Safety Manual

Q1. What is the Objective of Safety Manual?

A1. The objective of Safety Manual is as follows:

The objective of a Safety Manual is to establish and communicate comprehensive guidelines, procedures, and best practices aimed at ensuring the health, well-being, and safety of individuals within the workplace. It serves to:

• Outline safety protocols and procedures to prevent accidents, injuries, and illnesses.
• Provide guidance on proper handling of hazardous materials, equipment, and machinery.
• Define roles and responsibilities regarding safety compliance and enforcement.
• Ensure regulatory compliance with relevant laws, standards, and regulations.
• Promote a culture of safety awareness, education, and continuous improvement among employees.
• Serve as a reference document for training, emergency response, and incident reporting.
• Minimize risks and liabilities associated with workplace hazards.
• Enhance organizational efficiency and productivity by mitigating safety-related disruptions.

By fulfilling these objectives, a Safety Manual contributes to creating a safer and healthier work environment for all employees.

Q2. What is the purpose of the Safety Manual?

A2. The purpose of Safety Manual Is as follows:

The Safety Manual serves as a comprehensive guide outlining safety protocols, procedures, and best practices to ensure the well-being and protection of all individuals within the workplace.

Q3. What is the Scope of Safety Manual?

A3. The Scope of Safety Manual is as follows

• Safety policies and objectives.
• Roles and responsibilities for safety management.
• Hazard identification and risk assessment procedures.
• Safety training requirements and programs.
• Emergency response procedures.
• Procedures for incident reporting and investigation.
• Safe work practices and procedures for specific tasks.
• Compliance with regulatory requirements and industry standards.
• Safety equipment and personal protective gear requirements.
• Continuous improvement processes for safety performance.
• Guidelines for contractor safety management, if applicable.
• Procedures for safety audits and inspections.

The scope may vary depending on the specific needs and nature of the workplace, but generally encompasses all aspects of safety management to ensure the well-being of employees and compliance with relevant regulations.

Q4. What references are commonly used for Safety Manual preparation?

A4. The commonly used reference for Safety Manual Preparation is as follows:

• Indian Standard Acts, Rules, and Regulations, or
• OSHA and NFPA Guidelines, or
• Any other Guideline as per clients’ requirement

Q5. What is the order of precedence for Safety Manual preparation guidelines?

A5. The order of precedence used for Safety Manual preparation is as follows:

• Indian Standard Acts, Rules, and Regulations, or
• OSHA and NFPA Guidelines, or
• Any other Guideline as per clients’ requirement

Q6. What is the methodology for Safety Manual preparation?

A6. The methodology for Safety Manual preparation is as follows

• Data Collection
• Preparation:-
  • Preparing List of safety procedure required
  • Check the existing procedure and find out the gap
  • Identifying if any additional safety procedures required
• Preparation of Safety Manual report and internal review
• Preparation of Draft report and submission to client
• Comments incorporation
• Final report submission

Q7. What are the documents required for the Safety Manual preparation?

A7. The documents required for the Safety Manual preparation include the following

• Details of the company
• Details about Work permits & safety tags
  • Hot Work Permit
  • Working at Height Permit
  • Electrical Work Permit
  • Confined Space / Vessel Entry Permit
  • Civil / Excavation Permit
• Details of Hazard area classification, if carried out.
• List of Materials transported through Road / Rail
  • Quantity of material
  • No. of Trucks / Tankers used for different materials
  • No. of Wagons used for different materials
• List of Hazardous chemicals
  • List of chemicals for which TREM cards are prepared
  • List of chemicals for which MSDS cards are prepared
• List of Portable Fire Extinguishers available in the company i.e. Foam / CO2 / DCP / BCF / Light water
• Fire Alarm System details
  • Location of Fire Alarms in the company
  • Special Fire alarm system details
  • Smoke detectors / photo detectors / Heat detectors
  • Location of MCP & detectors
• Fire Detection System
  • Different types of detectors
  • Detection system of the company
• Hydrocarbon Sensors
  • Types of detection system / Principle of operation
  • Location of H/C sensors
• Fire Water System
  • Lay out plan & its criteria
  • Details of fire water reservoir
  • Capacity of different fire water pumps / differential heads / no. of hydrants / wet risers / dry risers etc.
• Details of fire water zones
• Details of Fire protection facilities
• Details about Sprinklers & MV Spray system
• Details of Fixed foam installation
• Details of Deludge water foam system / tank capacity etc.
• Details of CO2 system, its working principle / installations etc.
• Safety Appliances & Instruments
  • Types of PPE available in the company
  • Respiratory Protective appliances
  • Air line respirator & places of installations in the company
  • Non respiratory protection appliances for different parts of human body & full body
  • Protection against falling from height
• Safety Instruments
• Measurement of Explosive gases & vapours – Type of instrument, its principle, description & limitations
• Noise level measurement – Type of instrument, its description
• Accident / Incident reporting
  • Phone numbers of  Factory medical unit / Medical center / safety unit / Plant Manager / Head of the department / PR & Advt. dept. for taking photographs if necessary
  • Accident investigation & record keeping system – procedure of the company for accident response
• First Aid – No. of first aid boxes available & its location
• Emergency Action Plan
  • Details of Risk & environment impact assessment
  • Facilities available at company regarding firefighting arrangement / fire protection arrangement / medical services available / safety services available etc.
  • Details of Emergency Organization – Location of Assembly points / Location of Emergency control center / Fire & toxicity control arrangement / Medical arrangement / other arrangements
  • Details of Communication system – Siren, places of installations & siren code details
  • Action on site about different emergencies
  • Off-site emergency plan
  • Training / Rehearsals / records
  • List of Annexure for supporting information
  • Group wise Emergency Action Plan
• Statutory Regulations
  • Details about no. of pressure vessels, its testing / no. of Hoists & Lifts / safety committee / emergency exits
  • Licensed premises at the company for Petroleum products storage
  • Licensed premises at the company for gas cylinders storage
  • Licensed premises at the company for static & mobile pressure vessels
  • List of corrosive acids used

Q8. What are the contents of Safety Manual?

A8. The contents of Safety Manual include:

• Executive Summary
• List of Documents Review
• Submission of terms of reference
• Safety Manual Methodology
• Reference
• List of tables
• CHAPTER 01 GENERAL SAFETY RULES _ REGULATIONS
• CHAPTER 02 SAFETY PROCEDURES
• CHAPTER 03 OPERATIONS _ MAINTENANCE SAFETY
• CHAPTER 04 ELECTRICAL SAFETY
• CHAPTER 05 SAFETY RELATED TO CIVIL JOBS
• CHAPTER 06 SAFETY IN SPECIFIC AREAS
• CHAPTER 07 SAFE WORK ENVIRONMENT
• CHAPTER 08 CHEMICAL SAFETY GUIDE
• CHAPTER 09 FIRE PROTECTION SYSTEMS AT GSFC
• CHAPTER 10 SAFETY APPLIANCES AND INSTRUMENTS
• CHAPTER 11 ACCIDENT, INCIDENT REPORTING INVESTIGATION
• CHAPTER 12 FIRST AID MEASURES
• CHAPTER 13 EMERGENCY ACTION PLAN
• CHAPTER 14 STATUTORY REGULATIONS

These chapters may contain the following topics depending up on the requirement of the project:-

CHAPTER 01 GENERAL SAFETY RULES _ REGULATIONS-

• For Employees
• For Contractor And Laborers
• For Visitors

Chapter 02 Safety Procedures-

• Work Permit System
• Safety Tags And Locks
• Confined Space Entry Permit
• Hot Work Permit
• Line Breaking  _ Vessel Opening Permit
• Permission To Start The Work In Plant
• Electrical Isolation Permit
• Temporary Electrical Supply
• Permit To Work On Electrical Distribution
• Tank Farm Entry Permit

Chapter 03 Operations _ Maintenance Safety-

• Procedure For Isolation Of Safety Valves
• Hydro-Jetting
• Procedure For Preparation Of Equipment
• Furnace And Flare Operation
• Line Equipment Identification
• Safety Appliances Fire Fighting Equipments Checking
• Use Of Common Utilities And Temporary Hose Connection
• Eye Wash-Showers Fire Sprinklers Checking
• Shutdown Reminders
• Safety In Machine Shop
• Insulation On Pipe Lines Vessels
• Mechanical Material Handling Equipments
• Manual Material Handling Procedure
• Specific Hot Works _ Safety Precautions
• Online Repairs _ Clamping
• Blinding _ Blanking
• Welding _ Gas Cutting
• Sampling, Draining And Venting
• Work Involving Rotating Equipments
•  Working On Or Near Moving Or Running Machinery
• Working With Cryogenic Fluids
• Leakage _ Spillage Checking
• Checks Before Taking Equipment In Line
• Specific Hot Works _ Safety Precautions
• Sampling, Draining And Venting
• Procedure For Safety Valve Testing
• Eye Wash-Showers _ Fire Sprinklers Checking
• Tanker Farm Safety
• Loading _ Unloading Of Chemicals
• Procedure For Checking Trip System
• Decoking Operation Of Pipe Lines _ Its Cleaning
• Working With Gas Cylinders
• Hand Tools And Portable Power Driven Tools
• Checking Of Guards
• Radioactive Sources
• Mechanical System Safe Guards
• Identification Of Openings _ Trench Covers
• Drum Filling _ Handling
• Operational System Safe Guards

Chapter 04 Electrical Safety-

• Generators (Diesel Engine)
• Transformers
• Substations Panels
• Lightning Protection
• Switchyard
• Overhead Transmission Lines
• Electrical Area Classification,
• Earthing of Electrical System
• Power driven tools
• Hazards Of Electricity
• Temporary Electrical Power Supply
• Safe Use Of Megger Test Lamp
• Low Voltage Distribution System Installations
• Protection Against Static Electricity
• Electrical Cables
• Batteries _ Battery Room

Chapter 05 Safety Related To Civil Jobs-

• Design Criteria For Civil Structures
• Working At Heights
• Working On Roofs
• Excavation Work(Pits Roads)
• Painting Of Structures Buildings
• Grit Blasting (Sand Blasting Is Not Permitted Now)
• Accumulation Of Water In Drain Channels _ Its Cleaning
• Demolition Of Structures _ Buildings
• Water Proofing Using Hot Bitumen

Chapter 06 Safety In Specific Areas-

• Chlorination At Cooling Towers
• Safety In Warehouse
• Safety In Laboratory
• Safety On Road Rail At Gsfc
• Safety Guidelines To Follow During Natural Disasters
• Construction Safety

Chapter 07 Safe Work Environment-

• Ventilation And Heat Control
• Lighting And Color
• Noise And Vibration Control
• Good Housekeeping

Chapter 08 Chemical Safety Guide

• Hazardous Chemicals
• Dot Classification
• Trem Card
• Hazardous Properties Of The Chemicals
• Material Safety Data Sheet (Msds)
• Gsfc Chemical Safety Guide
• Hazchem Panel

Chapter 09 Fire Protection Systems At Gsfc-

• Sprinklers_Mv Spray System
• Hydrocarbon Sensors
• Fire Water System
• Fire Detection System
• Fire Alarm System
• Fire Detection System
• Portable Fire Extinguishers
• Fundamentals Of Fire,
• CO2 SYSTEM
• DELUGE WATER FOAM SYSTEM (DWFS)
• STEAM BLANKETING
• HALON SYSTEM
• FIXED FOAM INSTALLATIONS
• PORTABLE FIRE EXTINGUISHERS
• FUNDAMENTALS OF FIRE

Chapter 10 Safety Appliances And Instruments

• Safety Instruments
• Types Of PPE
• Safety Appliances_Instruments

Chapter 11 Accident, Incident Reporting Investigation-

• Accident Investigation _ Recordkeeping
• Accident. Incident, Near miss Reporting Procedures

Chapter 12 First Aid Measures

• Gas Poisoning _ Asphyxiation
• Burns
• Electric Shock
• Head Injury
• Cuts Or Buries

Chapter 13 Emergency Action Plan-

• Groupwise Emergency Action Plan
• Supporting Information Thorough Annexures
• Off-Site Emergency Plan
• Communication Systems
• Training, Rehearsal Records
• Action On Site
• Emergency Organization
• Risk And Environment Impact Assessment
•  Objectives.

Chapter 14 Statutory Regulations

• Civil Aviation Regulations
• Poisons Act, 1919_Rules, 1984
• The Indian Electricity Act, 1910_Rules, 1956-2002
• Static And Mobile Pressure Vessels (Unfired)
• Factories Act, 1948
• Manufacture, Storage Import Of Hazardous Chemicals
• Gas Cylinders Rules, 1981, 2002
• The Petroleum Act, 1934 And The Petroleum Rules, 1976

Q9. Who is responsible for implementing the guidelines outlined in the Safety Manual?

A9. Personnel responsible for implementing guidelines outlines in Safety Manual is as follows:

Itis the responsibility of every employee, supervisor, and manager to adhere to and enforce the guidelines outlined in the Safety Manual. Additionally, designated safety officers may oversee implementation and provide guidance as needed.

Q10. What personal protective equipment (PPE) is required, and how should it be used?

A10. Safety Manual specifies the following PPE requirement:

The Safety Manual specifies the required PPE for different tasks and work environments, along with instructions for proper use, maintenance, and storage of PPE.

Q11. Are there any hazardous materials or substances used in the workplace, and what safety precautions should be taken when handling them?

A11. Safety precautions taken when handling hazardous substances are follows:

The Safety Manual identifies hazardous materials and substances used in the workplace, along with safety precautions, handling procedures, and emergency response protocols to mitigate risks.

Q12. What is the Comment Resolution Sheet?

A12. The meaning of Comment Resolution Sheet (CRS) is as follows:

A comment resolution sheet is a document used to track and address comments, feedback, or issues raised during a review process, audit, or evaluation.

DISCLAIMER

This Blog is provided solely for informational and educational purposes. It is advisable to verify all information presented and consult with appropriate experts or professionals before making any decisions or implementing any strategies based on the content of this blog. HSE Risk Management Services Pvt. Ltd. accept no liability for any actions taken or not taken based on the information provided herein.