section 2(n-III), how many officials,
and help in maintaining safe working environment of the project?
One of the prime duties of the Safety officer is to advise the management by
contributing his experience, knowledge and judgment, so that various levels of
management can take appropriate decisions affecting safety.
This procedure of rendering such an advice.
1. The Safety Officer shall fill the form, ISF#-9 and send it to the various
management personnel, as safety advice note.
2. SECTIONAL PROCEDURES FOR TEMPORARY POWER SUPPLY TO

CONTRACTORS
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GENERAL
a) Number of contracts is being awarded by RAPP-5&6 at Construction Site and in
the colonies. In number of cases, because of the contract terms and conditions
electrical power RAPP-5&6 make supply available to the contractor.
b) Following procedure is applicable whenever RAPP-5&6 assumes the
responsibility to arrange power supply point available for the contract work.
c)
It shall be the responsibility of the contract awarding authority to comply with

this procedure.
3. SECTIONAL PROCEDURES PROCEDURE FOR REPORTING DANGEROUS

OCCURRENCES
GENERAL:
Under the Section 88-A of The Factories Act 1948 (as amended in 1987) and
provisions under Atomic Energy (Factories) Rules-1996, all dangerous Occurrences
as listed below are reportable:
Gas leakages,
Fall of equipments,
Bursting of line/equipment under pressure,
Natural calamities,
Electrical flash over,
Acid / alkali leakages,
Vehicle break failure,
Fall from height,
Any other incidents, whether causing bodily injury or disability or not, the concerned
section shall notify all such incidents to the Industrial Safety Section.
As soon as an incident as prescribed above takes place, the concerned

person shall immediately inform to:
a) Section Head / Engineer In-charge
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b) ENC (F&IS) / Safety Officer / Dy. C.F.O / FPE
ENC (F&IS) / Safety Officer / Dy. C.F.O / FPE shall immediately proceed
to the incident spot and shall
asses the situation and advise the concerned
people to take suitable action.
The concerned Supervisor/Engineer shall give details of incident it to the

Industrial Safety Section.
The Supervisor/Engineer shall submit his estimate of rehabilitation cost and

direct loss in term of rupees.
If ENC (F&IS) / Safety Officer feels that the incident was of a serious nature,
he shall put up his report to the Project Director.
If the incident was of minor nature, the ENC (F&IS) / Safety Officer shall put
up to the "Apex Safety Committee in its next meeting.
Recommendation of the committee shall be communicated to the

concerned section for implementation.
4. SECTIONAL PROCEDURES
REPORTING,
FOR
FIRE
INCIDENTS,
INVESTIGATION,
GENERAL
Section 38 of The Factories Act 1948 and Rule No. 42 of Atomic Energy (Factories.)
Rules 1996, describes the measures to be taken to prevent the outbreak of both
internal and external fire.
Fire incident reporting, investigation procedure is meant
to find out, whether
measures provided are inadequate, at the same time how to prevent the
reoccurrence of the fires in identical conditions.
FIRE REPORTING
As soon as any person notices fire he shall immediately notify fire station.
Indicating:
A) Name of person reporting
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B) Place of fire
C) Type of fire
FIRE CALL REPORT
Sub Officer on duty shall prepare "Fire call report in prescribed Performa and send a
copy of the same to the ENC (F&IS) / FPE.
INVESTIGATION
Fire Protection Committee shall investigate the fire incidents and submit a report in
shortest possible time giving,
a) Likely cause of fire,
b) Its prevention,
c) Recommendations to avoid fire incident,
d) List of jobs/modifications to avoid fire incident in future,
Report will be submitted to the Project Director through CCE.
LOSS ESTIMATE
Concerned Section Head will asses the extent of damage / cost of rehabilitation in
terms of Rupees and if it is more then Rs. 500/- then a report should be sent to:
a) ENC (F&IS)
b) FPE
c) Dy. C.F.O.
APEX SAFETY COMMITTEE
ENC (F&IS) / Safety Officer / Fire Protection Engineer shall put up fire report
summary to the Apex Safety Committee (ASC) in its next meeting. Apex Safety
Committee will consider the recommendations and approve the same with
modification if required.
IMPLEMENTATION
Recommendations of the Apex Safety Committee shall be communicated to:
a) Planning Engineer,
b) Section Head,
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IIt shall be the responsibility of the concerned section head to implement the
recommendations.
5. SECTIONAL PROCEDURES FOR SAFETY SUGGESTIONS, DEFICIENCY
GENERAL:
As per Section 7-A, 41-G & 41-H of The Factories Act 1948(as amended in 1987),
RAPP-5&6 Management gives an opportunity to all employees to participate in
safety management aspects, both at project level safety committee through
representatives and on individual basis in sectional level safety committees. This
procedure describes how a RAPP-5&6 employees can:
a.
Warn about imminent danger (Section 41-H)
b.
Participate and give suggestions regarding safety (Section 41-G).
c.
And compliance of the provisions of the section 7-A by RAPP-5&6

management.
REPORTING OF IMMINENT DANGER:

RAPP-5&6 employees can give his suggestion to improve safety in their Monthly
Sectional Level Safety Committee Meeting. Secretary of the Sectional Level Safety
Committee shall compile the minutes and note the suggestions.
He can also
express his apprehension of the imminent danger to the Safety Section for follow up.
The ENC (F&IS) will put up all those suggestions to Apex Safety Committee for
consideration & shall bring the imminent danger to the notice of the
Concerned Section heads through Safety Related Deficiencies Report.
The concerned Section Head shall take all appropriate action & implement the
desired action in the prescribed period of time & send the Implementation Status
to the Safety Section.
6.SECTIONAL PROCEDURES FOR SAFETY REFRESHER TRAINING.

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GENERAL:
Section 7-A of the factories act, describes general duties of the occupier. It is
obligatory on the part of the occupier to provide information, instructions, and training
to RAPP-5&6 employees.
Section 111- A described "right of workers under sub section (II). Workers have a
right to get trained, either locally or through training institutes imparting
training in
safety aspects.
Initial training & subsequent refresher training will be arranged by ENC (F&IS) /
Training co-coordinator.
The Training Co-coordinator shall contact various Government, Semi
Government,
private organizations, which are imparting training in safety and arrange
their
faculty to come to RAPP-5&6 and give refresher training.

The Training Co-coordinator shall provide a list of trained personnel to the safety
section for records.
7.SECTIONAL
PROCEDURES
FOR
PERSONNEL
SAFETY, PROTECTIVE
EQUIPMENTS
GENERAL:
The Factories Act 1948 (as amended in 1987) and the rules framed under it by
AERB, i.e. Atomic Energy (factories) Rules 1996, suggests various protective
equipments / instruments to be used to achieve personal safety. Rule 57 describes
the quality of the personal protective equipments and under Rule 43 framed under
section 40B, it is the duty of the ENC (F&IS) / Safety Officer to ensure compliance of
Rule 57.
This procedure is written to ensure compliance of the above.
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EQUIPMENTS:
The Safety Officer shall examine the various provisions of the act, rules, etc. and
prepare a list of:
a) Safety equipments,
b) Personnel protective equipment (PPE),
c) Safety instruments.
SPECIFICATIONS:
The Safety Officer will refer the specifications for each of the equipment, taking into
consideration relevant Indian Standard or various standards of exporting Countries
or AERB guide for Peps.
SAFETY CHECKS:
As safety equipments are generally required in emergency, they must perform this
function. Therefore whether such equipment is in stores or any other place, the ENC
(F&IS) / Safety Officer shall ensure that theses equipments are inspected &
maintained in working order.
8.SECTIONAL
PROCEDURES
FOR
REQUEST
FOR
EXEMPTION
FROM
PROVISION OF AE (FAC) RULES 1996.

GENERAL:
The AERB, AEC has framed "Atomic Energy (Factories) Rules
1996" These rules
are to be complied with by All the units of DAE and its undertakings.
While framing the rules, it was visualized by AERB, that it might not be possible to
comply with some of the rules, by some of the DAE units. Therefore, provisions have
been made under the various rules to request appropriate authority for the
exemptions from the provisions of the rules.
Factories Act has defined "Occupier" as the person who has ultimate control over
the affairs of the factory and in cases where factories are owned or controlled by
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the central Government, the persons or person appointed to manage the affairs at
the factory by the central Govt. is deemed to be the occupier.
This procedure is meant for obtaining exemptions from the provisions of the rules,
where there is provision in the rules for such exemptions.
INITIATION OF EXEMPTION REQUEST:
Section Head (S) can suggest ENC (F&IS) / Safety Officer or the Safety Officer on
his own can send a "Safety Advice Note" to the Project Director for obtaining
exemptions from the provisions of the rules.
The Project Director, RAPP-5&6 will approve to proceed with such a request.
The ENC (F&IS) / Safety Officer will fill Prescribed Performa and send it to the
Project Director for Signature.
The same request
from
will
be dispatched to
the
appropriate authority, AERB etc.,
the Project Directors Office, the appropriate authority of AERB takes the
decision on such a request and communicates it to the Project Director.

The Project Director will send a copy of the above-mentioned communication to the
ENC (F&IS).
ENC (F&IS) will communicate the contents of the communication received from the
appropriate authority/AERB etc. to the concerned section heads, and update the
records, accordingly.
9.SECTIONAL PROCEDURES FOR OBSERVED VIOLATION OF REGULATION
Various Acts are being passed by the parliament, applicable to the whole country;
Factories Act was passed in 1948. Thereafter, there were a few amendments to it.
The amendment of 1987 is very important. Taking into account the provisions of The
Factories Act, AERB has framed "Atomic Energy (Factories) Rules" - 1996.
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The provisions of the various acts and the rules framed under these needs to be
adhered strictly. Any deviation observed by the safety section, shall be brought to the
notice of the concerned section head, summary of the observed violation will be
discussed in Apex Safety Committee meeting and copy of the summary will be sent
to the Project Director, RAPP-5&6
INSPECTION:
ENC (F&IS) / Safety Officer / Inspector will carry out routine safety inspections. The
concerned inspectors in the safety section shall report any violation of the
regulations such as provisions of the acts, standards, codes, rules, etc.
The ENC (F&IS) / Safety Officer shall ensure that he is satisfied with the alleged
violation of the regulation & unsafe condition / Act.
The ENC (F&IS) / Safety Officer shall bring the violation to the notice of the
concerned Section Head through Safety Related Deficiencies Report & in Sectional
Safety Committee Meeting, the concerned section head shall take the appropriate
action & implement the desired action in the prescribed time period and send the
implementation status to ENC (F&IS).
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5.4-DUTIES AND RESPONSIBILITIES OF VARIOUS FUNCTIONARIES

RELATED TO SAFETY AT RAPP-5&6.
Duties of Head (F&IS): - (RAPP 5&6)
1. He shall advise and assist the management in fulfillment of its obligations,
statutory or otherwise concerning prevention of personnel injuries and
maintaining safe working environment at the site.
2. Will act as a member of Apex Safety Committee Meeting.
3. Will liaison with HQ, AERB, SARCOP, and State Govt. Official.
4. Will investigate fatal / serious accident.
5. Will render the advice regarding PPEs required for carrying of hazardous work.
Duties of ENC (F&IS): ENC (F&IS) shall discharge the duties of Head (F&IS) in his absence, normal duties
of ENC (F&IS) shall be:
(a)
To advise the concerned departments in planning and organizing measures

necessary for the effective control of personal injuries.
(b)
To advise on safety aspects in all job studies, and to carry out detailed job
safety studies of selected jobs.
(c)
To check and evaluate the effectiveness of the action taken or proposed to be

taken to prevent personal injuries.
(d)
To ensure that all Personal Protective Equipment provided to workers as

required under any of the provisions of the Act or the Rules conform to the
relevant Indian Standards.
(e)
To provide advice on matters related to carrying out plant safety inspections.
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(f)
To carry out plant safety inspections in order to observe the physical

conditions, work practices and procedures followed by workers and to render
advice on measures to be adopted for removing the unsafe physical
conditions and preventing unsafe actions by the workers.
(g)
To render advice on matters related to reporting and investigation of industrial

accidents and diseases.
(h)
To investigate selected accidents.

(i)
To investigate the cases of industrial diseases contracted and

reportable dangerous occurrences.
(j)
To advise on the maintenance of such records as are necessary

relating to accidents, dangerous occurrence and industrial diseases.
(k)
To promote setting up of safety committee and act as adviser and catalyst to

such committees.
(l)
To acts a member secretary in the internal Safety Audit Committee.
(m)
To organize in association with the concerned departments, campaigns,

competitions, contests and other activities which develop and maintain the
interest of the workers in establishing and safe working conditions of work and
safe work procedures and maintaining the same.
(n)
To design and conduct either independently of in collaboration with the

training department, suitable training and educational programme for the
prevention of accidents & inculcate safe work practices.
Duties of Safety Officer / Asstt. Safety Officer: In absence of ENC (F&IS) Safety Officer shall discharge the duties of ENC (F&IS).
Duties of Safety Officer / Asstt. Safety officer shall be:
1.
To take daily safety inspection round, note down the safety related
deficiencies (SRD) and prepare SRD report.
2.
To act as an advisor in the section safety committee meeting.

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3.
To acts as member of fire protection committee, house keeping committee.
4.
To organize and deliver lecture to dept & contractor staff on Ind. Safety &
emergency preparedness.
5.
To inspect PPEs used by contractor and dept. staff.
6.
To suggest safety measure in work procedure and safety manual of

contractor.
7.
To suggest safety measure in the safety work permit and to see its
implementation.
8.
Asstt. ENC (F&IS) in organizing programmers for National Safety Day / Week,
Environment Day, Seminar on safety etc.
9.
To prepared Monthly, Quarterly and Annual Report required to be sent to ISG,

NPC, AERB, SARCOP etc. and other NPC sites.
10.
To prepare schedule for medical examination for employees.
11.
Advice safety supervisor / Inspectors on monitoring of noise level, illumination,

oxygen deficiency, presence of H2S or combustible gases etc. as applicable.
12.
To maintain list of available PPEs and PPEs issued.
Duties of Safety Inspectors / Supervisors: 1. Visit the each side of Project, note down the unsafe condition and Act and inform
to Safety Officer / Asstt. Safety Officer.
2. Asstt. ENC (Safety) / Safety Officer / Asstt. Safety Officer for organizing safety
competition and celebrating National Safety Day / Environment Day.
3- Display stickers, slogan boards and poster related to safety, fire and environment
in the project.
4. Carry out noise and illumination survey of various area of project.
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5. Check the personal protective equipment given to contractor person.

6. Check hazardous jobs like working in confined space, working at height, hot job
etc. are done with safety permit.
7. To monitor the level of O2 Ammonia, CO, oxygen level with the help of
portable
gas monitors as applicable.

Duties of the Safety Committee: The main job of the safety committee is to ensure health & safety of all employees
and the neighbourhood and shall (a)
See that all the provisions of relevant Acts & Rules are conformed to.
(b)
Assess the potential hazards and dangerous occurrences at the work place
and examine the effectiveness of the Safety & Control measures.
(c)
See that the processes for the manufacture of the main products and for the
disposal of gaseous, liquid & solid effluents are safe to ensure conformance to
the Environmental Protection Act, 1986.
(d)
See that a well-documented safety programme exists.
(e)
See that a work permit system exists for handling of hazardous material and
working as indicated below:
(i)
At hazardous locations such as at height.
(ii)
Near electrical installations and high pressure and enthalpy area.
(iii)
With flammable and toxic material.
(iv)
Under high noise environment.
(f)
See that the work environment and the neighborhood is monitored for
physical, chemical & biological agents & see that the limits specified by the
Acts & Competent Authority are not exceeded any time.
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(g)
See that all employees are informed of all hazards involved in their work &
provided with adequate instructions & protective equipments.
(h)
See that periodic medical examination of all employees is carried out to the
extent required as per the work environment.
(i)
Discuss accidents & dangerous occurrences at the work place and examine
causes of accidents & suggest to the management for necessary
improvements.
(j)
Organize safety circles in the unit for developing safe work habits &
procedures.
(k)
Investigate genuine complaints received from any quarter about the risks or
dangers.
(l)
Promote safety & healthy by organizing accident prevention programme,

safety campaigns, & meets.
10.SECTIONAL PROCEDURES FOR PROCEDURE FOR REPORTING OF

INDUSTRIAL ACCIDENTS
1. RESPONSIBILITY OF THE INJURED
1.1 Every case of accident, however small shall be reported to the immediate
superior / Engineer / Section Head / Unit Head, immediately by the injured and
will be considered for getting medical help. If not informed, the injured person
shall not be entitled for injury on duty leave.
1.2 In case of serious / Fatal accident, where the individual is not in a position to
communicate, the person in whose notice the accident has come should inform
the
immediate Supervisor / Engineer concerned for medical help, etc.
2. RESPONSIBILITY OF THE PERSONNEL WORKING IN THE VICINITY
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2.1 The personnel working in the vicinity / the person who notice the injured first
shall render help to the victim as early as possible and shall arrange the
medical aid by the quickest possible manner. Wherever possible first aid should
be given immediately.
2.2 One of the persons available in the vicinity shall inform the accident to the
concerned
Contractor / Engineer-in-charge of the works (in case of accident
to contractor
employee) / Section Head (in case of accident to departmental
employee).
2.3 In Case of On the Spot Fatal Accident, the person who notices the accident shall
inform the Sectional Head / Unit Head / Senior Manager (P&IR) / CISF and
Safety Officer, immediately. The personnel working around shall not disturb any
evidence leading to the accident and get barricade the area to prevent
personnel entry with the
help of CISF / other security personnel till some
senior person shall take charge of the area.

3. RESPONSIBILITY OF CONCERNED SUPERVISOR / ENGINEER
3.1 The Supervisor / Engineer under whose jurisdiction, the accident occurred shall
give information about the accident, immediately to the following
Section Head / Senior Officer of the Section
Unit head
ENC (F&IS) / Safety Officer
AGM (HR)
3.2 The Supervisor/ Engineer shall immediately arrange medical help to the
injured. Wherever possible, First aid shall be given, immediately.
3.3 The Supervisor / Engineer shall fill the Form-A in triplicate (in case of injury to
department person) and arrange to fill the Form-A by the Contractor (in case the
injury to contractors person), immediately and send all the three copies of the
Form-A to the Medical Officer for his endorsement. This should be done within
Six hours of occurrence of the accident.
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3.4 In case of
On the Spot fatal accident, Concerned Supervisor / Engineer shall
call for the Medical Officer, who will examine the case. In such cases, the CISF
shall be called for cordoning of the area to preserve evidence of the accident for
investigation. Dead body shall be removed only after getting POLICE clearance.
4. RESPONSIBILITY OF MEDICAL OFFICER
4.1 When an injured person is taken to the hospital, the Medical officer shall render
all medical help to the injured. If he feels expert medical opinion is required, he
may refer the injured for expert treatment.
4.2 The Medical Officer shall obtain Form-A (duly filled by the Supervisor/ Engineer
concerned) for endorsement of his recommendation on it (from the injured /
person accompanying the injured) The Injury will be treated as Injury on duty
(I.O.D.), if it is certified by the Medical Officer in the Form-A. And it is approved
by Apex Safety Committee Meeting.
4.3 In case the condition of the injured is serious or the injured succumbs to his
injuries at Hospital, he shall inform the matter to the Senior Manager (P&IR).
4.4 In case the Medical Officer gets a call regarding an On the Spot Fatal accident,
he should immediately proceed to the accident spot and will give his medical
opinion about the injured / deceased and endorse the same in Form-A.
4.5 In Normal accident cases, Medical Officer will certify in Form-A whether the
person is fit for duty or otherwise the probable period of disability. Such period
may be extended if the Medical Officer considers so in his subsequent
examination of the injured. Out of the three copies of Form-A, Medical Officer
shall keep one copy with him and remaining copies will be forwarded to.
1.
Head (F&IS) / ENC (F&IS)
2.
Concerned Section Head
5. RESPONSIBILITY OF SECTION HEAD
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5.1 Section Head shall ensure that prompt Medical Help is given to the injured.
5.2 Section Head shall inform the accident to the following.
Project Director
Chief Construction Engineer
Senior Manager (P&IR)
Head (F&IS) / ENC (F&IS)
5.3 In case of Fatal accident, he shall also inform CISF and Senior Manager (P&IR).
In such cases he shall request Senior Manager (P&IR) to inform / confirm about
the accident case to the Police.
5.4 Section Head shall ensure that duly filled Form-A in triplicate is sent to the
Medical Officer, immediately.
5.5 The Section Head shall ensure that one copy of Form-A (duly filled by
Supervisor/ Engineer / Contractor and endorsed by the Medical Officer) is
reached to Safety Section within 12 Hrs.
5.6
In case, the Injured is declared unfit for more that 48 hrs, Section Head shall
fill the Form-B in six copies and forward all the six copies to the Safety
Section.
5.7
Electrical accident shall be reported in Form-C in place of Form-B.
5.8
Vehicle accidents shall be reported in Form-E in place of Form-B.
5.9 Section Head shall render all help to the ENC (F&IS) for investigation of the
accident. He shall ensure that the accident site is kept undisturbed and work
should be restarted only after obtaining Safety Clearance.
5.10 Section Head should counter sign all the accident reports from contractor and
forward them to ENC (F&IS).
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6.
RESPONSIBILITY OF ENC (F&IS) / SAFETY OFFICER
6.1
On receipt of information about the accident Safety Officer along with the
Engineer-In-Charge shall visit the accident spot and make On the Spot
assessment of the accident.
6.2 ENC (F&IS) / Safety Officer along with the Engineer-In-Charge shall
conduct
necessary
inquiry
and
arrange
to
record
statement
of
eyewitnesses and prepared the Joint accident investigation Report in

Form-D.
6.3 In case of Serious / Fatal accident, ENC (F&IS) / Safety Officer will visit the
hospital for ascertaining more details regarding the injury.
6.4 ENC (F&IS) / Safety Officer shall inform Serious / Fatal accident to the following.
Project Director
Chief Construction Engineer
AGM (HR)
6.5 In case of fatal accident ENC (F&IS) shall prepare Fatal accident report (Fax
massage) on Form-G and submit it to the Project Director for forwarding the
same immediately to the following as per format.
Secretary, Department of Atomic Energy, Mumbai
Chairman, AERB, Mumbai
Chairman SARCOP, Mumbai
Chairman cum Managing Director, NPC, Mumbai
Executive Director (Projects)
Director (HSE&PA), NPC, Mumbai
Chief Engineer, Industrial Safety Group, NPC, Mumbai
7.
Responsibility of Project Director / Chief construction Engineer
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In case of fatal accident / accident involving serious disability to person, Project

Director / Chief Construction Engineer shall immediately appoint Accident
Investigation Committee comprising senior officers of the project and include
member from HWPK.
Project Director / Chief Construction Engineer shall ensure that preliminary report
prepared well in time before visit of the Accident Investigation Committee of AERB.
Final report should be ready before the meeting of Fatal Accident Assessment
Committee (FAAC) of AERB, and shall ensure that investigation report by
investigation committee is sent to the following:
Secretary, Department of Atomic Energy, Mumbai
Chairman, AERB, Mumbai
Chairman SARCOP, Mumbai
Chairman cum Managing Director, NPC, Mumbai
Executive Director (Projects)
Director (HSE&PA), NPC, Mumbai
Chief Engineer, Industrial Safety Group, NPC, Mumbai
Director, IPSD, AERB
8. RESPONSIBILITY OF AGM (HR)

8.1
In case of Serious accident (likely to be Fatal) / Fatal accident AGM (HR) shall
intimate the accident telephonically immediately and a written report within 24
hrs. to the following.
Police Station, Rawatbhata
Additional Collector and Magistrate, Rawatbhata
Assistant Labour Commissioner, Chittorgarh
8.2
AGM (HR) shall arrange to send information to the Family of the victim.
8.3 AGM (HR) shall arrange for removal of the dead body after getting clearance
from Police.
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8.4 AGM (HR) shall arrange to regulate Hospital Leave, Disability leave, Payment of
Compensation and ensure the implementation of other statutory requirements
under workmen Compensation Act and Rules.
9. RESPONSIBILITY OF CONTRACTOR
9.1 Contractor concerned shall arrange immediate Medical assistance to the injured
and inform immediately to the Engineer-In-Charge of the Work and Industrial
Safety Section.
9.2 Contractor shall arrange to send the Form-A (duly filled and counter signed by
ENC) in triplicate to the Medical Officer (attending the injured) and after the
endorsement from the Medical Officer, Contractor shall submit it to the ENC of
the work who will forward one copy of the Form-A to Industrial Safety Section.
9.3
In case of reportable injury (if injured is disabled for more that 48 hrs.),
Contractor shall fill form Form-B, Form-C and Form-E filled in six copies
according to the nature of accident (Normal accident, Electrical accident and
Vehicle accident) and submit it to the concerned ENC. The ENC will forward all
the six copies to Industrial Safety Section.
THE CONTRACTOR SHALL BE RESPONSIBLE FOR THE FOLLOWING ALSO
Informing Fatal accident to Police and other statutory bodies (labour

commissioner, compensation commissioner).
Payment of Compensation
Medical treatment of the Victim
Disability leave to the injured
Removal of dead body after getting clearance from Police and

Authorities
.10.
of RAPP-5&6.
To implement all recommendations pertaining to accident

RESPONSIBILITY OF THE SAFETY OFFICER OF THE CONTRACTOR
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10.1 The Safety Officer of the Contractor/Company shall have to ensure the
compliance of duties and responsibilities of the Contractor / Company
w.r.t. Industrial accident / injuries as per point no. 8.1 to 8.3 of the Accident
handling procedure.
10.2 The Safety Officer of the Contractor / Company shall also be responsible
for
reporting of Near miss incident to the Industrial Safety Section RAPP5&6

immediately after the occurrence of the incident.
10.3 The Safety Officer of the Contractor/Company shall compile and send the
Monthly safety performance report of their Contractor / company and
submit it to the Industrial Safety Section-RAPP-5&6.
10.4 The Safety Officer of the Contractor/Company must ensure that all the
recommendations made by the Accident Investigation Committee/ Safety
Officer, RAPP-5&6/Statutory bodies are implemented in toto.
10.5
The Safety Officer of the Contractor/Company shall be responsible for the

implementation of provisions under the Factories Acts-1948, The Atomic
Energy (factories) Rules-1996, The Indian Electricity Acts-1910 and I.E.
Rules-1956,Workmans Compensation act-1923 and all others statutory rules
and regulations which are applicable at RAPP-5&6 Site.
10.6 He shall ensure that job Hazard Analysis of hazardous job is carried out and
its report is sent to Dept. Safety Section for its review.
11.
INJURY ON DUTY (I.O.D.) LEAVE
11.1
ENC (F&IS) / Safety Officer, RAPP-5&6 shall put up all accident cases in the
Apex Safety Committee meeting along with all relevant documents, for
discussion and approval for Injury On Duty Leave (I.O.D. leave), etc.
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5.5- APPLICATION OF ACTS/RULES FOR SAFETY AT RAPP-5&6

Needs for acts and rules: In order to avoid any disaster we need to have.
1. Comprehensive rules, regulation, standards instructions & procedure.
2. Effective implementation of rules / regulation.
3. Auditing to ensure that rules / acts are implemented and modification if required.
4. Action / Penalty for non-compliance.
ACTS/RULES related to Health & Safety in Department of Atomic Energy.
1.The Factories Act :- First enacted in 1881, re enacted and amended several
times. The last version being that of 1948 as amended in 1987.
2.Atomic Energy (Factories) Rules 1984 :- Revised in 1996. Under Section
41,49,50,76,83,112 of Factories Act &
Section 23 & 30 of Atomic Energy Act, 1962.
3.
Atomic Energy Act, 1962.
4.
Radiation Protection Rules,1971.
5.
The Indian Electricity Act, 1910.
6.
The Indian Electricity Rules, 1956.
7.
The Indian Boiler Act, 1923.
8.
The Indian Explosive Act, 1884.
9.
The Petroleum Act, 1934.
10.
Gas Cylinder Rules, 1981.
11.
Static & Mobile Pressure Vessel (unfired) Rules, 1981.
12.
Water (Prevention & Control of Pollution) Act, 1974.
13.
Air (Prevention & Control of Pollution) Act, 1981.
14.
Environment (Protection) Act, 1986 (made after Bhopal disaster).
15.
Building and other construction workers Act, 1996.
BOCW Act
A Bill was introduced in 1988.
It Become an Act only in 1996.
- 90 -
Centre Government enacted and notified the Central Rules in Nov1998.

The States are also required to frame and notify the Rules under the
act
for establishment in their states not covered by the Central
Rules.
The Factories Act, 1948

The Factories act, 1948 was enacted to consolidate and amend the law regulating
labour in factories. It extends to the whole of India except J&K and came into force
on April, 1949.
Section 2 (m) of the Act a Factory means any premises.
i)
Whereon ten or more workers are working or were working on any day
of the preceding twelve months, in any part of which a manufacturing
process is being carried on with the aid of power.
ii)
Whereon twenty or more workers are working, or were working on any

day of which a manufacturing process is being carried on without the
aid of power.
The Factories Act is divided into various chapters and they deal with definition with
respect to the
factories,
Act,
duties
approval,
of
licensing
occupiers,
and
registration
appointment
of
of
Factory
Inspectors, welfare measures, working hours for adults, annual

leave,
employment
of
young
persons,
penalties
in
case
of
default etc.
The safety provisions dealt in Chapter IV deals with fencing of machinery,
work on or near machinery in motion, hoists, lifts, lifting machines, ropes
and lifting tackles revolving machinery, pressure plant, excessive weights, protection
of eyes, precautions in the case of fire, appointment and duties of safety officer etc.
In the aftermath of the Bhopal gas tragedy in December 1984 a new chapter
(chapter-IV-A) on Provisions relating to hazardous process was included in
the Act in 1987. The added provisions deal with constitution of site Appraisal
Committees, responsibility of the occupier in relation to hazardous processes,
- 91 -
emergency standards and permissible limits of exposure of chemicals and toxic

substance. It also provides for workers participation in Safety Management.
This is a Central Act leaving the powers of administration and framing the rules to the
respective State Governments. as per the Section 24 of Atomic Energy Act,
1962, the administration and powers of framing of rules under various sections
of factories act rest with the department of atomic energy. Hence, no atomic
energy installations are subjected to check by the respective Inspector of
Factories (State Govt.).
Atomic Energy (Factories) Rule,1984, revised in 1996, apply to the factories under
the Department of Atomic Energy.
Health
Cleanliness, disposal of wastes and effluents, control of dust and fumes into the
working atmosphere, proper ventilation and lighting, provision of drinking water,
urinal, latrines and rest places are some of the sections coming under this
chapter.
Safety
Section 21. Fencing of Machinery The moving parts of the prime mover,
flywheel, any part of the stock bar which project beyond the head stock of a
lathe, every part of an electric generator, transmission machinery and every
dangerous part of machinery shall be securely fenced by suitable guards of
sturdy construction.
Section 22. Working on or near machinery in motion If it is necessary to
examine or carry out any adjustment or to lubricate or shift the belt of any parts
of machinery in motion, then such examination or operation shall be carried out
only by a specially trained adult male worker by wearing tight fitting clothes.
Secure foot hold and handhold shall be provided for the operator.
Section 23. Employment of young persons on dangerous machines- No young
person shall work on machines unless he has received sufficient training in
work at the machine or he is under adequate supervision of a person who has
a through knowledge and experience of the machine.
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Section 26. Casing of new machinery Every set screw, bolt or key on any
revolving shaft, spindle wheel or pinion shall be effectively guarded. Similarly all
spur, worm and other gears which do not require frequent adjustment shall be
completely encased or covered.
Section 28. Hoists and lifts Every hoist and lift shall be good mechanical
construction and shall be thoroughly examined by a competent person atleast
once is six months and a register shall be kept containing the particulars of
every examination. The maximum safe working load shall be plainly marked
one every hoist and lift and no load greater than such load shall be carried.
Where the cage is supported by rope or chain, then there shall be two ropes or
chains separately connected with the cage and balance weight and each rope
or chain with its attachments shall be capable of carrying weight of the cage
together with maximum load.
Section 29. Lifting machines chains, ropes and lifting tackles All pats of the
lifting machines and every chain, rope or lifting tackles shall be of good
construction. They shall be properly maintained and thoroughly examined by a
competent person at least once in twelve months and a register shall be kept
containing particulars of every examination. No lifting machine, chain rope, and
lifting tackle shall be loaded beyond safe working limit except for the purpose of
tests.
Section 31. Pressure Plant If in any factory any part of the plant or machinery
used in manufacturing process is operated at a pressure above atmospheric
pressure, effective measures shall be taken to ensure that the safe working
pressure of such part is not exceeded.
Atomic Energy (Factories) Rules, 1996 provides Rules for provision of safety fittings
and in service test and examination of pressure plant.
Section 32. Floors, stairs and means of access All floors, steps, stairs,
passages shall be of sound construction and kept free from obstruction and
where it is necessary to ensure safety, steps, stairs, passages and gangway
shall be provided with hand rails.
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Section 33. Pits, sumps, openings in floors All pits, sumps, openings in floors
shall be securely covered or fenced.
Section 34. Excessive weights- No persons shall be employed in the factory to
carry lift or move excess load which may cause any injury to him.
Section 35. Protection of Eyes Effective screens or suitable goggles shall be
provided for protection of eyes of the person who is involved in a process or in
the immediate vicinity of the process which involves: (a) risk of injury to the
eyes from particulars or fragments thrown off in the course of process, or (b)
risk to the eyes by reasons of exposure to excessive light.
Section 36. Precautions against dangerous fumes No person shall enter any
tank, vessel, pipe or any confined space in a factory where dangerous fumes
are likely to be present unless that tank, vessels provided with the manhole of
adequate size or other effective means of egress. Similarly the workers shall
wear suitable breathing apparatus and a belt securely attached to a roper the
free end of which is held by person outside the confined space.
Section 36 A. Precautions regarding the use of portable electric light No
portable electric light or other appliance of voltage exceeding 24 V shall be
permitted to be used inside any chamber, tank, pipe or other confined space
and if any inflammable gas, fumes or dust is present in a chamber tank, the
lamp or light other than flame proof construction shall not be permitted to be
used therein.
Section 40-B. Safety Officers In every factory (a) where in one thousand or more
workers are ordinarily employed, or (b) wherein, any manufacturing process or
operation is carried out which involves any risk of bodily injury, poisoning or
disease or any other hazard health, to persons employed in the factory then
such number of Safety Officers shall be employed as prescribed.
Section 87. Dangerous Operations where any process or operation carried on in
a factory exposes person employed in it to a serious risk of bodily injury,
poisoning or disease, then rules providing precautions to be observed during
process or operation shall be made.
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Section 88. Notice of Certain Accidents where in any factory an accident occurs
which causes death or any bodily injury by reasons of which the person injured
is prevented from working for a period of forty eight hours or more
immediately following the accident, the factory manager shall send notice to the
authorities, in such form and within such time as prescribed by State
Government (AERB).
Section 88 A. Notice of certain dangerous occurrences If there is any
dangerous occurrence whether causing any bodily injury or disability or not, the
factory manager shall send notice to the authorities (AERB).
ATOMIC ENERGEY (FACTORIES) RULES, 1996
1. (a) In exercise of power conferred by Section 41,49,50,76,83,112 and other
enabling sections of Factories Act, 1948 (63 of 1948) and section 23 and 30
of the Atomic Energy Act, 1962,Atomic Energy (Factories) Rules has been
made.
(b) It is applicable to all the factories owned by the Central Government and
engaged in carrying out the purposes of the Atomic Energy Act, 1962 (33 of
1962).
2. DEFINITIONS :(a) Act means the Factories Act, 1984 (63 of 1948).
(b) Certifying Surgeon means the Medical Officer of the factory authorised by
AERB.
(c) Competent Authority means any officer or authority appointed by the Central
Government by notification in the official Gazette for the purpose of these
rules (Chairman AERB).
(d) Inspector means an officer appointed under Section 8 of the Act and
includes the Competent Authority (AERB)..
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(e) Manager of the factory means the person responsible to the occupier for the
working of the factory for the purposes of the Act.
Rule-3 Approval of Plans:- Needs to be taken from AERB for
1) Locating the site on which the factory is to be situated or
2) For the construction or expansion of a factory.
Rule- 6.POWERS OF THE AERB INSPECTOR :- Inspector have powers to do
all or any of the following Acts,
(1) To photograph any worker, to inspect, examine, measure, copy, photography,
sketch or test, any building or room, any plant, machinery, appliances or
apparatus, any register or document or anything provided for the purpose of
securing the health, safety and welfare of the persons employed in the factory,
and for protecting and securing the environment.
(2) To carry out such medical examinations as may be necessary provided he is a
Medical Inspector.
(3) To enquire into safety and health related accidents & unusual occurrences.
(4) To advise the Manager of the factory against unsafe acts and practices and to
point out unsafe conditions, if any, existing in the premises of the factory.
(5) To report any unsafe conditions or practices existing in the factory to the
competent authority.
Recent Notification :- AERB Inspector shall have power to stop work in case safety
requirement for working at height, excavation works, material handling operation,
portable electrical equipment, fire safety, personnel protective equipment, working in
confined space, are not followed / in place.
Rule- 7. DUTIES OF CERTIFYING SURGEON:(1) The Certifying Surgeon visit the factory for the purpose of examination of all
Persons employed.
(2) The Certifying Surgeon shall, carry out examination and furnish report for factory
where cases of illness have occurred which, are due to the hazardous nature of
- 96 -
the manufacturing process carried on or by reason of any change in the

manufacturing process carried on / or in the substances used therein.
(3) If the Certifying Surgeon finds that any person employed in process is no longer
fit for medical reasons to work in that process, he shall suspend such person
from working in that process for such time as he may think fit and no person
after suspension shall be employed in that process without the written certificate
of fitness by the Certifying Surgeon.
HEALTH
Rule-11. ILLUMINATION, TEMPERATURE AND VENTILATION:
(1)
Illumination :- (a) General :- Adequate lighting is necessary for all buildings

and in
the open area so as to.
(i) Promote work and other activities carried out in the area.
(ii) Promote safety of the people.
(iii) Create a pleasing environment conductive for feeling of well being.
(b) Adequate lighting will be achieved by:(i) Planning of brightness in relation to task itself, immediate background
of the task and the general surrounding.
(ii) Avoiding glare produced by excessive contrast or abrupt and large
change in brightness.
(iii) Planning of lighting for movement about a building and around.
TABLE
Sr. N0.
Visual Tasks
1.
Industrial Buildings & Process
(a)
General Factory Areas
Illumination (Lux)
100-150
-canteens, cloakrooms, entrances

corridors , stairs.
(b)
Factory outside Areas

- Stockyards, main entrances
(c)
20
Assembly, Inspection, Wood working

Welding & Soldering, Machine & Fitting
- 97 -
Shops.
(i) Rough Work Frame assembly
150
(ii) Medium Work Assembly of parts
300
(iii) Fine Work Electronic assembly,
700
inspection.
(iv)Very Fine Work Assembly of
1500
precision parts, optical aids to be

provided.
(d). Offices
(i) Entrance & Reception
150
(ii) Conference rooms & Gen. office
30
(iii) Drawing offices
300-450
(iv) Corridors & Lifts
70
(v)Stairs, Lift landing
100 150
(vi) Telephone exchanges
150 200
(e). Steel Fabrication Shop

(i) General
150
(ii) Marking Off
300
(f) (i) Turbine hall
200
(ii) Boiler house
100
(iii) Reactor & steam generating plants
150 20
Ventilation :- Ventilation in buildings to be provided.

1. To supply fresh air for respiration & to dilute inside air to prevent vitiation by body
odours
2. To remove any other products of concentrated sources such as smoke, heat &
fumes shall be collected separately by local exhaust ventilation.
3. The recommended air changes per hour for various areas is given in the Table
below :
TABLE
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Area
Air Changes / hour
Factories
36
Dining Hall
12 15
Offices
36
Bathroom & Toilets
6 - 12
Temperature :- To provide such temp if worker is exposed to it repeatedly shall have

no adverse heath effect. The permissible heat stress which is measured in WBGT
index (= 0.7NWB +0.2 GT +0.1DB) (= 0.7 NWB + 0.3 GT) Out door with solar load
Indoor or out door without solar load.
Rule- 12. QUANTITY OF DRINKING WATER :- At least 5 litres per worker employed
should be readily available at all times during working hours.
Rule-17. COOLING OF WATER :- Where in 250 workers are ordinarily employed.
(1) The drinking water supplied to the workers shall be cooled.
(1) The cool drinking water shall be supplied in every canteen, lunchroom and
rest - room and also at conveniently situated points throughout the factory.
Rule-18. LATRINE ACCOMMODATION:- Latrine accommodation shall be provided
in every factory on the following scale, namely :(a) Where females are employed, there shall be at least one latrine for every 25
females.
(b) Where males are employed, there shall be at least one latrine for every 25
males.
Rule-19. TOILET BLOCKS :- The toilet block shall consist of wash basins, latrines
and urinals ( in cases of male workers ). The number of wash basins will the same
as number of latrines. Each wash basin shall be provided with mirror and liquid /
cake soap. Each toilet block shall be provided with clean towel or electric hand drier.
- 99 -
Rule-21. SIGN BOARDS TO BE DISPLAYED :- Where workers of both sexes are

employed, there shall be displayed outside each latrine block a notice For Men
Only or For Women Only as the case may be, in the language understood by the
majority of the workers. The notice shall also bear the figures of a man or of a
woman as the case may be.
Rule-22. URINAL ACCOMMODATION:- Urinal accommodation shall be provided for
the use of male workers and there shall be at least one urinal for every 50 males :
Provided that where the number of males employed exceeds 500, it shall be
sufficient if there is one urinal for every 50 males upto the first 500 employed, and
one for every 100 thereafter.
Rule-34. HOISTS AND LIFTS:- (1) A register shall be maintained to record
particulars of examination of hoists and lifts and shall give particulars as shown in
Form 3.
Hoist and lifts should be tested once in six month.
Rule 31 Qualification of Competent person :- Competent person is a person who
is having a degree in the discipline concerned or equivalent followed by experience
and designated by the Competent Authority.
Rule-35. LIFTING MACHINES, CHAINS, ROPES AND LIFTING TACKLES :(1) No lifting machine and tackles, sling, should be taken into use in any factory for
the first time unless it has been tested & thoroughly examined by a competent
person and a certificate of such a test and examination has been obtained and is
kept available for inspection.
(2) Automatic indicator of safe working loads or an automatic jib angle indicator and
a table indicating the safe working load at corresponding inclinations of the jib or
corresponding radii of the load is required for every jib crane. An audio visual
alarm be preferably provided in addition, to give alarm wherever the limits given
in table are exceeded.
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(3) A table showing the safe working loads of chain, rope or lifting tackle and, in the
case of a multiple sling, the safe working loads at different angles of the legs,
should be pasted in the store in which the chains, ropes or lifting tackles are
kept, and in prominent positions on the premises, and no chain, rope or lifting
tackle not shown in the table shall be used.
(4) All rails and track on which a travelling crane moves should be of proper size,
adequate strength, have an even running surface, and rail or track should be
properly laid, adequately supported and properly maintained.
(5) All chains and lifting tackles be effectively annealed under the supervision of a
competent person at the following intervals:(a)
All chains,slings, rings, hooks, shackles and swivels use in connection with
molten metal or molten slag or when they are made of 12.5 millimeters bar or
smaller, once at least in every six moths.
(b)
All other chains, rings, hooks, shackles and swivels in general use, once at
least in every twelve months.
Provided that chains and lifting tackle not in frequent use shall, subject to the
Competent Authoritys approval, be annealed only when necessary.
(6) Slinging :(i)
Chains shall not be joined by bolting or wiring links together. They shall not
be shortened by tying knots.
(ii) While using multileged slings, each sling or leg shall be loaded evenly and
the slings shall be of sufficient length to avoid a wide angle between the
legs.
(7) Cranes shall be operated only by authorised persons who are well trained and
experienced, operators shall ensure that all safety devices are functioning
- 101 -
properly before crane is put into operation (operator should have medical fitness
certificate).
(8) A mobile crane shall be operated so that none of its parts can approach live
electric lines closer than 3 m. While lifting loads such a crane shall be located
on level ground.
(9) Standard signals shall be used and operators shall recognize signals from only
one person (Signal man) during crane operation.
(10) No person shall be permitted to work or walk under a load.
(11) Through inspection and load testing of a crane shall be done by a competent
person at least once every 12 months.
Safe working load
Test load
Up to 20 tons
25 % in excess
20 50 tons
5 tons in excess
Over 50 tons
10. 5 in excess
(12) All lifting machines and lifting tackles or fiber sling, which have been lengthened,
altered or repaired by welding or otherwise, shall, before being again taken into
use, be re- tested and re-examined by a competent person and certificate of
such test and examination by obtained.
(13) No person under 18 years of age and no person who is not competent and
reliable shall be employed as driver of a lifting machine whether driven by
mechanical power or otherwise, or to give signals to a driver.
Rule-36. PRESSURE VESSELS OR PLANTS.Pressure vessel means a vessel that may be used for containing, storing,
distributing, transferring, distilling, processing or otherwise handling any gas, vapour
or liquid under pressure greater than the atmospheric pressure and includes any
pipeline fitting or other equipment attached there to or used in connection.
- 102 -
Exceptions
(a) Vessels made of ferrous materials having an internal operating pressure not
exceeding 1 kg / cm2.
(b) Steam boiler, steam and feed pipes and their fittings coming under the purview of
the Indian Boilers Act, 1923.
(c) Metal bottles or cylinders used for storage or transport of compressed gases or
liquified or
dissolved gases under pressure covered by the Gas Cylinder
Rule, 1981 framed under the Indian Explosives Act, 1884.

(d) Vessels in which internal pressure is due solely to the static head of liquid.
(e) Vessels with a nominal water capacity not exceeding 500 litres connected in a
water pumping system containing air that is compressed to serve as a cushion.
(f) Vessels for nuclear energy application shall be covered by rules framed by
Competent Authority.
(g) Refrigeration plant having a capacity of 3 tons or less of refrigeration in 24 hours.
(h) Working cylinder of steam engines or prime mover, feed pumps, turbine cassing,
compressor cylinder, steam separator or dryer, oil separate, steam desuper
heater, air receive for fire sprinkler, air receiver of circuit breaker, relays.
Safety devices.- Every pressure vessel shall be fitted with(a) A suitable safety valve or other effective pressure relieving device of adequate
capacity to ensure that the maximum permissible working pressure of the
pressure vessel shall not be exceeded.
(b) A suitable pressure gauge with a dial range not less than 1.5 times the maximum
permissible working pressure, easily visible.
(c) A suitable nipple and globe valve connected for the exclusive purpose of
attaching a test pressure gauge for checking the accuracy of the pressure
gauge.
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(d) A suitable stop valve or valves by which the pressure vessel may be isolated form
other pressure vessels or plant or source of supply of pressure.
(e) A suitable drain cock or valve at the lowest part of the pressure vessel for the
discharge of the liquid or other substances that may collect in the pressure
vessel.
(f) Every pressure gauge, stop valve, nipple and globe valve, shall be mounted at a
height not more than 1.5m from the working level.
No pressure vessel to be used in factory unless certificate specifying design
pressure or max. permissible working pressure and test from maker of pressure
vessel or from competent person is taken.
In- service test and examinations:- (a) Every pressure vessel or plant in service
shall be thoroughly examined by a competent person.
(i) Externally, once in every period of six month.
(ii) Internally, once in every period of twelve months (it not possible, hydro test
once in 2 years).
(i)
Hydra statically tested once in four year (1.25 times the design
pressure or 1.5 times max. permissible working pressure
whichever is less).
Rule-38. EXCESSIVE WEIGHTS:- No person, unless aided by another person or

any mechanical device, shall carry or move by hand or head any material, article,
tool or appliance exceeding the maximum limit in weight set out in the following
Table.
Table
a) Adult Male
55
b) Adult Female
30
Rule 42 :- Fire Protection, Prevention & Fighting

1. Segregate process, item, plant having potential for explosion or fire hazard.
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2. Separation of process / handling fire hazard by walls of fire resistant construction.

3. Use of flame arrestor or fire dampers interlocked with heat sensitive / smoke
detecting to be provided in ventilation duct, pneumatic conveyor etc involving fire
risk.
4. Passage between fire prone area / machine to be 90 cm wide and clearance
between ceiling and top of combustible material to be less than 2m.
5. Main exist way < 4.5 m and vertical clearance 5m.
6. Door / window on all external walls for easy access for fire fighting.
7. Lighting arrestor required for (a) Building & storage tank used for explosive or
highly flammable substance grain elevators (b) Tall chimneys or stacks where
flammable
gases,
fumes
dust
present(c)
Substation
building,
outdoor
transformers (switchyard).
8. Not more than 30 litre of flammable liquid (<23 0C flash point) to be used unless
licence is taken.
9. Fire Exist :- May be door way, corridor, to the external stair ways or internal stair
way or internal stair way separated from rest of building by fire resistance wall lift,
escalators or revolving door can not be a exist. Travel distance to reach exist >30
mtr. (In case highly explosive building it>22.5 m). Exist should provide
construction egress to exterior of building or external open space with width of
exist door is 50 cm.
Rule- 40. MINIMUM DIMENSIONS OF MANHOLES.- Every chamber, tank, pipe,
other confined space, which persons may have to enter and which may contain
dangerous fumes to such an extent as to involve risk to the persons being overcome
thereby, shall (unless there is other effective means of egress), be provided with a
manhole which may be rectangular, oval or circular in shape, and shall have the
following dimensions as minimum, namely:-
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Rectangular shape -
50 cm X 30 cm
Oval shape
Major & minor axis diameters
50 cm and 30 cm respectively.
Circular shape
- 50 cm diameter
SAFETY OFFICERS AND STAFF :- (1) Number of safety officers.-
Competent
Authority shall notify the number of safety officers & staff required for any particular
factory.
FOR RAPP-5&6
1. Up to 1000 worker, one safety officer in each shift. Above 1000 worker there
should be one safety officer for every 1000 worker.
2. Up to 500 worker, one safety supervisor per shift. Above 500 worker, there
should be one safety supervisor for every 500 worker.
(2) Duties of safety officers:- The duties of safety officers shall be to advise and
assist the management in the fulfillment of its obligations, statutory or
otherwise, concerning prevention of personal injuries and maintaining a safe
working environment. These duties shall include the following, namely :(a) To advise the concerned departments in planning and organising measures
necessary for the effective control of personal injuries.
(b) To advise on safety aspects in all job studies, and to carry out detailed job
safety studies of selected jobs (Job safety analysis).
(c) To check and evaluate the effectiveness of the action taken or proposed to be
taken to prevent personal injuries.
(d)
To ensure that all Personal Protective Equipment provided to workers are

required under any of the provisions of the Act or the Rules conform to the
relevant Indian Standards.
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(e) To provide advice on matters related to carrying out plant safety inspection.
(f) To carry out plant safety inspections in order to observe the physical conditions
or work and the work practices and procedures followed by workers and to
render advice on measures to be adopted for removing the unsafe physical
conditions and preventing unsafe actions by workers.
(g) To render advice on matters related to reporting and investigation of industrial
accidents and diseases.
(h) To investigate selected accidents.
(i) To investigate the cases of industrial diseases contracted and reportable
dangerous occurrences.
(j) To advise on the maintenance of such records as are necessary relating to
accidents, dangerous occurrences and industrial diseases.
(k) To promote setting up of safety committee and act as adviser and catalyst to such
committees.
(l) To organise in association with the concerned departments, campaigns,
competitions, contests and other activities which will develop and maintain the
interest of the workers in establishing and maintaining safe conditions of work
and procedures.
(m) To design and conduct either independently or in collaboration with the training
department, suitable training and educational programme for the prevention of
personal injuries.
(3) Facilities to be provided to Safety Officers.- The occupier of the factory shall
provide each Safety Officer with such facilities, equipment & information as are
necessary to enable him to discharge his duties effectively.
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(4) Prohibition of performance of other Duties.- No Safety Officer shall be

required or permitted to do any work which is inconsistent with or
detrimental to the performance of the duties prescribed in sub rule (2).
(5) Qualifications.- A person shall not be eligible for appointment as a Safety
Officer unless he (i) possesses(a)
A recognised degree or equivalent in any branch of engineering or technology

and has had practical experience of working in a factory in a supervisory
capacity for a period of not less than 2 years. Or
(b)
A recognised degree in physics or chemistry and has practical experience of

working in a factory in a supervisory capacity for a period of not less than 5
years or
(c) Possesses a degree or diploma in industrial safety recoginsed by the Central /

State Government in this behalf.
(d) Has adequate knowledge of the language spoken by majority of the workers in
the region in which the factory where he is to be appointed is situated
AERB :Sectional Level Safety Committees:Constitution of committee
Section Head
Chairman
Safety Officer
Member Secretary
Representative of worker :
Member
Supervisor, Engineer
Frequency :- One in month.
Rule-44. Duties of the Safety Committee :- The main job of the safety committee is
to ensure health & safety of all employees and the neighbourhood and towards this
the committee shall.
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(a) See that all the provisions of relevant Acts & Rule are conformed to.
(b) Assess the potential hazards and dangerous occurrences at the work place
examine the effectiveness of the Safety & Control measures.
(c)
See that the processes for the manufacture of the main products and for the
disposal of gaseous, liquid & solid effluents are safe to ensure conformance to
the Environmental Protection Act, 1986.
(d) See that a well documented safety programme exists.

(e) See that a work permit system exists for handling of hazardous materials and
working.
(i) At hazardous locations such as at height.
(ii) Near electrical installations and high pressure and enthalpy area.
(iii) With flammable and toxic materials.
(iv) Under high noise environment.
(f) See that the work environment and the neighourhood is monitored for physical,
chemical & biological agents & see that the limits specified by the Acts &
Competent Authority are not exceeded any time.
(g) See that all employees are informed of the hazards involved in their work & are
provided with adequate protective equipments.
(h)
See that a detailed schedule for periodic calibration & preventive maintenance
of all the machinery & equipments is being implemented.
(i) See that periodic medical examination of all employees is carried out to the
extent required as per the work environment.
(j) Discuss accidents & dangerous occurrences at the work place and examine
causes of accidents & suggest to the management necessary improvements.
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(k) Organise safety circles in the unit for developing safety culture.
(l)
Investigate complaints received from any quarter about the risks or dangers.
(m) Promote safety & health by organising accident prevention programs,

campaigns, & meets.
Rule-46. Safety Requirements for Erection of Structural Steel Work:Safety of Men : (i) General skilled workers trained in relevant jobs shall only be
employed in jobs requiring skills.
(1) All personnel protective equipments like helmets, goggles,safety shoes, gloves,
aprons etc. shall be suitable for the job & shall conform to relevant Indian
Standards.
(2) When the work is in progress, the area shall be cordoned off by barricades to
structural components, or falling into excavated trenches or getting injured by
falling objects.
(3)
Warning signs shall be displayed where necessary to indicate hazards, for

example (a)
440 VOLTS, (b) DO NOT SMOKE, (C) MEN WORKING
AHEAD, etc.
(4)All electrically operated hand tools shall be provided with proper earthing.
(5) Hand lamps shall be of low voltage preferably 24 V to prevent electrical hazards.
(6) Safety belts shall always be provided & used for working at heights.
(7) During the erection of tall buildings, nylon nets at a height of 3 to 4 m. shall be
provided to ensure safety of men it there is a fall from heights.
Shoring :- (a) Additional precautions by way of shoring and bracing shall be taken to
prevent slides, slips when excavations or trenches are made in locations subject to
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vibration form railways or road traffic, the operation of machinery or any other source
of vibration.
(b)
Excavations over 1.2 m in depth, unless in solid rock or hard soil shall be
shored and braced or sloped to the angle of repose of the material when
consolidated. All shoring and bracing shall extend to the bottom of the
excavation when necessary.
Night work :- (a) Excavated areas shall be adequately lighted up for night work.
(b)During night , a red danger light shall be displayed at a conspicuous place near
the excavation site to warn approaching traffic and men.
Disposal of soil:- The excavated material shall be duped sufficiently away form the
edge of the excavated trench to avoid the excavated material slipping and falling into
the trench. The excavated materials and any other material or load shall not be
dumped or placed within 1.5m of the edges of the trench or half of the depth of the
trench whichever is more.
Scaffolding :- (1) Scaffolding or staging more than 3.5 metres above the ground
floor swung or suspended from an overhead support or erected with stationary
support shall have a guard rail properly attached, bolted, braced and otherwise
secured at least one metre high above the floor or platform of such scaffolding or
staging and extending along the entire length of the outside . Such scaffolding or
staging shall be so fastened as to prevent it from swaying from the building or
structure.
(2) All scaffolds, before use, shall be examined by the engineer in charge.
(3) On unprotected scaffolds at high elevation the man must wear life belts suitably
anchored to some substantial parts of the structure.
(4) The platform of as suspended scaffold should not be less than 45 cm wide and
point of suspension not more than 3 m apart.
(5) No uninsulated electrical wire exists within 3 mtrs. of the working platform,
gangways of the scaffold.
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PLATFORMS:- The following minimum width of platforms are recommended for

various types of works, namely :(a) Where platform is not more than 2 m above the ground or solid floor :
(i) For painters, decorators and similar workmen 30cm.
(ii) For other types (Men and tools only) 50cm.
(b) Where platform is more than 2 m above the ground or solid floor :
(i) For men, tools and materials 120cm.
(iii)For men, tools, materials and vehicles such as wheel barrows 150cm.
Rule- 52. LADDERS :- (1) Every ladder shall be of good construction, sound
material and of adequate strength for the purpose for which it is used. The rungs
shall be parallel, level and uniformly spaced at 30cm.
(2) Ladders shall be in a safe position before being climbed. The best angle for a
ladder is 75 with the horizontal i.e., the distance of the base of the ladder from
the wall, pole structure etc. as the case may be shall be the its length.
Rule- 55. EXAMINATION OF EYE SIGHT OF CERTAIN WORKERS :(1) No person shall be employed to operate a crane, locomotive or fork-lift truck, or
to give signals to a crane or locomotive operator unless his eyesight and colour
vision have been examined and declared fit by a qualified Medical Officer to
work whether with or without the use of corrective glasses.
(2) The eye sight and colour vision of the person employed shall be examined at
least once in every period of 12 months up the age of 45 years and once in
every 6 month beyond that age.
(3) The record of examination or re-examination carried out as required under subrule 1. shall be maintained in Form 1.
- 112 -
Rule- 57. Quality Protective Equipment :- All PPEs provided to worker as

required under any applicable Rule / Act / instruction should be of good quality
and should conform to relevant IS.
Rule-58. Protection Equipment :- The inspector may order the occupier or the
Manager in writing to supply required PPEs to workers.
Rule-66. NOTICE REGARDING FIRST AID :- A notice containing the names of the
persons working within the factory who are trained in first- aid treatment and who are
in charge of the first-aid boxes or cupboards shall be posted in every factory at a
conspicuous place and near each such box or cupboard.
Rule-67. AMBULANCE ROOM :- Every ambulance room shall be under the charge
of at least one whole-time qualified Medical Officer who shall be assisted by at least
one qualified nurse or dresser cum- compounder and one nursing attendant in
each shifts. The Medical Officer shall be readily available on call during working
hours of the factory.
Provided that where a factory works in more than one shift, the Competent Authority,
if it satisfied that on account of the size of the factory, nature of hazards or frequency
of accidents, it is necessary to employ a whole time medical officer for each shift
separately, may, order so in writing.
Rule-71. ANNUAL MEDICAL EXAMINATION :- Annual medical examination for
fitness of each member of the canteen staff who handles foodstuffs shall be carried
out by the factory Medical Officer or the Certifying Surgeon.
Rule-72. SHELTERS, REST ROOMS AND LUNCH ROOMS:- The shelters, or rest
rooms and lunch rooms :(a) The building shall be soundly constructed and all the walls and roof shall be of
suitable heat resisting materials and shall be water-proof. The floor and walls to a
height of 90 cm. shall be so laid or finished as to provide a smooth, hard impervious
surface.
Rule 88 (Sch.XI)
- 113 -
Table
Permissible Exposure in Cases of continuous Noise
Total tine of exposure
sound pressure level
(continuous number of short
in dBA
Term exposures)
8
6
4
3
2
3/2
1
3/ 4
1/2
1/ 4
90
92
95
97
100
102
105
107
110
115
Note :- 1. No exposure in excess of 115 dBA is to be permitted.

2. For any period of exposure falling between any figure and the next higher or lower
figure as indicated in column 1, the permissible sound pressure level is to be
determined by extrapolation on a proportionate basis.
Legislation / Act / Organisation for Safety at International level
1. Occupational Safety & Health Act (OSH Act),1970.
2. Code of federal Regulations (C.F.R)
(Part 1926 for construction industry).
3. Occupational Safety and Health Regulation, US.
4. ILO ( International Labour Organisation).
5. WHO (World Health Organisation).
6. Safety councils of USA,UK,Sweden.
7. ASSE (Americal society of Safety Engineer).
8. NIOSH (National Institute of Occupation Safety & Heath).
9. AIHA (American Industrial Hygiene Association).
10. Japanese Industrial Safety and Heath Association.
11. OSHA (Occupational Safety and Heath Administration),US.
- 114 -
12. HSE (Heath and Safety Executive, HSE (UK).

13. UNEP (United Nation Environment Programme).
14. NFPA (National Fire Protection Association), US.
5.6- EMERGENCY PREPAREDNESS & PROCEDURES

Procedure for handling H2S Canisterin case of emergency at RAPP5&6
H2S CANISTERS & FACEMASKS
(1)
(2)
(3)
Responsibilities of Assembly Area Coordinator

Safe and proper storage of the canisters and face masks
Issue of the canisters and facemasks to personnel, in case of
emergency. During emergency exercises, canisters shall not be
distributed.
If any canister or facemask if inadvertently damaged, the Assembly Area Coordinator

shall intimate the same to Safety Section immediately, for replacement.
Responsibilities of Safety Section

(1)
Maintaining H2S canisters and facemasks in required quantity in

all assembly areas.
(2)
Replacement of damaged facemasks and canisters.
(3)
Replacement of canisters after its expiry date.
(4)
Training plant personnel on how to use H2S canisters.
How to use H2S Canister

(1) Unscrew the top lid and remove the bottom lid of the canister
- 115 -
(2) Connect one end of the breathing hose to the top end of the canister and the
other end to the facemask.
(3) Fasten the harness to the canister.
(4) Wear the facemask and fasten its belts so that the mask fits properly on the face
with no leakage of air from any place.
(5) Fasten the canister to your waist using its harness.
(6) Do not remove the lids of the canister except in case of H2S emergency.
REMEMBER !
H2S IS A POISONOUS GAS.
NEGLIGENCY MAY HAVE SERIOUS CONSEQUNECES.
Procedure for work in Confined Space at RAPP 5&6
1.0
SCOPE :
This procedure deals with Safety precautions to be taken during working

inside confined space at RAPP-5&6
2.DEFINITION OF CONFINED SPACE :
A confined area refers to a space by design, which has
-
limited openings for entry and exit
Unfavorable natural ventilation.
Such areas may be deficient in oxygen or may contain toxic,

flammable or asphyxiating gases, which may cause danger to life or
health.
2.1
SOME EXAMPLES OF CONFINED SPACE AT RAPP-5&6
(1)
Inside Turbine
(2)
Inside Condenser
(3)
Large pipe lines like CCW Pipe lines

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(4)
Stressing Gallery
(5)
All Storage tanks
(6)
Under ground drain lines/tanks
(7)
Cable tunnels and pipe trenches
(8)
Any other spaces, which fall within the definition of Confined space,
as, defined in S.No. 2.0. In case of doubt, the opinion of Safety
Engineer shall be considered as final.
3.0
STATUTORY REQUIREMENTS UNDER THE FACTORIES

(AMENDMENT) ACT, 1987
3.1
Section 36: Precautions against dangerous fumes
(1) In any factory, no person shall enter or be permitted to enter any

chamber, tank, pit, pipe, or other confined space in which
dangerous fumes are likely to be present to such an extent as to
involve risk of persons being overcome thereby unless it is provided
with a manhole of adequate size or other effective means of egress.
(2) No person in any factory shall enter or be permitted to enter any
confined space, until all practicable measures have been taken to
remove any fumes which may be present and to prevent any
ingress of fumes and unless either
(a) A certificate in writing has been given by a competent person based
on a test carried out by himself; that the space is free from
dangerous fumes and fit for persons to enter; or
(b)
The worker is wearing suitable breathing apparatus and a belt

securely attached to a rope, the free end of which is held by a
person standing outside the confined space.
(3)
Suitable breathing apparatus, reviving apparatus and belts and

ropes shall in every factory be kept ready for instant use beside
any such, confined space as aforesaid which any person has
- 117 -
entered, and all such apparatus shall be periodically examined

and certified by a competent person to be fit for use and a
sufficient number of persons employed in every factory shall be
trained and practiced in use of such apparatus and in the method
of restoring respiration.
(4) No person shall be permitted to enter in any factory, any boiler
furnace, boiler, flue chamber, tank, pipe or other confined space for
the purpose of working or making any examination therein; until it
has been sufficiently cooled by ventilation or otherwise to be safe
for persons to enter.
(5) Minimum dimensions of manholes:
i)
Rectangular shape 50cm x 30 cm
ii)
Oval shape Major and minor axis diameters 50cm and 30cm
respectively.
iii)
Circular shape - 50cm diameter.
Section 36-A: Precautions regarding the use of portable electric light

in any factory
(a)
No portable electrical light or any other electrical appliance

of voltage exceeding 24V shall be permitted for use inside any
chamber, tank, pit, pipe or other confined space unless adequate
safety devices are provided; and
(b)If an inflammable gas, fume or dust is likely to be present in such

chamber; tank, pipe or other confined space, no lamp or light
other than that of flameproof construction shall be permitted to be
used there in.
4.0
CLASSIFICATION OF CONFINED SPACES

Confined spaces are classified into categories A, B and C
depending on the hazards that exists in the space.
S. Characteristics
N
o.
1. Oxygen
(for life support)
2. Flammable gases
Class A
Class B
< 16%
16-19%
> 20% LEL
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10-20% LEL
Class C
> 19%
< 10% LEL
3.
Toxic Gases
4.
Category
hazard
5.0
Very High
> TLV
< TLV
of Immediately
Dangerous not Potential
Dangerous
immediately life hazard
To
Life
and threatening
Health
(IDLH)
HAZARDS ANTICIPATED IN CONFINED SPACES
(i)
Oxygen deficient atmosphere
(ii)
Presence of poisonous gases
(iii)
Explosion/Fire hazard
(iv)
Accidental entry of corrosive liquids or steam
(v)
Electrocution due to faulty equipment or exposed electrical
(vi)
Poor or lack of illumination
6.0
SAFETY PRECAUTIONS TO BE TAKEN BEFORE ENTRY AND

WHILE WORKING IN CONFINED SPACES
6.1
Positive isolation from all possible sources, i.e. electrical,

mechanical, hydrological etc. and blanking the inlet and outlet with
appropriate caution tags. Work permit from Safety section must be
ensured.
Action By: Permit holder/ concerned Section Head

6.2.
The equipment shall be Blinded or Blanked
Action By: Permit Holder & concerned Section Head

6.3.
The equipment shall be cleared of its contents with steam or

water. Where chemical reaction with water is likely, the equipment
shall be purged with nitrogen/ CO 2 till all toxic/explosive gases are
removed. The area shall then be purged with air or oxygen.

6.4.
Area shall be inspected; tested and certificate shall be given by

Competent Person by ensuring & verifying all the requirements
- 119 -
contact
stipulated in Section 36 of The Factories (Amendment) Act, 1987,

that the area is fit to work.
The atmosphere of the confined space shall be tested for oxygen
content, explosive vapors and poisonous gases. The test result
should be:
(a) Oxygen > 19%
(b) Explosive vapors < 10% of LEL
(c) Asphyxiates or toxic gases < TLV
Action By: Competent Person
6.5.
No portable electric light or any electrical appliance of voltage

exceeding 24 volts shall be used.

6.6.
If two manholes are available, then for ventilation, exhaust fan

shall be provided over one of them. If ventilation is insufficient,
mask-air line or BA set shall be used.

6.7.
While working at height, use of safety belt & proper working

platform shall be arranged to prevent fall from height. Height work
permit shall also be followed.

6.8.
When the confined space is hot & humid, in addition to certificate

from the competent person, the following shall be ensured:
(ii)
Before & after entry, sufficient quantity of cold water

shall be drunk, to avoid dehydration
(iii)
In case of contact with very hot surface or steam jet, cold water
shall be applied on the affected parts immediately. First Aid Center
should be contacted for further treatment
- 120 -
Action By: Competent Person, Permit Holder & concerned Section

Head
6.9.
Proper communication with the persons working inside the

confined space shall be ensured. So that, in case of necessity,
prompt help may be extended.

6.10. In addition to the above, the instructions given by Safety
Officer/Competent Person based on local conditions of the
confined space shall be complied with.
SAFETY PROCEDURE
Procedure for Safe Handling of Ammonia
1.0
Scope: -
1.1
These procedures will covers handling of Ammonia (25% concentration): For transporting the ammonia from store / other place to Planning Section.
1.2
Storage of ammonia in Planning Section.
1.3
Use of ammonia from container while operating the ammonia-printing

machine.
2.0
Properties & Hazards of Ammonia
Permissible exposure limit: 25 ppm (TLV) : 35 ppm (STEL)

Lower explosive limit: 16%
Upper explosive limit: 25%
Auto ignition temp. : 650 C
Mode of entry to person: Inhalation, skin or eyes
3.0
Effect of exposure
S.
Conc. in Effect
No. ppm
Exposure period
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1.
Least perceptible odour
2.
25-50
Odour detectable and 8 hour

no
adverse
effect
3.
100
No adverse effect
4.
400
5.
700
6.
17005000
500010000
7.
4.0
4.1
Exposure to 8 hours not

advisable
Immediate nose and No serious effect for 30 to 600
throat irritation
minutes
Immediate eye irritation
No serious effect for 30 to 60
minutes
Coughing, severe eye Can be fatal after 30 minutes
and throat irritation
Respiratory
spasm, Fatal within minute
rapid asphyxia
Emergency first aid treatment

Inhalation: - * Remove the victim to fresh air and provide artificial respiration
or oxygen if necessary. Seek a medical help.
Skin & eye: - Wash the affected area for 15 minutes with plenty of water, seek
medical aid immediately.
5.0 Safe transportation of Ammonia from store/ other place to Planning
Section: 5.1
Transportation of ammonia should be done in presence of authorized trained

person.
5.2
Ammonia container should be labelled as per relevant statute.
5.3
Transportation should be done by avoiding direct sunlight. In presence of

sunlight, it should be transported in covered vehicle.
6.0
Safe storage of Ammonia at Planning Section
6.1
Storage area should be identified and labelled.
6.2
Manual as well as mechanical ventilation should be provided in storage

area.
6.3
All containers should be kept in bund.
6.4
Flammable and chemical, which reacts with ammonia, should not be

stored with ammonia.
- 122 -
6.5
Arrangement to wash away the spillage should be readily available.
6.6
Fire fighting appliance of appropriate type should be readily available.
6.7
Monitoring of storage area to detect the leak should be done regularly.
6.8
Suitable Personnel Protective Equipment such as hand gloves, plastic

suit, facemask etc. should be used.
6.9
Entry of unauthorized person should be restricted.
6.10 Warning and causing notice, emergency instruction should be prepared

and displayed.
7.0
Safe use of ammonia during machine operation
7.1
Transfer of ammonia-to-ammonia printing machine should be done by

authorized trained persons only.
7.2
Equipment for transfer should be properly mentioned and inspected.
7.3
While working on machine, it should be ensured that room exhaust and

machine exhaust are working.
7.4
Transfer / Operation of machine should be stopped immediately if any exhaust

fan is stopped.
7.5
If smell of ammonia comes, stop machine and come out of the machine room.
GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT

CONSTRUCTION SITE 5& 6
1.
GENERAL
Following safety requirements shall be complied with before the Contractor uses the
power supply.
1.1
The Contractor shall submit a list of licensed electrical staff to be posted at

site.
1.2
It shall be the responsibility of the Contractor to provide and maintain electrical

installation on the load side of the supply point with regard to the safety
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requirements at site. All cabling and installation shall comply with the
appropriate statutory requirements given below and shall be subject to
approval of the Departmental Engineer- in charge / Electrical Engineer/ENC
(F&IS).
a)
Indian Electricity Act, 1910.
b)
Electricity (Supply) Act, 1948.
c)
Indian Electricity Rules, 1956.
d)
National Electricity Code 1985.
d)
Other relevant rules of Local Bodies and Electricity Boards.
After installation of the electrical power wiring works by the contractor, Form of
completion certificate as per IS 732 (Form SGCW-1) shall be submitted by the
contractor duly singed by the authorized valid licensed electrical contractor and / or
supervisor along with one copy of the contractors license and / or competency
certificate of supervisor issued by the Electricity Board/ government Electricity
Organizations as per the enclosure.
The power supply shall be regulated as per the terms and conditions of the supply of
the respective electricity boards.
1.3
(a) For purpose of electrical load and power planning by the electrical
section, the contractor shall furnish along with the tender, the estimated load
requirement of electric power for the execution of the contract works in terms
of maximum Kilo Watt or KVA demand during various periods/ months of the
contract period along with the details and location / locations of power supply
requirement for availing temporary electric power supply in the standard
Performa enclosed.
(b)
The electric power supply will be generally made available at one point in
the works site of the contractor by the department.
(c)
Where distribution boards are located at different places the Contractor

shall submit schematic drawing indicating all details like size of wires, Over
- 124 -
Head cable feeders, earthling etc. the position and location of all equipment
and switches shall be given.
1.4
The Contractor shall make his own arrangements for main earth electrode
and tapping thereof. The existing earth points available at site can be used at
the discretion of the Departmental Electrical Engineer with prior permission.
Method of earthing, installation and earth testing results shall conform to
relevant I.S. Specifications (IS-3043)
1.5
All three-phase equipment shall be provided with double earthing. All light
fixtures and portable equipment shall be effectively earthed to main earthing.
1.6
All earth terminals shall be visible. No gas pipes and water pipes shall be
used for earth connection. Neutral conductor shall not be treated as earth
wire.
1.7
The contractor shall not connect any additional load without prior permission
of Departmental Electrical Engineer. For obtaining additional power required,
test reports of the tests mentioned in (d) of Form SGCW-1 shall be submitted.
1.8
Joints in earthing conductors shall be avoided. Loop earthing of equipment

shall not be allowed. However tappings from an earth bus may be done.
1.9
The entire installation shall be subjected to the following tests before

energisation of installation including portable equipment.
1.
a)
Insulation resistance test.
b)
Polarity test of switches.
c)
Earth continuity test.
d)
Earth electrode resistance.
The test procedures and their results shall conform to relevant IS

Specifications. The Contractor shall submit a test report for his completed
installation every 2 months or after rectifying any faulty section in the
specimen test report.
- 125 -
2.
The following are provided for general guidance of the Contractor and shall be
read as specific requirement, in addition to complying with Indian Electricity
Act, Indian Electricity Rules and IS Specifications.
2.1
Installation
a) Only persons having valid wiremans license/ competency certificate shall be

employed for carrying out electrical work and repair of electrical equipment,
installation and maintenance at site. A qualified licensed Supervisor shall
supervise the job.
b) Electrical equipment and installations shall be installed and maintained as to
prevent danger from contact with live conductors and to prevent fires
originating from electrical causes like short circuits, overheating etc.
installation shall not cause any hindrance to movement of men and materials.
c)
Material for all electrical equipment shall be selected with regard to working
voltage, load and working environment. Such equipment shall conform to
the relevant standards.
d)
The minimum clearance to be maintained for all overhead lines along roads
and across roads shall be as per the statutory requirements as listed in clause
1.2 of Annexure.
e)
Grounding conductor of wiring system shall be of copper or other corrosion

resistant material. An extra grounding connection shall be made in appliances/
equipment where chances of electric shock are high.
f)
Electric fuses and/ or circuit breakers installed in equipment circuits for short
circuit protection shall be of proper rating. It is also recommended that high
rupturing capacity (HRC) fuses be used in all circuits. For load of 5 KW or
more earth leakage circuit breaker shall be provided in the circuits.
g)
Wherever cables or wires are laid on poles, a guard wire of adequate size
shall be run along the cables/ wires and earthed effectively. Metallic poles as a
- 126 -
general rule, shall be avoided and if used shall be earthed individually. Ant
climbing guards and danger notice shall be provided on poles. Each equipment
shall have individual isolating switches.
h) Wires and cables shall be properly supported and an approved method of fixing
shall be adopted. Loose hanging of wires & cables shall be avoided. Lighting
and power circuits shall be kept distinct and separate.
i) Reinforcement rods or any metallic part of structure shall not be used for
supporting wires and cables, fixtures, equipment, earthing etc.
j)
All cables and wires shall be adequately protected against damage. In case
the cable is required to be laid under ground, it shall be adequately protected by
covering the same with bricks, Plain Cement Concrete (PCC) tile or any other
approved means.
k)
All armored cables shall be properly terminated by using suitable cable glands.
Multistranded conductor cables shall be connected by using cable lugs /
sockets. Cable lugs shall preferably be crimped. They shall be of proper size
and shall correspond to the current rating and size of the cable. Twisted
connections will not be allowed.
l) All cable glands, armoring and sheathing of electric cables, metal circuits and
their fittings, metallic fittings and other non-current carrying parts of electrical
equipment and apparatus shall be effectively grounded.
m) All the Distribution Boards, Switch Fuse units, Bus bar chambers, ducts,
cubicles etc. shall have MS enclosures and shall be dust, vermin and
waterproof. The Distribution Boards, switches etc. shall be so fixed that they
shall be easily accessible. Change shall be done only after the approval of the
Departmental Electrical Engineer.
n) The Contractor shall provide proper enclosures / covers of approved size and
shape for protection of the entire switch board, equipment etc. against rain.
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Exposed live part of all electrical circuits & equipment shall be enclosed
permanently. Crane trolley wires and other conductors, which cannot be
completely insulated, shall be placed such that they are inaccessible under
normal working conditions.
o)
p)
Ironclad industrial type plug outlets are preferred for additional safety.
Open type Distribution Boards shall be placed only in dry and ventilated
rooms; they shall not be placed in the vicinity of storage batteries or otherwise
exposed to chemical fumes.
q)
Isolating switches shall be provided close to equipment for easy disconnection

of electrical equipment or conductors from the source of supply when repair or
maintenance work has to be done on them.
r)
In front of distribution boards a clear space of 90 cm shall be maintained in

order to have easy access during an emergency.
s)
Adequate working space shall be provided around electrical equipment, which

requires adjustment or examination during operation.
t)
As far as possible electrical switches shall be excluded from a place where

there is danger of explosion. All electrical equipment such as motors; switches
and lighting fittings installed in workroom where there is possibility of explosion
hazard shall be explosion proof.
u)
All connections to lighting fixtures, starters or other power supplies shall be

provided with PVC insulated, PVC sheathed twin / three / four core wires to
have better mechanical protection for preventing possible damage to equipment
or injury to personnel. Taped joints shall not be allowed and the connections
may be made in looping system. Electric starter of motors, Switches shall not be
mounted on wooden boards. Only sheet steel mounting or iron framework shall
be used.
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v) All the lighting fixtures and lamp holders shall be of good quality and in good
condition badly repaired or broken holders, etc. shall not be used.
w) Only PVC insulated and PVC sheathed wires or armored PVC insulated and
sheathed cables shall be used for external power supply connections of
temporary nature. Weatherproof rubber wires shall not be used for any
temporary power supply connections. Taped joints in the wires shall not be
used.
x) The bulbs/ lamps used for illumination and testing purpose shall have covered
or guard to protect them from accidental breakages. Only 24 V supply system
shall
be used for hand lamps etc, while working inside metallic tanks or
conducting vessels.
y) After installation of new electric system and or other extensive alterations to
existing installations, Departmental Electrical Engineer shall make critical
inspection before the new system or new extension is put in use.
z)
Contractor shall ensure that power factor for their loads shall be maintained at
0.85. In case the power factor falls below 0.85, the contractor shall provide
necessary capacitor units.
2.2
Operation & Maintenance
a) All persons who work with electrical installation/ equipment shall be aware of the
electrical hazards, use of protective devices and safe operational procedures. They
shall be given training in fire fighting, first aid and artificial resuscitation techniques.
b)
The supervisor shall instruct the workers in the proper procedure. specify and
enforce the use of necessary protective equipment such as adequately
insulated pliers, screw drivers, fuse pullers, testing lamps and similar hand
tools. Only wooden ladders shall be used to reach the heights in electrical
work.
c)
No material or earthwork shall be allowed to be dumped below or in the

vicinity of the bare overhead line conductors.
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d)
Separate work permits shall be issued for individual group leaders working on
the same system which shall be returned after the completion of the work to
Safety Supervisor and no system shall be energized without the clearance of
Safety Section.
e)
Before any maintenance work is commenced on electrical installations/

equipment, the circuits shall be de-energized and ascertained to be dead by
positive test with an approved voltage-testing device. Switches shall be
tagged or the fuse holders withdrawn before starting the work. Adequate
precautions shall be taken in two important aspects viz.
i) That there shall be no danger from any adjacent live parts and
ii) That there shall be no chances of re-energisation of the equipments on which the
persons are working.
f) While working on or near a circuit, whenever possible the use of right hand may
be practiced even through the circuit is supposed to be dead. The left hand may
preferably by kept in pocket.
g) When it is necessary to touch electrical equipment (for example when checking
for overload of motors) back of the hand may be used. Thus, if accidental shock
were to cause muscular contractions, one would not freeze to the conductor.
h) Operation of electrical equipment shall be avoided when standing on wet floor or
when hands are wet.
i) Before blown fuses are replaced, the circuit shall be locked out and investigation
should be done for the cause of the short circuit or overload.
j)
When two persons are working within reach of each other, they shall never
work on different phases of the supply.
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k)
When structural repairs, modification or painting work are to be undertaken,

appropriate measures shall be taken for the protection of persons whose work
may bring them into the proximity of live equipment/ circuit.
l)
It shall be ensured that the insulation and wire size of extension cords are
adequate for the voltage and current to be carried.
m)
While tapping electricity from the socket, plug top must be used. It shall be
ensured that no extension board is over loaded while tapping. Only standard
three pin plugs shall be used for tapping electricity. Broken sockets /plugs
shall be replaced immediately. Only joint free cables shall be used for
connecting equipment / apparatus.
n)
o)
Floors shall be kept free from electrical cables to avoid tripping hazard.
Power supply to all the machines and lighting fixture shall be kept off when
not in use.
p)
Temporary electrical connections shall be removed as soon as the stipulated

work is over. After completion of the works, the Contractor shall dismantle the
distribution boards and the other facilities.
q)
Unauthorized tapping of power by others from distribution boards under the
control of the contractor shall be prohibited at all circumstances.

r)
No flammable materials shall be stored in any working area near the

switchboards.
s)
Safety work permits shall be used for switching off the main feeder and
equipment by the contractor.
t)
MEN ON LINE
DO NOT SWITCH ON
DANGER or
CAUTION board as applicable shall be used during maintenance works on

the electrical equipment.
- 131 -
2.3
a)
Portable Electrical Equipment

Portable electrical equipment shall be regularly examined, tested and
maintained to ensure that the equipment and its leads are in good order.
Register shall be maintained for inspection recording the testing dates and
results of the equipments.
b)
All portable appliances shall be provided with three-core cable and three-pin
plug. The third pin of the plug shall invariably be earthed. It shall be ensured
that the metal part of the equipment shall be effectively earthed.
c)
All connections to portable equipment or machines from the panel /

distribution board / extension board shall be taken us 3 core double insulated
PVC flexible cooper wire in one length. No joints shall be allowed in flexible
wire. In case single length of wire is not sufficient for a particular location then
the supply can be tapped by providing another extension board comprising of
switch and socket.
d)
Flexible cables for portable lamps, tools, and apparatus shall be regularly
examined, tested periodically and maintained to ensure safety.
- 132 -
FORM NO. SGCW 1

FORM FOR COMPLETION CERTIFICATE
(Prescribed
under
Cl . 1. 2 of Annexure)
I / We certify that the installation detailed below has been installed by me / us and tested
and that to the best of my / our knowledge and belief, it complies with Indian Electricity Rules,
1956 as well as IS : 732- 1963 code of practice for Electrical Wiring Installations. (System
voltage not exceeding 650 Volts) (Revised).
Electric installation at .
a) Particulars of work
i)
Number
load
Total
Voltage
and
system
of
supply
Type of system
of wiring
Light Points
ii) Fan Points

iii) Plug Points (3 pin)
iv) Motors
b) If the work involves installation of overhead lines and / or underground
cable _____________________________________________________
c) Earthing :
Description of earthing electrode, size of earth wire and number of electrodes provided :
d) Test Results :
1. Insulation resistance for the whole installation :
i. Between conductors
ii. Between each conductor and earth
2. Resistance of earthing electrode or earthing system.
- 133 -
3. Maximum earthing resistance of installation _______________________
Signature of Supervisor
Name and Address
of Supervisor
Signature of Contractor
Name and Address
of Contractor.
CHAPTER - 6
FINDINGS & RECOMMENDATIONS
1.
Arrangement to be made for scrutinizing the safety policy of RAPP-5&6

with expert agency.
2.
The safety policy is to be revised & include the following.

(i)
Arrangement for involving the workers.
(ii)
Accountability for health & safety performance of individuals at different

levels while considering their career advancement.
(iii) Arrangement / provision for informing, educating and training / retraining of

employees.
1. Safety policy should be the part of the induction training programme of the new
employees & retraining programme (for other employees) and made them aware
for their duties & responsibilities related to safety.
4.
Safety policy should be placed in the Annual Progress Report of RAPP-5&6.
5.
Training / retraining schedule to be made for retraining of Safety Officers in

the latest techniques of total safety management.
6.
Status of Engineer In Charge (F&IS) & Safety Officer to be given as per

the Atomic Energy (Factories) Rules 1996.
- 134 -
7.
Reconstitute the Apex Safety Committee & include all Section Heads as
members of the Apex Safety Committee.
8.
A system is required to be make for appraisal

recommendations of the Apex Safety Committee.
9.
For appraisal of the latest development in Safety, Health and Environment,

Joint safety inspection by the committee to be carried out one day before the
schedule date of the Apex Safety Committee meeting.
10.
Elected / nominated workers representative by the workers themselves should

be included in the Apex Safety Committee. This will promote co-operation
between workers and the management.
11.
A procedure / system should be introduced for reporting of all near miss and
first aid accidents.
It is to be made mandatory that all accidents / near miss incidents including
first aid injuries be investigated by line management supervisors / engineers.
The recommendations based on the investigation should be implemented at
the earliest.
12.
the implementation of
13.
A training programme may be organized for all line supervisors/ engineers on

accident investigation.
14.
Continuous ongoing safety inspection is the responsibilities of the workers,

foreman, supervisors & engineers of the line management, as part of their job
responsibilities. Hence, it is recommended that these responsibility along with
the accountability should be enthirusted with the line management. The
greatest advantage for supervisors continuous inspection is his familiarity
with employees, equipment, machines, and environment.
15.
Planned safety inspection at intervals is real safety & health inspection. It is

deliberate, thorough and systematic. Hence therefore it is recommended that
planned safety inspection should be carried out by the safety professional with
the help of checklist.
16.
Checklist for inspections of different areas to be prepared.
17.
Plans should be made & use for periodic, intermittent & general inspection of
the project site of RAPP-5&6.
18.
Separate infrastructure facilities with audio-visual support may be provided to

safety section.
19.
Assessment of trainee worker should be started with immediate effects.

Schedule of refresher training of employees to be followed strictly.
- 135 -
20.
Safety suggestion scheme should be introduced at RAPP-5&6 site.
21.
RAPP-5&6 should participate in National Awards / Suggestion Schemes.
22.
One qualified Medical Officer should be deputed at RAPP-5&6 First Aid

Center, who shall be assisted by at least one qualified nurse and one nursing
attendant in each shift.
23.
First Aid Centre to be made readily available during the working hours of the
project.
24.
Although good housekeeping system maintained at equipment erection area,

these system to be extended to all civil construction area also.
25.
Floor wise Area- In charge for all buildings to be identified & make them
responsible & accountable for the health, safety of the area.
26.
Ear muff stations to be maintained with sufficient Nos. of ear muff at high
noise level area for immediate use of visitors / near by workers in case of
requirement.
27.
At present during construction phase use of wet methods (use of water

sprinklings) to control air Borne dust contaminations during sweeping &
cleaning of main plant area should be adopted.
28.
Illumination level of project area to be improved up to the minimum required

level on top priority.
29.
Periodical illumination level survey should be carried out.
30.
Follow up system to be introduce for compliance of recommendations of the

illumination level survey report.
31.
All steps taken to prevent hazards, which are given in observation No. 3 (in
6.1.9 Hazard identification and control), should be followed strictly.
32.
Calibration of all monitoring equipment to be carried out time to time &

maintain all monitors in working order all the time.
33.
All safe-operating procedures to be made available in the local language (i.e

Hindi language) & provide to all concerned workers and display in working
area.
34.
All safe operating procedure & job safety analysis should be reviewed
periodically.
- 136 -
35.
Procedure for issue of work permits should be revised, work permit issuing
authority to be changed from ENC (F&IS) or his representative to concerned
Area In-charge / Engineer In- charge of works and ENC(F&IS) or his
representative works should be introduced advisor not a issuing authority.
36.
Safety is a line Management function this massage should be made clear to

the line management.
37.
The power to stop any work (not being done in a safe manner) with the
approval of competent authority is to be given to safety department
CONCLUSION OF NUCLEAR CONSTRUCTION ACTIVITIES
2nd largest economic activity in India next to Agriculture.
Constitute 10 to 20% of the world labour force.
Injured persons more than 10 million workers / year through out the
world.
Accident Rate 160 250 / thousand compare to 60 80 in
other
industries.
Fatal accident at NAPP 19, MAPP-16, RAPP-14
This year TAPP-4 one each in ,Kaiga, RAPP-5&6, RAPS 1&2 = 7 fatal
accidents.
Main obstruction to Safety in construction
Each construction job is unique in nature and therefore defies

standardization.
Each construction project has a new team which does not help
in
building team spirit.
Each construction job is on new site where infrastructural facilities not

available.
Management does not have direct control as work is done by sub
contactor which makes it difficult in enforcing the safety rules.
Frequent changing of work force.
- 137 -
Workers may not have any past experience and any training.
Worker exposed to new area frequently.
Multiple activities / contractor at same location.
Type of Accident
Fall of person (35%).
Fall of objects (20%).
Electrical shock 10%.
Hitting by object 15%.
Steeping in or caught between (10%).
Others 10%.
Main Activities in Construction work.
Excavation
Reinforcement preparation.
Shuttering work.
Concrete pouring & EP embedment.
Structural / equipment erection.
Cable lying.
Scaffolding installation.
Electrical work.
Fabrication.
Excavation :- It involve the removal of soil and rock.

Rock Blasting work:-
Main hazards :1. Explosion during Handling of explosives during transportation & storage and
its
use.
2. Misfire.
3. Unguarded blasting areas.
4. Premature detonation.
5. Fly rocks.
6. Inhalation of dust produced during rock drilling.
Precaution: Use explosive magazine in scripted with
transportation of explosive.
- 138 -
DANGER EXPLOSIVE for
It should be protected from shock, frictions, collision, light or sparking.
Ensure trained licensed person (Blaster) and workers to load, transport and
unload explosives.
Detonator to be transported in separate component.
Smoking not to be allowed.
Package containing explosive not to be dropped or opened with metal tools.

Explosive not to be carried out during the approach or progress of electrical
storms.
Explosive not be exposed to flame, excessive heat or sparking.
Explosive to be placed in a hole that is not wet, free from shock or
The length of safety fuse should not < 76 cms.
Before blasting, area (around 200 mtrs.) should be evacuated.
After
vibration.
blasting, explosive loaded area should not be approached before15
minutes of blasting.
In
case electrical blasting, all cable and detonator should be checked for
continuity.
Sufficient
nos. of steel plate and sand bags should be used for muffled
blasting to
avoid fly rock.
Use of delay detonator to be ensured to limit the vibration.
Safe
operating procedure to be made and instruction given on blasting
permit to
be followed.
Rock driller to be given dust mask.
PPV
not to be exceeded 10 mm/s for general building / equipment and 3m
m/s for reactor building, critical building housing deli gate electronics /
systems.
b)
Mucking and rock disposal Hazards :-
1) Fall of stone / hip of stone due to undercutting.

2) Fall of person in excavated pit / holes.
3) Striking against / falling of pocklen / muck remover/ dozers.
Precaution :-
- 139 -
electrical
Side of the excavated pits to be sloped to the angle of repose of the soil being
excavated.
Sides of excavated pits to be protected by proper shoring and barricading.
IS 3764- Safety code for excavated to be followed.
Excavated stone / soil to be dumped at least 1.5 mtr. Away from edge of pit.
Measure to be taken to prevent falling of loose material / soil in the working
area loose muck / stone to be removed.
Precaution mentioned in NBC to be followed.
Side of excavated pit / trench should be protected by guard rails.
Excavated area to be well illuminated and red light to be put around
excavated pits for warning.
Ensure warning light, back horn on pocklen,truck, excavators.
Excavation must be inspected before any person carries out any work, after
any event likely to have affected the strength or stability of the excavation or
after any accidental fall of rock, earth etc. by competent person.
All the material handling equipment should be tested as per AEFR
and
capacity to be marked on equipment.

JHA to be prepared and implemented.
Every vehicle used for muck disposal should have head & tail light, power &
hand brakes, reversing alarm, search light for forward and backward
movement.
Reinforcement Preparation and shuttering work Hazards :(1) Fall of material while manual loading and unloading and while handling with
material handling equipment or material.
(2)
Fall of person while working at height.
(3)
Fire hazards due to shuttering material.
(4)
Fall of material from overhead.
(5)
Sticking against the object while handling of material by crane / truck
.
Precautions
- 140 -
etc
As far as possible avoid handling of reinforcement and shuttering material

manually.
For transportation of rebar / shuttering material from stock yard, tailor / vehicle
of adequate capacity with back horn, head & tail light should be used. Trolley
carrying these material should not handled manually. Safe load carrying
capacity should be clearly marked on transport equipment.
Loading and unloading of material to be done with help of
cranes. Warning
hooter to be blowed by crane operator while handling material over the

working area.
Scaffolding of sufficient strength with working platform of proper width and
railing should be used.
Proper base plate, sole plate, cross bracing, lateral support, ladder or climbing
arrangement should be ensured.
Use of safety helmet, safety belt, safety net to be ensured while working at
height.
Welding / cutting flux / hot slag / hot spatter should be shielded from free
falling.
Cutting torch cylinders, welding sets cables, hole etc. should be checked for
their sound condition to prevent fire.
Availability of proper earthing and ELCBs to be ensure.
Form work and shores should properly braced or tied together.
Form work should have walks or other secure access for inspection.
Concrete Pouring and Deshuttering work Hazards:(1) Collapsing of moving concrete bucket.
(2) Striking against concrete bucket.
(3) Dermatitis due to exposure of concrete.
(4) Striking against movable concrete mixer (vehicle).
(5) Fall of shuttering material.
Precaution
- 141 -
Proper walkways / working platform with handrails to be provided while

concreting.
Proper ramps to be provided if concrete is transported manually overhead
from ground floor to the elevated places.
Proper illumination, especially for night hours.
Concrete buckets used with crane should be free from projection.
Movement of concrete bucket should be governed by signals.
Pipe carrying pumped concrete should be securely anchored at its end point
and each curve on it.
When dry ingredient of concrete are being mixed in confined space, the dust
to be exhausted at the time of mixing or use of dust mask to be ensured.
Vibrators used should be properly earthed and its leads to be installed.
Deshuttering
Free fall of shuttering plates to be prevented.
Evacuation to be done before deshuttering and entry to the area to be
stopped.
Deshuttering personnel should stand on firm working platform / support.
Structure Steel Erection
It poses hazards due to
Heavy handling and maneuvering.
Need for fixing the member at unguarded elevated places.
Lifting involved.
Hazards
Fall of structural items.
- 142 -
Collapse of structure items.

Fall of person from height.
Fall of hand tools / bolts / nuts.
Failure of lifting tackles and slings.
Human failure, etc.
Precautions
1. Rebar cutting machine should have guarding & earthing.
2. Ensure use of adequate load capacity and tested lifting machinery / tackles as
required by AEFR.
3. Operator & riggers lifting machinery should be trained and medical
examination of operator to be done before deployment.
4. Whenever handling the load overhead, area below should be cleared of by
sounding siren / horn.
5. Ensure proper working platform with railing and toe boards and proper
scaffolding while handling / erecting material at height.
6. Use of safety helmet, belt, net to be ensured.
Scaffolding
Basic consideration before the erection of any scaffold.
What is the scaffold for ?
Exactly where is it to be erected?
What material are to be used?
Can safe access be provided for the erection and use of the scaffolding?
How many working platform will there be?
What loading will be imposed upon working platforms, and on the scaffold as
a whole?
Is the ground condition where the scaffold is to be erected suitable ?
How and where can the scaffold tied in?
What bracing will be required?
Following parts are required to be kept in mind.
- 143 -
It a should have proper working platform with safe access and egress.
Scaffolding must be erected, altered and dismantled under
the
supervision
of a competent person.
It should be of sound construction.
No scaffold should be left partly erected or dismantled unless adequate notices are
displayed and access blocked.
Ends, fitting should be free from corrosion, not be warped, twisted, split.
It should conform to IS 4041 part 1 and IS 2750.
After erection of scaffolding it should be certified by Engineer- In-charge as
per AERB work guide.
Bamboo scaffolding is not allowed as per AERB safety guide.
Foundation
It should be of adequate strength to support and disperse the load.
On hard surface such steel and concrete of sufficient strength and thickness,
scaffold may be directly placed on the surface.
However it is preferable to use base plate.
On other surface, load should be spread by using base plate and sole pate. The
soil or ground beneath the sole pate should be level and properly compacted.
Sole plate (as per BS)

a) For hard ground 450 mm x 225 mm x 35 mm
b) For soft ground 760 mm x 225 mm x 35 mm
Thermal block or scraps of timber should not be used on sole plates.
Standards :- Should be
Placed vertically or slightly inclined towards the structure.
Spaced closely enough to provide adequate support.
On a base plate and sole boards to prevent displacement.
Near to ledgers.
Size min. 40 mm.
Ledgers
- 144 -
Should be horizontal and fixed securely to the inside of standards with right
angled load bearing couplers.
Size min. 40mm.
Transoms
Fixed to ledgers or standard with right angled couplers.
Nominal thickness of
Maximum span of transom
board or platform
32 mm
1.0 mtr.
38 mm
1.5 mtr.
50 mm
2.6 mtr.
63 mm
3.5 mtr.
The distance apart of transoms must not result in a bay length greater than as shown
below
Duty
Max.
Very duty light duly (inspection, painting etc.)
2.7 mtr.
Light duty (plastering,painting, cleaning)
2.4 mtr.
General purpose (brick work,window fixing)
2.1 mtr.
Heavy duty (block work)
2.0 mtr.
Special duty (masonary work, concrete block work)
1.8 mtr.
Scaffolding Platform
to conform to IS: 4041 part II.
min. uniformly distributed design load / m2 be 365 Kg.
no concentrated load which exceed 365 Kg.
proper railing at level at least 1. 0 mtr. height and toe board.
Platform Height
Type of Occupancy
Min. width of platform
Less than 2 m
a) Painter, decorator similar
30 cm
b) for other type
50cm
a) men, tools & material
120 cm
b) at vehicles (wheel barrow)
150 cm
workers
(men and tools)
More than 2m
- 145 -
Bracing :- Required for stability and prevent over turning of
scaffold.
a) Ledger bracing :- Shall be fitted on alternate pairs of standard except
where
the width of the bays are 1.5 mtr. or they should be fitted on every third pair.
b)Longitudinal or facade bracing
It should be provided for all scaffold unless the longitudinal
stability
of
the
scaffold is obtained by other means.

To be connected either zigzag from bottom to top, between a pair
of
standard or as a continuously diagonal sloping tube.

Brace assembly to be provided along each face of scaffold at intervals not
exceeding 30 mtr.
Ties
:-
It
normally
pass
through
opening
into
the
building.
A tie links the scaffold to a building.

It resist the inward and outward movement of the scaffolding.
It also gives additional longitudinal stability.
Scaffold fitted with sheeting, tarpaulin etc. is subjected to
extra stress due
to wind pressure. Hence they require more ties.

Safety nets, belts & harness
Used when it is impracticable to provide standard working platform with guardrails
and toe boards.
But even if safety nets are installed, working platform should be made above
the net.
Safety nets
Types
Personnel nets :- 100 mm mesh, intended to catch a person falling from
above.
Material or debris protection nets :- smaller mesh size 12 mm 13 mm,
intended to protect those working below from falling objects.
- 146 -
To be Conform to IS 3521 / EN 1263 1&2.

To be installed as close as possible to the working level.
If on the outside of the structure, it should be higher at the outer edge than the
inner edge.
The max. recommended distance a person should fall before encountering a
net is 6m.
Fall Height
Catching width of net
> 1.0 mtr.
> 2.0 mtr.
> 3.0 mtr.
> 2.5 mtr.
> 6.0 mtr.
> 3.0 mtr.
Installation of net to be done by qualified person.

Ensure that supporting frame work withstand impact or shock loading and that
frame work itself does not present a hazard to personnel who may fall
into the net.
Net to be securely attached to supporting frame work, with tie cords, hooks,
rings or timbles spaced at a max of 750mm.
The strength of actual tie should be at least double the net.
Test certificate should be made available from supplier specifying type of net,
breaking strength of the net (when mesh and border cord was under test.
Once in three month, test tie rope attached to net should be tested.
Net used for two year, or if there is deterioration, advice to be sought from its
supplier for its use and test.
Nets to be washed occasionally during the use and always before use to
remove grit, dirt to avoid deterioration.
To be stored in storage cupboard well ventilated and not in wet stage.
Safety belts, harness and lanyards
Type
a)
Pole belt :- used by lineman etc. not intended for drop > 600mm.
- 147 -
b)
General purpose safety belt :- used in conjunction with a lanyard and

anchorage point limits the drop to 600mm.
c) Chest harness:- safety belt with shoulder straps where lanyard and anchorage
point limit the drop the mix 2m. It should be worn tightly to prevent any slippage
after a fall.
d) General purpose safety harness :- full harness with thigh and shoulder straps.
limit drops to 2m, persons suspended in a reasonably upright position from the
attachment point.
e) Safety rescue harness :- designed to be worn by anyone in a confined space or
location where person can be incapacitated or rescued.
In case of simple belt, the shock loading is highly concentrated and resulting
suspension position is unsatisfactory when person falls. Full body harnesses
is better for this.
To limit the drop the anchorage points should be as high as possible above
the person and as near to vertical as possible to avoid the swing.
Anchorage points should be capable of with standing shock loading.
Breaking load of belt should be 2000 Kg. min.
Shock Absorbers :If a person wearying a harness and lanyard falls, there is a considerable shock
loading to the body and the more the fall, the greater the shock. The maximum
distance a person should fall before fall arrest is 2 mtr.
Shock absorbers in the form of tear away sticking, stretch springs, may be build into
the lanyard or safety harness to reduce the shock loading.
Once used during fall, they should the discarded.
Fabrication shop safety
1.
Housekeeping should be proper.
2.
Material handling equipment should be in good order and regularly

examined, inspected and tested.
3.
Use of three pin tops, earthing, ELCB to be ensured.
4.
All the grinding, welding machine, oven, generator, rectifier should be

earthed.
5.
All metallic shed and equipment to be earthed.

- 148 -
6.
Guarding of cutting machine, grinder, belt pulley etc. to be ensured.
7.
Use of required PPEs as per the work to be ensured.
8.
Availability of proper and adequate quantity of fire extinguishers to be

ensured.
9.
First aid facility to be made available.
10.
Separate storage facility for different type of cylinders metal caps to be

provided for each cylinder.
11.
License from explosive department to be taken for storing gas
cylinder
or petroleum if it exceeds the limit prescribed in gas cylinder rules and

petroleum rule.
12.
All out door installation should have rain protection.
13.
Use of rubber mat, ELCB, indication lamp, artificial respiration chart, first
aid
box, fire extinguisher and earthing should be ensured for electrical panel.
14.
All metallic equipment / structure, shed, machine should be earthed.
15.
Electrical panel should be easily accessible. No obstruction should present in

way.
16.
Sand blasting is not be allowed it should replaced by short blasting.
17.
Radiography not to be allowed in day time. Use of proper warning sign,

TLDs, barrication to ensured.
Electrical safety at construction site

Dangers from electrical power.
i)
Electrical shock :- 20 mA is considered dangerous. Death can occurs if

current flow bet. 50 to 100 mA.
ii) Burns.
iii) Fire and explosion.
Fall of person & dropping of tools / material are the secondary hazards.
Precaution
- 149 -
1.
Before connecting power supply to the installation, get clearance from safety
point of view from safety engineer.
2.
Power distribution board should be of metallic type with double earthing with
proper size earth lead.
3.
Cable entry and exist points to be provided with terminal glands.
4.
Metallic body of all electrical appliance to be connected to earth.
5.
Use of bare wire for connection should not used. Proper three pin top to
be
used.
6.
Flexible cable not to be allowed. Use armoured cable.
7.
Avoid loose joints.
8.
Use 110 volt supply for lighting.
9.
Hand lamp should be of 24 volts.
General precaution / safety measures

1.
Building material / equipment to be stored or stacked in a safe and orderly

manner to avoid obstruction of any passage way or place of work.
2.
Run way or ramp should not < .43 mtr. in width and 25 mm thick minimum.
Run way or ramp located > 3 mtr. above floor
to be provided with
guardrail.
Run way to have slop not exceeding 1 in 4.
3.
Belt conveyor used for batching plant should have a ramp with railing.
Emergency rope switch should run along the entire length of conveyor, the
use of which should stop the entire conveyor.
All the morning part, nip points, trap point should be effectively guarded.
Protective shield to be provided below belts across passage and road to
catch falling material.
Monitor air for leakage of ammonia used in ice plant, spm level (due to dust
generator at crushing plant).
5.
Person employed at cement store should be provided with dust mask.
.Use of permit system to be ensured for
a)
Welding (cutting near combustible material or near critical equipment).
b)
While working at height.
c)
Working inside the confined space.
d)
Rock blasting.
- 150 -
e)
For removal of existing cover / railing from openings.
7.
Job safety analysis should be prepared and implemented for each hazardous
job.
8.
Person working at height (2.5 mtr. and above) should have valid height pass.
9.
Pep talk or pre job briefing to be ensured.
10.
Floor Opening :- Direct cause of many fatal accident. 700 floor opening in TB.
Opening to be provided with railing / cover. Permit to be taken for removal of
cover guard rail.
11.
Use roof ladder for work at AC roof to be ensured.
CONCLUSION
The overall study of safety system in construction sites, past accident
statistics and analysis of Safe Operating Procedures shows that safety
aspects in every hour are taken care taken care adequately. Management also
fulfills the overall statutory requirement. The Legislation and recommendation
given by different safety audits are already implemented and maintained
Nuclear Plant Construction.
- 151 -
But still safety has not end. There is further scope for improvement with
respect to safety specially working at height crane working places and
confined spaces. Few recommendations have been given for further
improvement. Almost all the recommendations are feasible for implementation
and do not involve much financial burdens on management. The change in
attitude and discipline of employees will definitely bring down the accident
rate further down and will help down and will help in improving the Safety,
Health and Environment in Nuclear Plant Constructions.
7 - LIST OF REFERENCES
Author
1.
2.
H.W. Henrich
Will Hammer
Title
Industrial Accident Prevention
Occupational Safety Management &
3.
4.
5.
Simond and Garibaldi

Bird Frank P.
National safety Council
Engineering
Safety Management
Management Guide to Loss Control
Accident Prevention Manual Vol . I ,II & III
6.
7.
8.
,Chicago
ACGIH ,USA
ACGIH ,USA
SAX , IRWIN
Industrial Noise Control Manual

Industrial Ventilation
Dangerous Prosperities of Industrial
- 152 -
9.
10.
11.
12.
Material
Health & Safety in Factories
Commentaries of Factories Act
Loss Prevention in Process Industrial Vol. I,
Red grave
Srivastava KD
Frank P. Less
to III
How to prepare workplace emergency
U.S. Dept. of Labour

OSHA
8 - ANNEXURES
FIRST - AID TIPS
1.
ANNEXURE - 1
SHOCK.
1. Lay the patient on his back
2. Stop bleeding if any.
3. Relieve pain by supporting injured part.
4. Keep the patient comfortable, but not hot do not let him cause
sweating.
5. Fluids may be given in small amounts unless the patient is not
unconscious likely to be operated on ,or has an abdominal wound.
- 153 -
6. Reassure and cheer up the patient.

2.
WOUNDS.
1. Stop the bleeding by any one of the following methods by Direct,
Direct finger pressure into the wound in cases of larger bleeding
wounds and Tourniquet (seldom need) use only as a last resort.
2. Avoid touching the wound with hands or unsterlised material.
3. Clear the wound with running water and surrounding area with soap
or spirit with clean gauze washing away from the wound, Apply
readymade adhesive gauze bandage or sterilized qauze and ruled
bandage as needed.
4. Keeps the patient quite, raising the extremity if it is the bleeding part.
Give no stimulants.
5.
Never apply antiseptic ointment lotion or iodine or germicide to the

wound.
3.
ABDOMINAL WOUNDS:
1. No time must be lost in sending the patient to the hospital.
2. Keep the patient flat.
3. Give noting by mouth.
4. Maintain warmth.
5. If intestines protrude from the wound do not attempt to touch or
replace them.
6. Apply sterilized dressing and binder for wounds..
7. Provide careful, immediate transportation to the hospital.
4.
EYE INJURIES.
1 Removal may be attempted by washing if foreign body if is not
embedded.
- 154 -
2 Do not is a foreign body embedded in the eyeball, send the worker

immediately to the doctor after applying pad and loose bandage.
5.
CHEMICAL BURNS OF THE EYES.

1. Immediate washing of the eye at least for fifteen minutes is of great
importance.
2. Apply sterilized bandage and send the worker immediately to the
doctor.
3. Neutralizing agents or ointments should not be used.
6.
SUFFOCATION.
1. Remove the patient from the source of danger.
2. Make a rapid examination to ensure that the air passage is free ,and
clear it if necessary.
7.
ELECTRIAL SHOCK.
1. Remove the patient from the source of danger.
2. Make a rapid examination to ensure that the air passage is free , and
clear it if necessary.
3. Restore natural breathing by artificial respiration if breating has
ceased.
8.
INSENSIBILITY.
1. Call a doctor immediately.
2. Where the patients face is pale, lay him flat and face downwards with
his head turned to one side. If his face is flushed or blue, raise and
support the head and shoulders.
3. Control any serious bleeding.
4. Loosen any tight clothing and let him have plenty of air.
5. Do not give anything by mouth.
6. If doctor is not available send the causality to hospital.
- 155 -
9.
BACK BONE (SPINAL) FRACTURE.

1. Transport on the rigid frame. This frame may be improvised by using
available boards or a door.
2. The rigid frame may placed on a stretcher for transportation.
3. If a firm frame cannot be improvised transport patient on abdomen
on a stretcher made or canvas or blanket.
4. In neck fracture cases, it is much better to get a doctor to the
accident scene, as danger to life is great if Neil Robertson stretcher
is available use the stretcher for such injured person for safe
transportation.
10.
BRUISES:
1. Cold applications at first (apply ice if available).
11.
BURNS:
1. Act quickly, treat for shock.
2. Put the affected part in cold water.
3. Pour the water burns that cannot be immersed.
4. Cover with a sterilized dressing.
5. Transport the patient to nearest hospital.
12.
SNAKE BITE:
1. Treat for shock, keep the victim alert.
2. Apply ligature or construction band one to the proximity of bite and
second at distal point.
3 Incise the point of bite with sharp razor to allow controlled bleeding.
4 Clean the area with potassium permanganate solution Take the
person to nearest hospital.
- 156 -
TEN COMMANDMENTS FOR SAFETY:
ANNEXURE - 2
1)
Follow instruction, do not take chances if you dont know, ask.
2)
Correct or report unsafe conditions.
3)
Help keep things clean and orderly, keep gangways clear.
4)
Do not horseplay, do not run, avoid distracting others, and avoid

throwing things.
5)
Report all injuries, get first aid promptly.
6)
Uses adjust and repair equipments only though authorized persons.
- 157 -
7)
Use right tools and equipments for the right job, use them safety.
8)
Dont smoke in restricted areas. Do not flick cigarettes/beedies ends

in salvage areas.
9)
Use prescribed protective equipments; keep them in good working

condition.
10)
Respect signs / warnings; abide by rules laid down for your safety.
- 158 -

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A

EVOLUTION OF SAFETY AND

ADVANCE DIPLOMA IN INDUSTRIAL SAFETY

RAJASTHAN ATOMIC POWER PLANT

Institute ,Govt. of India, Ministry of labour, Sion,

NUCLEAR POWER PLANT , at Rawatbhata , (via) Kota,

I SANDEEP SURANA , a student of Central Labour Institute ,

Director I/C .Principal,

Institute, Sion, Mumbai.

This project report has been prepared in partial fulfillment of

ANALYSIS AND CASE STUDIES

SAFETY MANAGEMENT SYSTEMS

RELATED TO NUCLEAR SAFETY .

Health & Safety Policy.

Safety & Health Organization.

Accident Reporting, Investigation And Analysis.

Hazard Identification and Control.

Under this heading following elements were selected.

Safe operating Procedures.

Work permit system.

Personal protective equipment.

Lifting Machines & Tackle.

Mobile Equipment and Vehicular traffic.

On site Gas Cylinder Storage area.

SAFETY POLICY OF RAPP 5&6

The safety policy of Rajasthan Atomic Power Project- 5&6 is an expression of

The management of RAPP -5-6 firmly believes in the motto Production

There shall be a well-defined safety organization with well-defined powers.

Collected the following information and evaluated with the applicable

Safety policy and Safety manual.

Safe operating Procedures.

Emergency Preparedness Plan.

Fire emergency plan.

Collected the following data.

Brief description of the accidents in the past three years.

Accident statistics analysis of last three years.

Details of medical examination of all employees.

Record of testing and examination of all lifting machines and lifting

Details of various training programmes being conducted.

Details of various safety promotional activities like National safety day

To assess compliance of regulatory requirement and to identify deviations from

To critically evaluate the effectiveness of the safety managements programmes.

To recommend the various safety measures to be taken to improve the overall

BASIC SAFETY PRINCIPLES AND OBJECTIVES:

He understands that it is to his advantage to work safely.

He must co-operate in working safely and behave in disciplined manner.

Upgrading Plant and Switch Yard are

common to the two units.

pressure of 87 Kg / cm2 to 293 0 C.

The heat energy from hot coolant (pressurized heavy water) is

2. RAPS 3-4 2X220Mwe.

RAPP 5&6-2x220Mwe,at Rawatbhata (Rajasthan).

Kaiga3&4-2x220Mwe at Kaiga near Karwar (Karnataka state).

KKNPP-2x1000Mwe at Kudankulam near kanyakumari (Tamilnadu state).

ORGANISATION CHART OF SAFETY SECTION, RAPP-5&6

Fire Protection Engg.

Severity Rate (as per IS 3786-1983)

No. of days lost due to reportable injury

Incidence Rate (as per IS 3786 1983)

Reportable lost time Injury =

No. reportable loss time injury

TABLE -1 ANALYSIS OF ACCIDENTS FOR THE YEAR - 2003

Longest Accident Free Period: 324 days (11.08.2002 to 02.07.03)

TABLE - 4 ANALYSIS OF ACCIDENT TYPEWISE 2003