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Health, Safety & Environment (HSE)

Management Plan

Name Designation Signature

Developed by:

Reviewed and
approved by:

Issued on:

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Document History

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Table of Contents
PREFACE...................................................................................................................................................................6
1.0 HEALTH, SAFETY & ENVIRONMENT SAFETY PLAN...........................................................................7
1.1 INTRODUCTION............................................................................................................................................7
1.2 PROJECT OBJECTIVE...............................................................................................................................10
1.3 Leadership and Commitment.....................................................................................................................12
1.4 CONSULTATION AND PARTICIPATION OF WOKERS.......................................................................13
1.5 HSE PERFORMANCE EVALUATION, MONITORING, MEASURING AND IMPROVEMENT.........14
1.6 ROLES AND RESPOSIBILITIES...............................................................................................................17
1.7 Eye protection Policy:..................................................................................................................................21
1.8 Smoking Policy:............................................................................................................................................21
1.9 PPE Policy:...................................................................................................................................................21
1.10 Occupational safety and health programs – safety rules:.......................................................................21
1.11 Specific Safety Rules:..................................................................................................................................22
1.12 HAZARD IDENTIFICATION & RISK MANAGEMENT: -.........................................................................26
1.13 SIGNS, SIGNALS, TAGS AND BARRICADES........................................................................................54
1.14 WELDING AND CUTTING..........................................................................................................................72
1.15 Fire Prevention:............................................................................................................................................83
1.16 HEARING CONSERVATION PROGRAM (NOISE)................................................................................86
1.17 ELECTRICAL SAFETY: -............................................................................................................................90
1.18 EXCAVATION SAFETY:.............................................................................................................................94
1.19 CONFINED SPACE:....................................................................................................................................95
1.20 Fire Protection and Prevention...................................................................................................................96
1.21 EMERGENCY RESPONSE PLAN............................................................................................................98
1.22 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH)..............................................104
2.0 MATERIAL & PROCUREMENT...............................................................................................................107
2.1 General........................................................................................................................................................107
2.2 Frequently use Terms and Definitions.....................................................................................................107
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2.3 Selection & Approval of Vendors.............................................................................................................108

2.4 Surveys & Audit..........................................................................................................................................109
2.5 Special Cases Vendor Selection..............................................................................................................110
2.6 Procurement Process................................................................................................................................110
2.7 Verification of Purchased Products..........................................................................................................111
3.0 Inspection, Thorough Examination and Testing of Lifting Appliances and Lifting Gear...................112
3.1 Introduction.................................................................................................................................................112
3.2 Legal Requirements...................................................................................................................................115
3.3 Inspection....................................................................................................................................................116
3.4 Through Examination.................................................................................................................................121
3.5 Testing Through Examination...................................................................................................................129
3.6 Granting of Safe Working Loads and Scale Down of Load Ratings....................................................133
3.7 Safe System of Work for Inspection through Examination and testing...............................................135
4.0 Lifting Equipment - Inspection and Maintenance...................................................................................142
5.0 GUIDELINES AND PROCEDURE FOR LIFTING EQUIPMENT AND LIFTING OPERATIONS....156
6.0 INSPECTION..............................................................................................................................................176
6.1 Introduction and Purpose..........................................................................................................................176
6.2 Inspection and Test of Material................................................................................................................176
6.3 Receiving, In-process and Final Inspection & Testing..........................................................................177
6.4 Internal Pre-Inspection Plan.....................................................................................................................178
6.5 Material Inspection Request.....................................................................................................................179
7.0 PROJECT SITE HANDOVER..................................................................................................................182
7.1 General........................................................................................................................................................182
7.2 Instruction for Handover to new Project Manager.................................................................................183
7.3 Prepare Project Status Report.................................................................................................................183
7.4 Fill In Project Handover Checklist............................................................................................................184
7.5 Brief new PM on Project Details...............................................................................................................184
7.6 Review Project Handover Checklist........................................................................................................185
7.7 Introduce new PM to Project Team.........................................................................................................185
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7.8 Introduce new PM to Client and Project Stakeholders..........................................................................185

7.9 Start the Transition Process Gradually...................................................................................................185
7.10 Requirements for Project Handover........................................................................................................186
7.11 Monitoring Procedure................................................................................................................................186
7.12 Use of System Handover certification.....................................................................................................187
7.13 Offer to Consultant for Acceptance..........................................................................................................187
7.14 Offer to Client for Acceptance..................................................................................................................187
7.15 Acceptance.................................................................................................................................................188
7.16 After Services.............................................................................................................................................188
8.0 CONTROL OF PROJECT QUALITY PLAN (PQP)...............................................................................189
8.1 Review.........................................................................................................................................................189
8.2 Implementation...........................................................................................................................................189
8.3 Allocating Human Resources...................................................................................................................189
8.4 Induction Training.......................................................................................................................................190
8.5 Feedback & Improvement.........................................................................................................................190
8.6 Revision.......................................................................................................................................................190
8.7 Internal Audits.............................................................................................................................................190
8.8 TRAINING...................................................................................................................................................194
9.0 RISK MANAGEMENT...............................................................................................................................196
9.1 General........................................................................................................................................................196
9.2 Process........................................................................................................................................................196
9.3 Risk Management Methodology...............................................................................................................196
9.4 Risk Identification.......................................................................................................................................200
9.5 Risk Control................................................................................................................................................201
9.6 Management of Opportunities..................................................................................................................202
9.7 Risk Review................................................................................................................................................202
10.0 EQUIPMENT MANAGEMENT.................................................................................................................203
10.1 Equipment Identification & Placement.....................................................................................................203
10.2 Handling, Use, Transport and Storage of Equipment...........................................................................203
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10.3 Equipment Maintenance...........................................................................................................................204

Related Documents and Records............................................................................................................206
List of Machines & Equipment Appendix B...............................................................................................206
Equipment Calibration Program Appendix C............................................................................................206
Preventive Maintenance Plan Appendix D................................................................................................206
Machine Maintenance Order Appendix E..................................................................................................207

PREFACE

This management system is intended to give field personnel the minimum and basic
information from the Health and Environment Safety Management Plan at projects, to carry
out his work effectively and completing works to its highest quality. The content of this plan is
a reliable source of information carefully taken from the latest issuance of Certex Equatorial
Guinea (CEG) Specification and acknowledged international standards.

The information you get from this plan would be for your benefit and to CEG in getting its
target goals and objectives.

Hoping that this handbook in conjunction with program would serve its purpose in assisting
you to perform your daily duties effectively to its limit.

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1.0 HEALTH, SAFETY & ENVIRONMENT SAFETY PLAN

1.1 INTRODUCTION

Certex Equatorial Guinea (CEG) has developed a Health, Safety and Environment
management system that will be followed by the directors, employees and contractors to
ensure we are using the best practices, satisfying our clients, and improving on the overall
management of the organization. This HSE management plan is maintained by a member of
Certex management team for the HSE Management System and for use by Certex
Equatorial Guinea.

Aim and Goals of an HSE management system plan

The purpose of an HSE Management Plan is to provide a framework for managing safety
risks and opportunities. The aim and intended outcomes of the HSE management system are
to prevent work-related injury and ill health to workers and to provide safe and healthy
workplaces; consequently, it is critically important for the Certex Equatorial Guinea to
eliminate hazards and minimize HSE risks by taking effective preventive and protective
measures.

When these measures are applied by the Certex Equatorial Guinea through its HSE
management system, they improve its OH&S performance. An HSE management system
can be more effective and efficient when taking early action to address opportunities for
improvement of safety performance.

Implementing an HSE management plan conforming to this document enables an

organization to manage its safety risks and improve its OH&S performance. An HSE
management system can assist an organization to fulfil its legal requirements and other
requirements.

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Certex Equatorial Guinea has developed and implemented a Health and Safety Management
System (HSMS) that uses OSHA and ISO 45001:2018 as a framework for our organization to
document and improve our operational practices in order to prevent work-related injury and
ill-health.

Compliance with OSHA and ISO 45001:2018 help Certex Equatorial Guinea to achieve its
intended outcomes and demonstrate that our health and safety management system is
effective. Certex Equatorial Guinea management system documents help translate corporate
intentions to prevent incidents into a systematic and ongoing set of processes that are
supported by the use of appropriate methods and tools, that can reinforce our commitment to
proactively improving our performance.

The goals of health and safety management plan are to provide guidance for the
development of a framework where injuries, property damage, and other loss causing
incidents is mitigated. The stated goals of our health and safety management system are:

1. Development of a health and safety policy;

2. Demonstration of leadership and commitment to health and safety;

3. Establishing systematic processes for safety management;

4. Conducting hazard identification efforts;

5. Creating operational health and safety controls;

6. Increasing awareness and knowledge for employees about health and safety;

7. Evaluating safety performance and develop plans to improve continuously;

8. Establishing the necessary competencies;

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9. Creating and fostering a safety culture within our organization;

10. Ensuring employees participate fully and meaningfully in the health and safety
process;

11. Meeting all legal and regulatory requirements.

Success factors

The implementation of an HSE management system plan is a strategic and operational

decision for Certex Equatorial Guinea. The success of the HSE management system
plan depends on leadership, commitment and participation from all levels and functions
of the Certex Equatorial Guinea

The implementation and maintenance of an HSE management system, its effectiveness

and its ability to achieve its intended outcomes are dependent on a number of key
factors, which can include:

a) Top management leadership, commitment, responsibilities and accountability;

b) Top management developing, leading and promoting a culture in the organization that
supports the intended outcomes of the HSE management system;

c) Communication;

d) Consultation and participation of workers, and, where they exist, workers’

representatives;

e) Allocation of the necessary resources to maintain it;

f) HSE policies, which are compatible with the overall strategic objectives and direction
of the organization;

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g) effective processes for identifying hazards, controlling safety risks and taking
advantage of HSE opportunities;

h) Continual performance evaluation and monitoring of the HSE management system to

improve HSE performance;

i) Integration of the HSE management system into the organization’s business

processes;

j) HSE objectives that align with the HSE policy and take into account the organization’s
hazards, HSE risks and opportunities;

k) Compliance with its legal requirements and other requirements.

Plan-Do-Check-Act cycle

HSE management system approach applied in this HSE Plan is founded on the concept
of Plan-Do-Check-Act (PDCA). PDCA concept is an iterative process used by Certex
Equatorial Guinea to achieve continual improvement. It can be applied to a management
system and to each of its individual elements, as follows:

a) Plan: Determine and assess safety risks, HSE opportunities and other risks and other
opportunities, establish HSE objectives and processes necessary to deliver results in
accordance with the organization’s HSE policy;

b) Do: Implement the processes as planned;

c) Check: Monitor and measure activities and processes with regard to the HSE policy
and objectives, and report the results;

d) Act: Take actions to continually improve the HSE performance to achieve the intended
outcomes.
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1.2 PROJECT OBJECTIVE

CEG is committed to ensure a healthy and safe working environment for all personnel
associated with the Project. We believe that all work-related injuries, illnesses, property
losses and environmental damage are preventable, as well as maintaining a high standard
of health, safety and environmental protection, performance which is fully embodied in the
responsibility and accountability of the Project Management Team to achieve these goals.

CEG objectives in fulfillment of its Health, Safety and Environmental protection policy are:
 To fully support and comply with the Client’s health, safety and environmental
management requirements (as required)
 To fully comply with all HSE legislation, regulations, standards and codes of
practice
 To become a recognized leader in occupational health, safety and environmental
protection in the field of critical process control systems and support services
throughout the region
 To give health, safety and environmental protection first or top priority
 To provide a safe place, safe systems and safe practices of work for all
employees
 To ensure project personnel are instructed to cease work whenever conditions
are unsafe or where there is an unacceptable risk to personnel, the environment
or equipment which HSE Representative/ Manager will handle it.
 To implement, audit and continually improve health, safety and environmental
protection standards, and procedures
 To ensure that project activities are conducted and supervise by competent,
trained personnel, with due regard to the health, safety and welfare of our
personnel and that no harm occurs in the environment
 To ensure that all personnel recognize their responsibility to identify, report, and
where possible eliminate hazards and prevent injury to themselves and other
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personnel
 To relentlessly pursue our HSE Goals of:
o No Accidents No Harm to People No Damage to the Environment
o To promote a proactive and coordinated approach to health, safety and
environmental awareness and to encourage active participation by all
personnel in the continuous health, safety and environmental protection
process including the reporting of all incidents and accidents and near
misses.
o To ensure that subcontractors, vendors and third parties adhere to company,
client and local government HSE and environmental protection policies,
standards, expectations and objectives throughout the life of the project.
Supporting Document: Appendix A, Management Plan for Objective

1.3 Leadership and Commitment

Management of Certex provides evidence of its leadership and commitment to the

development and implementation of the HSE management system plan and continually
improving its effectiveness through active participation in the Organization Review Meetings
on semiannual basis in which it is ensured that:

 HSE Policy are established

 HSE Objectives are established for the management system and are compatible with the
strategic direction and the context of the Certex;
 HSE policy is communicated, understood and applied within the Certex;
 Assigning responsibility and accountability for effectiveness of the HSE Management
plan

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 Taking overall responsibility for the prevention of work-related injury and ill health and
provision of safe and healthy workplaces and activities.
 Protecting workers from reprisals when reporting incidents, hazards, risks and
opportunities.
 Ensuring the organization establishes and implements a process for consultation and
participation of workers
 Supporting the establishment and functioning of a Health and Safety Committee.
 Ensuring that Health and Safety Policy & Health and Safety Objectives are established
and are compatible with strategic direction of the organization.
 Ensuring that resources needed for the HSE Management plan are available.
 Communicating on importance of effective to all concerned. Guiding and supporting
personnel to contribute to the effectiveness of HSE Management plan
 Promoting Risk Based and Process approach.
 Promoting improvements HSE Management plan
 Ensuring that HSE Management plan achieves its intended results by periodic review
 Integration of the HSE management system plan requirements into the processes of
Certex;
 The resources needed for the management system are available;
 Communicating the importance of effective HSE management and of conforming to the
management system requirements;
 Management system achieves its intended results;
 Engaging, directing and supporting persons to contribute to the effectiveness of the
management system;
 Support other relevant management roles to demonstrate their leadership as it applies to
their areas of responsibility.

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1.4 CONSULTATION AND PARTICIPATION OF WOKERS

Certex has established and implemented process for the Consultation and Participation of
workers at all levels and functions. Consultation and participation of workers is carried out
through the Health & Safety Committee.

The following events are normally carried out to facilitate participation:

Toolbox Meeting
HSE Manager will chair and take minutes of toolbox meetings.
The frequency of toolbox meetings is determined by the:
 Main Contractor/ Principal
 Contract requirements
 Company directive

All employees and contractors on the site at the time of the meeting MUST attend unless
excused by the Safety Manager for an extraordinary reason.

 HSE Manager or his representative will record

 Names of all attendees
 Concerns or hazards raised
 Accident reported
 A brief summary of specific topics covered or instructions given
 Completed site safety toolbox meeting records shall be held in Toolbox record

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1.5 HSE PERFORMANCE EVALUATION, MONITORING, MEASURING AND

IMPROVEMENT

Certex Equatorial Guinea has planned and implemented the monitoring system to
demonstrate the conformity of the product and also to ensure the conformity, continual
improvement & effectiveness of the Occupational Health and Safety Management System
plan.
Certex has planned and implemented the monitoring, measurement, analysis and evaluation
processes needed:
1. Applicable legal requirement and other requirements;
2. Its activities and operations related to identified hazards and OHSMS risks and
opportunities;
3. to continually improve the effectiveness of the Occupational Health and Safety
Management Systems.
4. Operational Controls;
5. Organization’s OHSMS Objectives;
The monitoring activities are carried out to the full requirements of the specification and the
data is analyzed using statistical techniques to guarantee conformity.
The semiannual meetings of the Company Reviews are directed towards reviewing the
OH&S and improving its effectiveness.

Reporting and Monitoring

Certex HSE Manager will monitor performance against targets and take Corrective actions
where negative trends are identified. The performance shall be monitored with the help of
KPI (Key performance Indicators that is Leading and Lagging indicators) and shall be
reported to customer as per their procedure and requirement.

Key Performance Indicators (KPIs):

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The following Key Performance Indicators will be reported as minimum, Customers direct KPI
shall also be included in the reporting system.

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Lagging Indicators Leading Indicators

Fatality Near Miss reported and Closed

TRIR - Total Reportable Injury
Customer Assurance Index
Rate.
Oil spills HSE Induction
HSE Training carried out to training
LTI’s (Lost Time Incidents)
matrix > 95%
Plans developed and drills
Restricted Work Case (RWC)
conducted as per the schedule
HSE Audits performed to audit
MTC (Medical Treatment
schedule (including subcontractors
Cases)
third party audits)
First Aid Cases (FAC) HSE Audit action items closed out
Occupational Illnesses HSE Site Management Walk.
Sickness Absenteeism Office and Camp Inspections
Hygiene Inspections Kitchens
Material Losses
/Facilities performed monthly
Security Incidents CAR / PAR Generated
Tool box meetings / TI Meetings
Property damage
performed
HSE Observation and Intervention
Fire & Explosion
card raised
HSE awareness campaigns
Fines and Legal Notices
conducted
HSE Bulletins/Alerts/Safety Flyers
issued
Road traffic violations reported

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Training Man-hours

The above KPI shall be part of management meetings and shall also be communicated to
site employees in some form via HSE Notice Board, TI and TBT meetings

1.6 ROLES AND RESPOSIBILITIES

All personnel are expected to fulfill their HSE responsibilities through actively participating in
the prescribed activities. The following provides a summary of responsibilities, activities, and
HSE support functions for project groups and individuals.
i. Project Manager:

Project Manager shall familiarize himself with this HSE plan in order to ensure adequate
site implementation procedures are in place. The Project Manager has the delegated
responsibility to ensure that the Health, Safety and Environment policies, objectives and
activities incorporated in the respective project HSE Plans are carried out and that related
HSE procedures are fully implemented. He shall continually review the effectiveness of the
HSE Plan's, procedures and those personnel under his control to whom HSE matters have
been assigned.
Responsibilities:
 The implementation of safety practices, including the safety program, regular
assessment of its effectiveness, and physical inspection of safety measures at
project.
 Ensuring that all site staff are aware of and comply with the safety regulations and
accident prevention requirements.
 Implementing procedures for health and safety corrective and preventative actions, to
prevent any potential hazards and evaluate accident prevention recommendations
with the side HSE supervisors/officers.

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 Coordinating with the HSE supervisors/officers in the investigation and reporting of

accidents and "near-miss" incidents.
 Allowing weekly meetings during which safety matters will be discussed, including
review of weekly safety reports.
 Ensuring that an adequate supply of appropriate personal protective equipment is
available.
 Ensuring that all personnel under his supervision are knowledgeable of the safety
regulations and emergency response procedures related to their work areas. This
includes ensuring that new personnel are appropriately trained before begging work
that any potential hazards specific to their work areas are appropriately pointed out,
and that employees know the locations of emergency related equipment such as fire
extinguishers and first aid facilities.
 Remaining constantly alert for any safety hazards within his work area, offering
suggestions for additions and modifications to the safety manual and encouraging his
subordinates to do the same.
 Liaising and cooperating with the HSE officer on matters concerning safety.
 Ensure that Risk Assessments are performed at the earliest practicable opportunity.
 Promote a high degree of Health, safety and Environmental awareness amongst all
project personnel
 Provide adequate resources for emergency response.
 Accountable for ongoing development and implementation of HSE activities and
practices
 Ensuring engineering Health and safety standards are developed and implemented
 Provide the necessary resources to ensure the HSE group can effectively develop
and implement full Health, safety and Environmental protection management
systems
 Ensure sufficient welfare facilities for all staff.
ii. General Manager:
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The General Manager has the following responsibilities and activities concerning health,
safety and environmental management:

Responsibilities:
 Review and monitor adherence by the workforce and subcontractors to the standards
 Specify and make available resources to enable execution of the HSE activities
 Ensure participation and involvement of all employees
 Arrange and conduct regular subcontractor HSE reviews
 Monitor effectiveness of the HSE induction and training processes
 Monitor incident / hazard reports
 Involvement and attendance at HSE meetings
 Review and discuss incident/hazard reports, when required
 Review work planning and hazard analysis requirements
 Review and approve HSE training initiatives
 Motivate and inspire supervisors and HSE personnel via positive discussion on HSE
initiatives.
 Ensure that all personnel are competent to carry out their tasks.
 Attend all project HSE related meetings where practical,
 Ensure that adequate training of staff to enable them to work in a safe and
 Promote a high degree of health, safety and environmental awareness amongst all
project personnel
iii. Safety Officer:
The HSE Officer is responsible for devising and implementing programs and plans to
safeguard the health and safety of all employees, and to prevent loss or damage CEG
assets and projects. He reports to the Project Manager for the implementation of the safety
program. The HSE Officer, in cooperation with the Quality Manager, documents the safety

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system and ensures that there are sufficient trained personnel wherever it is appropriate to
have them
Responsibilities:
 Provide support to side HSE officer, advising them on safe working methods and
assisting
 with the training of personnel.
 Carry out regular site safety inspections l audits and report, correct unsafe work
practices and potential hazards.
 Investigate and report to PMC HSE all major accidents, including "near-miss"
incidents that may have led to such, and recommend preventative measures.
 Ensure maintenance of good hygiene standards and availability of safety equipment
and first aid treatment.
 Present monthly safety reports to the Project Manager as required.
 Recording and following up on any noted safety hazards and non-conformances to
safety regulations.
 Providing impartial advice on HSE matters to all employees.
 Reviewing any safety recommendations received.
 Assisting in the induction and safety training of new employees.
 Chairing and maintaining minutes of HSE committee meetings
iv. All Employees:
Use correct tools and the personal protective equipment provided, or ask for them if they
are not provided. Obey safety rules and do not damage or remove safety devices. Be alert
to hazards both to him and those around. Report any unsafe conditions and practices to
their supervisor.
v. HSE orientation and induction of employees/visitors:
All new arrivals and visitors shall undertake HSE induction to ensure that they are fully
conversant with project health, safety, and environmental protection requirements and
emergency Plans, prior to commencing work or more around the project /site.
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The Safety Officer shall conduct the induction and the content shall include the following:
 Overview of all company HSE Policy's
 Discussion of company "Stop work for Safety" policy
 Management's vision for health, safety and environmental performance
 Project Health, safety and environmental protection strategy, expectations,
requirements and targets
 Getting HSE Right, Target Zero
 Overview of the project scope of work and current activities
 Responsibilities for HSE

1.7 Eye protection Policy:

Personal protective equipment (PPE) for the eyes and face is designed to prevent or lessen
the severity of injuries to workers. The employer must assess the workplace and determine
if hazards that necessitate the use of eye and face protection are present or are likely to be
present before assigning PPE to workers.

1.8 Smoking Policy:

Smoking is not permitted in any work area, this applies to all offices and work areas,
whether occupied by one person, or shared by two or more, Smoking allowed only in
designated area.

1.9 PPE Policy:

All personal protective equipment should be of safe design and construction and should be
maintained in a clean and reliable fashion. It should fit well and be comfortable to wear,
encouraging worker use. If the personal protective equipment does not fit properly, it can
make the difference between being safely covered or dangerously exposed. When
engineering, work practice and administrative controls are not feasible or do not provide
sufficient protection, employers must provide personal protective equipment to their workers
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and ensure its proper use. Employers are also required to train each worker required to use
personal protective equipment.

1.10 Occupational safety and health programs – safety rules:

The General Safety Rules related to legal and other requirements of this project to be
displayed at entrance and standard notice board include. All persons must wear a safety
helmet, eye protection, high visible vest and safety shoes when entering or working within
the site boundary, use a safety harness when working at height. Scaffolds/working platform
must be secured and stabilized. Scaffolds/working platform, scaffolding inspection and
scaffold tags which Scaffolding Inspector/Safety officer will do it, when higher than 1.8
meters must be provided with guardrails, toe-boards to prevent the fall of a person. All
electrical tools must be properly connected/ earthed. Extra care consideration for oneself
and for others when operating the machine. Safety equipment must be used to protect
person on site. Safety installations must not be interfered by falling objects. Unauthorized
entry is prohibited while construction work is in progress. Everybody within the site
boundary must wear their worker’s I.D., otherwise entry will be prohibited. Security in charge
of this site is authorized to expel those people without I.D.‟s. illegal workers are prohibited
within the site boundary; offenders will be subjected to prosecution. Beware of trucks at site
entrance, all vehicles are not allowed to enter this site without permission. Everybody enters
the site must be over age of 18 and show their I.D. upon request of the security in charge of
the site, otherwise entry will be prohibited.

1.11 Specific Safety Rules:

All subcontractors, suppliers and workers shall follow the requirements to carry out CEG
works.
Powered Hand Tools Operational Rules as per follows: -
 Always read, understand and follow the Instruction Manual before attempting to
use any power tool in any way. Also read the nameplate information and follow

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the warning labels on the tool itself.

 Always use the right tool for the right job. No substitutions allowed.
 Make sure cutters or blades are clean, sharp and securely in place. Never use
bent, broken, or warped blades or cutters.
 When using hand-held power tools, always keep a firm grip with both hands.
Losing control creates a hazardous situation. Do not use any tool that is too
heavy for you to easily control.
Welding Operational Rules are as follows: -
o Always wear face shields. Use a dust mask for dusty operations, if you’ll be
using the tool for an extended period of time.
o Never use power tools in wet or damp conditions.
o Before you plug in any power tool, make sure the power switch is off.
o Never overreach when using a power tool. Stay firmly planted on both feet.
Work at Heights Safety Rules are as follows: -
 All work at height is properly planned and organized.
 A risk assessment is carried out for all work conducted at height.
 People working at a height are trained and familiar with wearing a safety
harness.
 Equipment used for work at height is properly inspected and maintained.
 Risks from fragile surfaces are properly controlled. 
Manual Handling Safety Rules are as follows: -
Risk associated with Manual handling operations can be reduced to minimum if careful
planning is done.

 Consider whether you can use a lifting aid, such as a forklift truck, electric or hand-
powered hoist, or a wheel-barrow.
 Think about storage as part of the delivery process – maybe heavy items could be
delivered directly, or closer, to the storage area

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 Reduce carrying distances where possible

 Loads greater than 25kg must not be lifted manually by an individual.
 Remove obstructions from the route.
 For the long lift, plan to rest the load midway on a table or bench to change grip.
Manual Handling Principles
There are some basic principles that every work will observe prior to carrying out a manual
handling operation:

 Ensure that the object is light enough to lift, is stable and unlikely to shift or
move
 Heavy or awkward loads should be moved using a handling aid
 Make sure the route is clear of obstructions
 Make sure there is somewhere to put the load down wherever it is to be moved
to
 Stand as close to the load as possible, and spread your feet to shoulder width
 Bend your knees and try and keep the back's natural, upright posture
 Grasp the load firmly as close to the body as you can
 Use the legs to lift the load in a smooth motion as this offers more leverage
reducing the strain on your back
 Carry the load close to the body with the elbows tucked into the body
 Avoid twisting the body as much as possible by turning your feet to position
yourself with the load
Safety Responsibility of Subcontractors:

Must be familiar with the Site Safety Plan, statutory regulations and special safety rules
applicable to the work on which their gangs are engaged; insist that the regulations are
observed and all accidents are reported immediately. Ensure that protective clothing and
equipment are used where appropriate. Release the workers for safety training upon
request. Ensure that plant and equipment are controlled in a safety state and strictly comply
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with all statutory requirements. Cooperate with site management to implement the
requirements laid down in the Safety Plan. Supervise subcontractors and workers to ensure
that their operations comply with relevant safety and health regulations.
Practices a good personal example:

Provide assistance in preparing the monthly report be familiar with the statutory regulations
applicable to the work on which their gang is engaged insist that the regulations are
observed, and all accidents reported immediately. Keep informed of the Site Safety Policy
and take all reasonable practicable steps to carry it out. Incorporate safety instructions in
routine orders and see that they are obeyed. Take all reasonable steps to prevent workers
from taking risks. Arrange for new employees, particularly apprentices or new starters, to
receive site specific safety induction course and to learn to take safety precautions. Ensure
that protective clothing and equipment are used whenever appropriate. Discourage
“horseplay” and reprimand those who fail to consider their own safety and that of others.
Must be familiar with the Site Safety Plan, statutory regulations and special safety rules
applicable to the work on which their gangs are engaged; insist that the regulations are
observed and all accidents are reported immediately.
 Ensure that protective clothing and equipment are used where appropriate.
 Release the workers for safety training upon request.
 Ensure that plant and equipment are controlled in a safety state and strictly
comply with all statutory requirements.
 Cooperate with site management to implement the requirements laid down in
the Safety Plan.
 Supervise subcontractors and workers to ensure that their operations comply
with relevant safety and health regulations.
 Assist Safety Officer to investigate any accident / incident.
 Discourage workers to take any unnecessary risk.
 Assist in issuing personal protective equipment if necessary.

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 Demonstrate when and how to use the appropriate types of personal protective
equipment.
 Practices a good personal example.
 Provide assistance in preparing the monthly report
 Keep informed of the Site Safety Policy and take all reasonably practicable
steps to carry it out.
 Incorporate safety instructions in routine orders and see that they are obeyed.
 Take all reasonable steps to prevent workers from taking risks.
 Arrange for new employees, particularly apprentices or new starters, to receive
site specific safety induction course and to learn to take safety precautions.
 Ensure that protective clothing and equipment are used whenever appropriate.
 Discourage “horseplay” and reprimand those who fail to consider their own
safety and that of others.
 Ensure that plant and equipment are in a safe and secure state when left
unattended.
 Report to the management and/or Safety Officer on matters relating to health
and safety of the labor group.

1.12 HAZARD IDENTIFICATION & RISK MANAGEMENT: -

Risk Assessment shall be completed for all hazardous activities or where there is a
reasonable probability of an accident occurring if the work process is not assessed and
appropriate controls introduced especially non-routine tasks.

Risk Assessment shall be undertaken as a team approach involving employees who are
going to undertake the work. A register of Risk Assessment’s shall be made accessible to
all personnel for review the effectiveness of the Job Safety Analysis process shall be
assessed by way of the audit process Permit to Work forms shall indicate the necessary
Risk Assessment to be completed and attached to it prior to commencement of activity; the

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site supervisor is fully responsible to ensure compliance with this. Method Statements for
precast production and site construction shall contain relevant Risk Assessment documents.
Daily Risk Assessment requirements shall be discussed at the pre-job start meetings and
these shall be completed by the supervisor in-charge of the shift prior to start of activity.
They shall be posted at the site and discussed with all personnel involved in the activity. If
the scope of work shall change during the shift, the Risk Assessment shall be re-visited and
personnel shall be re-briefed on the scope of new work and any associated hazards with it
prior to re- commencement of the activity. As an ongoing process, hazards to which
employees are likely to be exposed shall be identified and entered into the Risk Assessment
register. The register shall contain data sheets, which document essential information on
hazards that have been identified prior to commencement and updated during the course of
the project.
Methods of identifying workplace hazards:
 Developing a hazard checklist.
 Reviewing information from designers or manufacturers.
 Analyzing unsafe incidents, accidents and injury data.
 Analyzing work processes and Consulting with employees.
 Examining material safety data sheets and product labels.
 Seeking advice from specialist practitioners and representatives.

Hazard Identification process will be done by HSE representation along with site execution
team. Once hazards are identified, an assessment shall be conducted to assess the risk of
injury or harm to employees and controls and intervention activities conducted to eliminate
or minimize the risk.

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Risk Assessment Flowchart

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Risk assessment Matrix:

CONSEQUE
LIKELIHOOD
NCES
A B C D E
Never Has Has Has Has
heard of happe happen happe happe
in the ned ed once ned 2- ned
Severity

People

industry. once in the 3 on

Remote in the last one times more
Chance last year in last than 6
of two or one times
happeni three year per
ng years year
More than 1
5 M H H H H
fatalities.
PTD or up to
4 M M M H H
1 fatalities.
Major injury
3 or health L L M M M
effect PPD.
Minor injury
2 or health L L L M M
effect MTC.
Slight injury
1 or health L L L L L
effect FAC.
No injury or
0 L L L L L
health affect.
P
Not Permanent Total
H High T
es Disability
D
M
FA Medical Treatment
M Medium First Aid Case T
C Case
C
P
Lost Time Permanent Partial
L Low LTI P
Incident Disability
D
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Risk Assessment Matrix – Definition of Terms Consequence and Category

A- Harm to People

No Description
.
0 No injury or damage to health
1 Slight Injury or Health Effects (including first aid case and medical treatment
case) - Not
affecting work performance or causing disability.
2 Minor Injury or Health Effects (including Lost Time Injury) - Affecting work
performance, such as restriction to activities (Restricted Work Case) or a need to
take a few days to fully recover (Lost Workday Case). Limited health effects, which
are reversible, e.g. skin irritation, food poisoning.
3 Major Injury or Health Effects (including Permanent Partial Disability) - Affecting
work performance in the longer term, such as a prolonged absence from work.
Irreversible health damage without loss of life, e.g. noise induced hearing loss,
chronic back injuries.
4 Single Fatality or Permanent Total Disability - From an accident or occupational
illness (poisoning, cancer).
5 Multiple Fatalities – From an accident or occupational illness (poisoning, cancer)

B- Impact on Reputation

No. Description

0 No Impact - No public awareness

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1 Slight Impact - Public awareness may exist, but there is no public concern.

Limited Impact - Some local public concern. Some local media and/or local
2
political attention with potentially adverse aspects for company operations.

Considerable Impact - Regional public concern. Extensive adverse attention in

3 national media. Slight national media and/or local / regional political attention.
Adverse stance of local government and/or action groups.

National Impact - National public concern. Extensive adverse attention in the

4 national media. Regional / national policies with potentially restrictive measures
and/or impact on grant of licenses. Mobilization of action groups.

International Impact - International public concern. Extensive adverse attention in

5 international media. National / international policies with potentially severe impact
on access to new areas, grants of licenses and/or tax legislation.

C- Asset Damage

No
Description (100% costs, USD.)
.

0 Zero damage

1 Slight damage - No disruption to operation (costs less than USD.1,000)

2 Minor damage – Brief disruption (costs less than USD.10,000)

3 Local damage – Partial shutdown (can be restarted but costs up to USD. 100,000)

Major damage – Partial activity loss (2 weeks shut down, costs up to

4
USD.1,000,000)

5 Extensive damage – Substantial or total loss of operation (costs in excess of

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USD.1,000,000)

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Safe work practices:

All works and activities shall be carried out in accordance to the requirements of contract in
relation to health, safety and the environment. Hazards that arise from activities performed
during combined / simultaneous operations are also identified and controlled in a formal
manner.

Safe working conditions and environment shall be assured by assessments on the effects
of:
 Work tasks.
 Dust and fumes.
 Noise from machinery and equipment.
 Vibration from mechanical toots and equipment.
 Temperature extremes.
 Ergonomic hazards.
 Ionizing radiation hazards.
 Bright light and heat/sparks generated by hot work (welding & gas cutting)
Additionally, suitable and sufficient workplace facilities shall be provided, these
include:

 Hygiene and welfare provisions.

 Cleanliness of premises.
 Good housekeeping of entry and exit routes.
 Ergonomics and comfort of employees.
 Good lighting standards.
 Shelter area for labors to relax during breaks.
Use of Personal Protective Equipment (PPE):

PPE includes protective clothing, body protection, full body fall protection harnesses and
high visibility clothing.

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WORK ACTIVITIES SUITABLE PPE

Protective goggles, hand gloves, Safety

Excavators, breakers, chippers, drillers.
helmets and Safety shoes.
Mixing cement, concrete, lime mortar, Safety goggles, gloves and protective foot
asphalt material, refractory material. wears.
Insulated tools, Rubber hand gloves and
Electricians
electrical resistant shoes, mat.
Grinders Protective goggles and leather hand gloves
Welding screen, safety shoes with rubber
Welders, Gas cutters ,welders helper sole, Leather hand gloves, Colored
goggles, leather hand gloves.
Workers engaged in insulation Dust mask ,hand gloves
Full body harness, Safety net, lifeline. Fall
Workers working at height
arrestor if required.
High noise level area i.e. D.G operator
working, near piling work, compressor Ear plug / ear muff
operator etc.
Working in dusty atmosphere Dust mask, Safety goggles.

Mandatory minimum PPEs required at Site consists of:

1. Safety Shoes
2. Hi-Visibility Vest
3. Safety Glasses
4. Hard Hat

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CEG ensures that PPE is: -

 Suitable for its intended use.
 Maintained fit for purpose, clean and replaced when damaged or no longer effective.
 Properly used by staff and subcontractors.
 Proper storage facilities are provided.

Employees are provided with training, information and instruction on PPE use and supervised
to ensure that it is used correctly when necessary. Long sleeve shirts and pants shall be
worn at all times outside of accommodation areas.
SAFETY EQUIPMENT & SYSTEMS CONTROL

CEG and sub-contractors shall take every practicable measure to eliminate hazards through
the selection of non-hazardous materials or by engineering controls. Control of hazards is
preferred to the use of personal protective equipment. However, where there are no
practical alternatives to the use of personal protective equipment, appropriate training shall
be given to employees to ensure that they are fully conversant with the operations,
processes and equipment they are working with and that the types of PPE employed are
suitable for the tasks being performed. Employees shall be provided with training in correct
fitting, maintenance and use of PPE, including the various types of PPE available for
specific tasks. The Storekeeper shall be responsible to maintain the records of the PPE
issuer to personnel; this shall be in accordance with company policy displayed at the work
site. The following items of P.P.E. shall be used when required by all personal engaged in
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project activities in the field: The Personal Protective Equipment (PPE) program has been
developed to provide employees and workers with the necessary information to identify
work situations that require the use of PPE, the proper selection and use of P.P.E. and
documentation of this information.
Personal Protective Equipment

Personal protective equipment, or PPE, includes a variety of devices and garments to

protect workers from injuries. PPE includes:
 Goggles.
 Face Shields.
 Safety Glasses.
 Hard Hat.
 Safety Shoes.
 Gloves.
 Safety helmet, Harness.
 Ear plugs and Ear Muffs.
 Respirators.
 Aprons, and Body Protection.
PPE should be used in conjunction with permanent protective measures, such as
engineered guards, substitution of less hazardous chemicals, and prudent work practices.
i. Head Protection:

Prevention of head injuries is an important factor in every safety program. Head injuries are
caused by falling or flying objects, or by bumping the head against a fixed object. Head
protection, in the form of protective hats, must do two things:
Resist penetration; Absorb the shock of the blow.

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This is accomplished by making the shell of the hat of a material hard enough to resist the
blow, and by utilizing a shock-absorbing lining composed of the headband and crown straps
to keep the shell away from the wearer’s skull.
ii. Eye and Face Protection:

Suitable eye protectors must be provided where there is a potential for injury to the eyes for
face from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical
gases or vapors, potentially injurious light radiation or a combination of these. Protectors
must meet the following minimum requirements:
 Provide adequate protection against the particular hazards for which they are
designed.
 Be reasonably comfortable when worn under the designated conditions.
 Fit snugly without interfering with the movements or vision of the wearer.
 Be durable.
 Be capable of being disinfected.
 Be easily cleanable and kept clean and in good repair.

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Each eye, face, or face-and-eye protector is designed for a particular hazard. In selecting
the protector, consideration should be given to the kind and degree of hazard, and protector
should be selected on that basis
iii. Foot Protection:

Statistics showed that most of the workers in selected occupations who suffered foot injuries
were not wearing protective foot-ware. For the protection of feet and legs from falling or
rolling objects, sharp objects, molten metal, hot surfaces, and wet slippery surfaces, workers
should use appropriate foot guards, safety shoes, or boots. Safety shoes should be sturdy
and have an anti-resistant toe. In some shoes, metal insoles protect against puncture
wounds.

iv. Hand Protection:

Employees are required to use appropriate hand protection when their hands are exposed
to hazards such as:
 Absorption of harmful substances.
 Severe cuts or lacerations.
 Severe abrasions.
 Punctures.
 Chemical burns.
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 Harmful temperature extremes (cold/heat).

v. Respiratory Protection:

Respirators shall be selected on the basis of hazards to which the worker is exposed. In
selecting the correct respirator for a given circumstance, many factors must be taken into
consideration:

 The nature of the hazard

 Location of the hazardous area
 Employee’s health
 Work activity
 Respirator characteristics, capabilities, and limitations.
In order to make subsequent decisions, the nature of the hazard must be identified to
ensure that an overexposure does not occur. One very important factor to consider is
oxygen deficiency. Air-purifying respirators can be used only at atmospheres containing

greater than 19.5 percent oxygen.

vi. Hearing Protection:

Exposure to high noise levels (more than 90 decibels) can cause hearing loss or
impairment. It can create physical and psychological stress. There is no cure for noise-
induced hearing loss, so the prevention of excessive noise exposure is the only way to
avoid hearing damage.
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vii. Permissible Noise Exposures:

Duration Per Day Sound Level dB

(Hours)
8 hours 90 dB
4 hours 95 dB
2 hours 100 dB
1 hour 105 dB
½ hour 110 dB
¼ hour 115 dB
Hearing protectors will always have an assigned Noise Reduction Rating (NRR) which
should be printed on the packaging of each hearing protector. NRR is the amount of
decibels by which a given device will reduce noise exposure, by subtracting the NRR value
from the noise exposure levels.
viii. HAND AND POWER TOOLS

Some jobs would be impossible without using hand tools. Everyone is familiar with common,
everyday hand tools, but you should not take them for granted. Hand tools mishaps can
cause serious injuries. If you know how to use the tools and take care of them, you will have
a better chance of avoiding an injury.
ix. Tools Injuries:

There are many types of injuries that can be caused by tool use. Serious eye injuries can
result if materials shatter while using hammers or mallets. Filling or chiseling creates chips
that can get into your eyes. While you are looking up to use the tools above your head, dust
and debris can fall into your eyes. A screwdriver could slip and because puncture wound. If
a knife slips, you could cut a tendon, artery, or nerve. Tool use presents plenty of other
opportunities for minor scrapes, cuts, or bruises.

x. Avoid Tool Injuries:

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Tool injuries can be prevented by keeping tools in good condition, using the right tool for the
job, using the tool properly, and setting up the work so you are not straining yourself, and
wearing personal protective equipment.
 Always wear safety glasses when using hammers, chisels, punches, wire cutters,
saws, files, crowbars, bolt cutters, or any tool that could create chips or pieces.
 Wear cut resistant gloves when handling knives or other sharp edges.
 Arrange the work and use tools so that the tool will move away from your hands and
body if slips.
 Make sure that the material you are working on is held securely – use clamps or a
vise if you need to.
 Stand where you have firm footing and good balance while you use tools.
xi. Select the tool you need:

 Use durable tools made from good quality materials.

 Metal tools should have working points that resist bending, cracking, chipping, or
excessive wear from normal use.
 The handles should be made of a durable material that does not crack or splinter
easily if the tool is dropped or hit.
 You may need a handle with a cushioned grip to help absorb impact or squeezing
pressure.
 Selecting tools with comfortable grips eases strain and gives you better control over
the tool.
 Pay extra attention to any tools that you will be using around electrical parts. Make
sure that the handles are electrically insulated and rated to handle the voltage.
 If you need to use tools to work in areas where flammable liquids are stored or used,
the tools must be made from non-sparking alloy in order to prevent sparks that can
ignite flammable vapors.
xii. Use the Right Tool the Right Way:

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Look at your hand tools. Their shape and design shows you how they are intended to be
used.

a. Knives:

Using knives as pries, screwdrivers, can openers, or punches can easily damage the blade.
A sharp blade needs less pressure to cut and has less of a chance of getting hung up and
slipping. Always move the blade away from you as you cut.
b. Screwdrivers:

 Screwdrivers are made in various shapes and sizes and for many uses. Use the
correct screwdriver for the job.
 Use a slot screwdriver with a blade tip width that is the same as the width of slotted
screw head.
 Keep the screwdriver handle clean. A greasy handle could cause an injury or
damage from unexpected slippage.
 Store screwdrivers in a rack or partitioned pouch so that the proper screwdriver can
be selected quickly.
 Do not hold the stock in one hand while using the screwdriver with the other. If the
screwdriver slips out of the slot you may cut your hand.
 Do not try to use screwdrivers on screw heads for which they are not designed.
 Do not use a defective screwdriver (i.e. ones with rounded or damaged edges or tips;
split or broken handle; or bent shaft.
 Do not use screwdrivers for prying, punching, chiseling, scoring, scraping or stirring
paint.
 Do not carry screwdrivers in your pockets.
c. Hammers and Mallets:

Nail hammers are designed to drive nails. Mallets have a striking head of plastic, wood, or
rawhide and are designed for striking wood chisels, punches, or dies. Another type of
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hammers is designed for striking concrete or stone. You can damage a hammer by trying to
use it for the wrong purpose. Do not use a hammer with mushroomed striking surface or a
loose handle.

d. Pliers:

Do not substitute pliers for a wrench. The face of the pliers is not designed to grip a fastener,
and the pliers can easily slip off of the nut or bolt. Pliers are designed for gripping so you can
more easily bend or pull material. They will provide a strong grip if you protect them from
getting bent out of shape and keep the gripping surface from being damaged.

e. Cutters:

Use cutters or snips to remove banding wire or strapping. Trying to use a pry bar to snap
open banding can cause injury. Keep the cutting edges sharp and protect them from getting
nicked or gouged.
f. Wrenches:

 Use adjustable open-ended wrenches for light-duty jobs when the proper sized
wrench is not available.
 Position yourself so you will be pulling the wrench towards you, with the open end
facing you.
 Box and socket wrenches should be used when heavy pull is required, because they
completely encircle the fastener.
 Do not try to increase the torque by hitting the wrench with hammer or by adding a
cheater bar to the wrench ‟s handle – This can break or damage the wrench.
 If the fastener is too tight, use some penetrating oil to lubricate it.
g. Wood Saws:
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 Select a saw with coarse teeth for sawing green wood, thick lumber, or for making
coarse cuts.
 Select a saw with fine-toothed to make fine cuts in dry wood.
 After use, wipe the saw with a lightly oiled rag to keep the teeth clean.
 Protect the saw from getting bent or damaged in storage.

h. Metal working Hand Tools:

 Hack saws should have the blade installed with the teeth facing forward, and apply
pressure on the forward stroke.
 Use a light pressure to avoid twisting and breaking the blade.
 Metal files need to be kept clean and protected from damage. Use files with proper
handles.

i. Maintain Your Tools:

 Tools will last longer when you take care of them:

 Inspect tools before you use them and before you put them away.
 Maintain and repair tools before it is too late. Sharpen cutting edges regularly.
 Avoid waiting until they are completely dull before trying to sharpen them. Replace
loose handles on hammers or mallets.
 Keep tools clean. Grease and dirt can hide damage, and prevent you from getting a
good grip when you use the tool.
 Discard damaged tools. Striking tools with mushroomed surfaces, screwdrivers with
rounded edges or bent shafts, or bent pliers are examples of tools that can cause
more harm than good.
j. Work at Working Safely:

Take out only the tools that you will need for the job. Piles of extra tools can get in the way
or get lost. Carry your tools safely. Use a tool box or a tool chest to move tools around. If
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you need to carry tools, especially on a ladder, wear a tool belt. If you are working on a
platform or a ladder, keeping the tools in your tool belt helps keep them from being dropped
onto unsuspecting victims below.

Always wear appropriate personal protective equipment

xiii. Grinder Safety Requirement:

 The RPM of a wheel shall always exceed the RPM rating of the grinder on which it is
used.
 RPM rating shall be marked legibly on grinders.
 General purpose wheels are not to be used for grinding on soft metals such as
aluminum.
 Special adapters or arbors shall not be fabricated or purchased without the
permission of the Project Manager/Supervisor and the HSE Manager.
 Construction of wheel guards shall comply with the minimum requirements outlined in
OSHA Standard.
 Shirt tails shall be tucked in and loose-fitting clothes are not be permitted while using
grinders.
 Employees shall warn personnel in the immediate area prior to grinding, and/or
provide spark containment such as screens.
 Ear protection is mandatory for operators.
 RPE in the minimum form of a „nuisance dust mask‟ is mandatory
 Never use the cord to lower grinders from elevations.
 Deflection screens may be needed to protect personnel or other equipment.
 Perk's washers shall be used on all vitreous (inorganic) bonded wheels.
 On all portable tools, the control switch shall be constant pressure controlled without
locking pin.
 Wheels should be stored in a dry place with constant temperature above freezing
and protected from physical damage.
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Note: Grinding is to be performed on the rim face only of abrasive discs (cutting discs are
NOT to be used for grinding).

 Check cut-off discs for chips - DO NOT USE IF CHIPPED.

 Consider fire potential from sparks.
 For bench applications, anchor small materials securely by mechanical means - DO
NOT HOLD BY HAND. (Use vise grips or other suitable means)
 For applications where a portable disc is applied to work or work is hand-fed into
disc, avoid binding through misalignment.
 Consider the need for respiratory protection or ventilation systems.
 Face shields, Safety glasses, and ear protection and a dust mask are required when
using disc grinders.
xiv. Site Transport Safety Measures:

Transport is defined as vehicles used to convey persons or materials, and on construction

sites, this includes trucks, tipper Lorries, refueling tankers and dumpers.

 All vehicle routes are to be planned to minimize the need for vehicles to reverse by
introducing one-way-systems wherever reasonably practicable;
 Road construction and surface quality for traffic routes will be appropriate for the
vehicle types that will use them;
 Consideration will be given to vehicle access route widths and the turning radius of
bends to ensure clear access for emergency vehicles;
 Appropriate lighting for roads and pedestrian walkways will be provided;
 All vehicles including sub-contractor and visitor vehicles will be subject to the
workplace rules for vehicles;
 arrangements will be made by the Project/Construction Manager to brief sub-
contractors and visitor’s drivers and operators on the safety requirements of the
workplace traffic routes;
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 Parking area’s will be incorporated away from operational requirements;

 Traffic routes will be segregated from pedestrian routes wherever reasonably
practicable; and
 Engineering control measures will be given priority over administrative controls when
planning traffic management systems.
 The maximum speed of vehicles at site will be 20km/h.
 The Foreman/Supervisor will ensure that drivers on site are made aware of their
duties, all driver are to be at least 18 years of age and hold a current driving license for
the type of vehicle/equipment they are in control of.
 Drivers will report any defects immediately to their manager and Foreman/Supervisor.
This applies also to any accident or damage, however minor. Vehicles will be regularly
inspected for defects etc., by the driver and this will be recorded in relevant register.
 Drivers will wear suitable safety footwear, safety headwear and protective clothing
appropriate to the site conditions. Drivers will use all safety provisions provided i.e.
seatbelts, roll over protection systems, audio / visual warning systems etc.
 Where vehicles need to pass open edges or tip into excavations etc., suitable secure
stop blocks traffic banksman will be provided.
 Drivers will be required to cooperate with the site drugs and alcohol policy.
 Lorries should not be left with the tipping body raised and suitable props should be
used whenever men need to work under the raised body
 Vehicle keys will not be left unattended at any time and vehicles made secure when
not in use. Vehicles will never be left unattended with the engine running.
xv. Inspection and Maintenance of Vehicle:

 The subcontractors and the vehicle drivers shall periodically test examine and
maintain their vehicles by qualified fitters or mechanics. A copy of the testing report
and maintenance record shall be submitted to the Safety Officer.
 No vehicle shall be used unless they have been tested and certified in good working

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conditions by the local authority.

 The Safety Officer shall keep all relevant maintenance records and documentations.
xvi. Mobile Crane
a. OPERATOR:

Mobile crane Operators he must be test passed from the authorized institute or
company (e.g. TUV, Bureau VERITAS) how to operate the safely mobile crane and
valid KSA driving license.
b. LOAD CHARTS:

A load chart must be posted where it is visible to personnel responsible for the
operation of the equipment. The load chart must be readily available at the job site to
personnel responsible for operating the equipment. Load charts must contain at least
the following information:

 Rated capacity at corresponding ranges of boom angle or operating radii.

 Specific lengths of components to which the rated capacities apply.
 Required parts for hoist revving.
 Size and construction of rope must be included on

c. INSPECTIONS:

Mobile crane must be inspected by authorized institute or company Third Party (e.g.
TUV, Bureau VERITAS).
Weekly inspection maintenance check list keep the document record.
d. Emergency stop crane procedure: Sandstorm, Earthquake, Major
Emergency ETC Warning wind speed: -

1st warning at 20Km/h, 2nd warning at 25Km/h and 3rd warning at 32Km/h and
stop all work activity.

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e. Approval:

 CEG first inform to CEG Safety Department about Mobile Crane.

 Submit all Mobile Crane valid documents.
 Take access pass from CEG Safety Department to work at site.
xvii. General Safety Requirements:

Employers must permit only thoroughly trained and competent workers to operate
cranes with licensed to operate and duly certified by third party (e.g. TUV, Bureau
VERITAS).

Operators should know what they are lifting and what it weighs, for example, the rated
capacity of mobile cranes varies with the length of the boom, the boom height, the boom
angle and the boom radius.
To reduce the severity of an injury, the employer must take the following
precautions:

 Equip all cranes that have adjustable booms with boom angle indicators.
 Provide cranes with telescopic booms with some means to determine boom
length.
 Post load rating charts in the cab of cab-operated cranes.
 Require workers to always check the crane ‟s load chart to ensure that the crane
will not be overloaded by operating conditions.
 Instruct workers to plan lifts before starting them to ensure that they are safe.
 Tell workers to take additional precautions and exercise extra care when
operating around power lines.
 Teach workers that outriggers on mobile cranes must rest on firm ground, on
timbers, or be sufficiently cribbed to spread the weight of the crane and the load
over a large enough area.

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 Direct workers to always keep hoisting chains and ropes free of kinks or twists
and never wrapped around a load.
 Train workers to attach loads to the load hook by slings, fixtures, and other
devices that have the capacity to support the load on the hook.
 Instruct workers to pad sharp edges of loads to prevent cutting slings.
 Teach workers to maintain proper sling angles so that the sling is not loaded in
excess of their capacity.
 Ensure that all cranes are inspected frequently by persons thoroughly familiar
with the crane, the methods of inspecting the crane, and what can make the
crane unserviceable.
 Ensure that the critical parts of a crane – such as crane operating mechanism,
hooks, air, or hydraulic system components and other load-carrying components
– are inspected daily for
 any maladjustment, deterioration, leakage, deformation, or other damage.

When it is necessary to guide a suspended, use tag lines.

 Don’t distracts the crane operator. Only one signalman at a time. (see fig 04)
 Keep out from under suspended loads.
 Watch out for materials that could fall on you if hit by the moving load. (see fig 05)
 Make sure you provide yourself a way out when directing load drops.

Make sure the crane operator can see the:

 Rated Load Capacities
 Operating Speeds
 Special Hazard

All windows in cabs shall be of safety glass, or equivalent, that introduces no visible
distortion that will interfere with the operation of the machine.
A ladder, or steps, shall be provided to give access to a cab roof. Guard rails, handholds,
and steps shall be provided on cranes for easy access to the car and cab.

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xviii. Crane and Hoist Signals by Rigger: -

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xix. Forklift: -

Employees must be trained to work safely with forklifts, not just when they’re hired but
periodically thereafter. Refresher training for the experienced operator is just as important
as first-time training for new employees.
a. Forklift Inspection:

Although forklifts are designed to perform rugged tasks, each time they are used
they can get damaged in any number of ways. That’s why inspection is of critical
importance. At the start of each shift, perform both a visual inspection of the general
condition and cleanliness of the lift truck, as well as an operational check to test its
proper functioning. If you notice anything that may affect the normal operation of the
forklift, immediately alert your supervisor.
b. Checklist for Visual Inspection:

 Floor-clear of objects that could cause an accident.

 No obstruction overhead.
 Note any nearby objects to avoid as you drive away.
 Fire extinguisher present and charged.

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 Engine oil level, fuel level and radiator water level.

 Battery fully charged and securely in place.
 Cables for exposed wires.
 Battery plugs connections not loose, worn or dirty.
 Vent caps not clogged.
 Electrolyte level in cells.
 Bolts, nuts, guards, chains, or hydraulic hose reels not damaged, missing or loose.
 Wheels and tires not worn or damaged.
 Forks not bent or cracked.
 Chain anchor pins not worn, lose or bent.
 No damp spots or drips that may indicate a leak.

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c. Forklift Operation:

No one must ride or operate a forklift truck except for a trained forklift operator who is
able to maintain control of the forklift and operate it smoothly when stopping, starting,
lifting and tilting.
d. Guidelines on Forklift Safety:

 Travel with forks as low as possible from the floor and tilted back.
 Obey posted traffic signs.
 Decrease speed at corners, sound horn and watch the swing of both the rear of
the lift truck and the load.
 Avoid sudden stops.

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 If the load blocks your vision, travel slowly in reverse.

 Keep your hands, arms, head, feet and legs inside the forklift.
 Always look in the direction of travel.
 Keep an eye out for oil spots, wet spots, loose objects, holes, rough surfaces,
people, and vehicles on the floor or roadway.
 To ensure the safety of others, know the blind spots of the lift truck with and
without a load.
 When anyone crosses the route being traveled, stop the forklift truck. Lower the
load to the floor, and wait until the passage is clear.
e. Traveling on an Incline:

 Keep the forks pointed downhill without a load, and pointed uphill with a load.
 Do not attempt to turn the lift truck until it’s on level ground.
f. Steering:

 Support the load by the front wheels and turn with the rear wheels.
 Do not turn the steering wheel sharply when traveling fast.
 If the lift truck is overloaded, steering will be difficult.
 Do not exceed load limits, and do not add a counterweight as an attempt to
improve steering.
g. Loading:

 It’s important to know the recommended load limit of the forklift (shown on the data
plate) and the capacity of the fork, and never exceed these limits.
 Position the load according to the recommended load center. Do not add extra
weight to counterbalance an overload.
 Keep the load close to the front wheels to keep the lift truck stable.
 When inserting the forks, keep the mast of the forklift in an upright position before
inserting the fork into a pallet. Level the fork before inserting it.

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 Spread the forks as widely as possible for even distribution.

 Drive under the load until it slightly touches the carriage. Tilt the forks back to shift
the weight of the load back, making it more stable.
 If the load is unbalanced, keep the heavier end closer to you. Tilt the mast back.
 Keep the forks 4 to 8 inches above the ground to avoid potential ground hazards.
Raising the Load:

 Do not raise or lower the fork unless the lift truck is stopped and brake.
 Avoid lifting a load that extends above the load backrest if there is any risk of the
load, or part of it, sliding back towards the operator.
 Check for adequate overhead clearance before raising a load, and maintain a safe
working distance from overhead power lines.
 Lift the load straight up, and then tilts back slightly.
 Watch that the load doesn’t catch on adjacent loads or obstructions.
 Don’t back up until the forks are free.
 When a load is raised, the lift truck is less stable. The operator must stay on the
forklift when the load is in a raised position.
 Don’t allow anyone to stand on the forklift or walk under the
 Elevated part of the forklift, whether it’s loaded or unloaded.
Handling Pallets:

 Ensure that forks are level and high enough to go into the pallet, and that they go all
the way under the load.
 Forks must be the proper width to provide even weight distribution.
 Avoid trying to move or adjust any part of the load, the forklift or the surroundings
when on the forklift.
 Do not use pallets elevated by forklifts as an improvised working platform.
Unloading:

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 Turn the forklift slowly into position.

 If unloading into a truck, before driving straight in, make sure the rear wheels of the
truck are chocked, the brake is locked, and the dock plate is secure and won’t move.
 Then drive in, position the load, tilt if forward and release it.
Parking:

 Park only in an approved location.

 When leaving the lift truck unattended, secure it by setting the brakes, lowering the
forks or load to the floor, neutralizing the controls, and turning off the motor switch
and remove key.
 Do not block aisles, doors, exits, electrical panels, fire extinguishers.
Refueling:

 Only trained personnel should refuel forklifts.

 Refueling area should have appropriate fire warnings and emergency equipment
available.
 Turn off the forklift and set the brake and never smoke around the forklift.
 Start fueling and clean up spills quickly.

1.13 SIGNS, SIGNALS, TAGS AND BARRICADES

Signs, signals, and barricades are important, if not critical, to the safety of the construction
workers

i. Signs:

Are the warnings of hazard, temporarily or permanently affixed or placed, at locations where
a hazard exists?
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Accident Prevention Signs and Tags:

Signs and symbols required by this subpart G shall be visible at all times when work is
being performed, and shall be removed or covered promptly when the hazards no longer
exist
Danger Signs:

 Use danger signs only where an immediate hazard exists.

 Danger signs must have red as the predominant color for the upper panel, black
outline on the borders; and a white lower panel for additional sign wording.

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Caution Signs:

Caution signs shall be used only to warn against potential hazards or to caution against
unsafe practices.

Caution signs shall have yellow as the predominating color, black upper panel and borders;
yellow lettering of “Caution” on the black panel; and the lower yellow panel for additional
sign wording. Black lettering shall be used for additional wording.

Standard color of the background shall be yellow; and the panel, black with yellow letters.
Any letters used against the yellow background shall be black.
Exit Signs:

Exit signs, when required, shall be lettered in legible red letters, not less than 6 inches (15
cm) high, on a white field and the principal stroke of the letters shall be at least ¾ inch in
width.

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Safety Instruction Signs:

Safety instruction signs, when used, shall be white with green upper panel with white letters
to convey the principal message.

Any additional wording on the sign shall be black letters on the white background.
Directional Signs:

Directional signs, other than automotive traffic signs specified in the paragraph below, shall
be white with a black panel and a white directional symbol.

Any additional wording on the sign shall be black letters on the white background.
Traffic Signs:

Construction areas shall be posted with legible traffic signs at points of hazard.

All traffic control signs or devices used for protection of construction workers shall conform
as per Manual on Uniform Traffic Control Devices for Streets and Highways.

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ii. Tags:

Are temporary signs, usually attached to a piece of equipment or part of a structure, to warn
of existing or immediate hazards.

Accident Prevention Tags:

Accident prevention tags shall be used as a temporary means of warning employees of an

existing hazard, such as defective tools, equipment, etc.

They shall not be used in place of, or as a substitute for, accident prevention signs.
Specifications for accident prevention tags similar to those shown below shall apply.

iii. Signals:

Are moving signs, provided by workers, such as flagmen, or by devices, such as flashing
lights, to warn of possible or existing hazards.
iv. Flagmen:

When operations are such that signs, signals, and barricades do not provide the necessary
protection on or adjacent to a highway or street, flagmen or other appropriate traffic controls
shall be provided.

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Signaling directions by flagmen shall conform to, Manual on Uniform Traffic Control Devices
for Streets and Highways.
Hand signaling by flagmen shall be by use of red flags at least 18 inches (45 cm) square or
sign paddles, and in periods of darkness, red lights. (See Fig # 03)

Fig # 01 Fig # 02 Fig # 03

Flagmen shall be provided with and shall wear a red or orange warning garment while
flagging. Warning garments worn at night shall be of reflector material.
v. Barricades:

Means an obstruction to deter the passage of persons or vehicles.

Barricades for protection of employees shall conform to the portions, Manual on
Uniform Traffic Control Devices for Streets and Highways, relating to the barricades.

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vi. WORKING AT HEIGHTS

Personnel working at heights shall be strictly controlled by the policy working at heights
which clearly states that any employee required to be working 6ft above ground level in an
area not protected by suitable guard railings shall utilize a full body harness connected to a
shock absorbing lanyard attached to a secure location above the employee
vii. Stairways and Ladders:

A stairways or ladder must be provided at all worker points of access where there is a break
in elevation of 19 inches (48 cm) or more and no ramp, runway, embankment, or personal
hoist is provided.

Then there is only one point of access between levels, it must be kept clear to permit free
passage by workers. If free passage becomes restricted, a second point of access must be
provided and used.
When there are more than two points of access between levels, at least one point of access
must be kept clear.
All stairways and ladder fall protection systems required by these rules must be installed and
all duties required by the stairway and ladder rules must be performed before employees
begin work that requires them to use stairways or ladders and their respective fall protection
systems.

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viii. Stairways:

The following general requirements apply to all stairways used during the process of
construction, as indicated:
Stairways that will not be a permanent part of the structure on which construction work is
performed must have landings at least 30 inches deep and 22 inches wide (76x56 cm) at
every 12 feet (3.7 m) or less of vertical rise.
Stairways must be installed at least 30 degrees, and no more than 50 degrees, from the
horizontal.

 Variations in riser height or stair tread depth must not exceed ¼ inch in any stairway
system, including any foundation structure used as one or more treads of the stairs.

 Where doors or gates open directly onto a stairway, a platform must be provided that
is at least 20 inches (51 cm) in width beyond the swing of the door.

 Slippery conditions on stairways must be corrected.

All stairways’ parts must be free of dangerous projections such as protruding nails.

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Stairways having four or more risers, or rising more than 30 inches (76 cm) in height,
whichever is less, must have at least one handrail. An at air rail also must be installed along
each unprotected side or edge.

Handrails and the top rails of the stair rail systems must be capable of withstanding, without
failure, at least 200 pounds (890 N) of weight applied within 2 inches (5 cm) of the top edge
in any downward or outward direction, at any point along the top edge.

The height of handrails must not be more than 37 inches (94 cm) nor less than 30 inches
(76 cm) from the upper surface of the handrail to the surface of the tread.

The height of the top edge of a stair rail system used as a handrail must not be less than 37
inches (94 cm) nor less than 36 inches (91.5 cm) from the upper surface of the stair rail
system to the surface of the tread. {If installed before March 15, 1991, not less than 30
inches (76 cm)}.

Handrails must provide an adequate handhold for employees to grasp to prevent falls.
The ends of stair rail system and handrails must be constructed to prevent dangerous
projections such as rails protruding beyond the end posts of the system.

Unprotected sides and edges of stairway landing must be provided with standard 42-inches
(1.1 m) guardrail systems.
ix. Ladders:

The following general requirements apply to all ladders, including job-made ladders:
 Rungs, cleats and steps of portable and fixed ladders must not be spaced less than
10 inches (25 cm) apart, nor more than 14 inches (36 cm) apart, along the ladder
side rails.
 Ladders must not be tied or fastened together to create longer sections unless they
are specifically designed for such use.
 A metal spreader or locking device must be provided on each stepladder to hold the

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front and back sections in an open position when the ladder is being used.
 Ladder components must be surfaced to prevent injury from punctures or lacerations,
and prevent snagging of clothing.
 Wood ladders must not be coated with any opaque covering, except for identification
or warning labels which may be placed on one face of a side rail.

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x. Portable Ladders:

The minimum clear distance between side rails for all portable ladders must be 11.5 inches
(29 cm).

The rungs and steps of portable metal ladders must be corrugated, knurled, dimpled, coated
with skid- resistant material, or treated to minimize slipping.

xi. Fixed Ladders:

Each step or rung of a fixed ladder must be capable of supporting a load of at least 250
pounds (114 kg) applied in the middle of the step or rung.

The rungs and steps of fixed metal ladders must be corrugated, knurled, dimpled, coated
with skid- resistant material, or treated to minimize slipping.

If the total length of a climb on a fixed ladder equals or exceeds 24 feet (7.3 m), the
following requirements must be met: fixed ladders must be equipped with either (a) ladder
safety devices; (b) self-retracting lifeline, and rest platforms at intervals not to exceed 150
feet (45.7 m); or (c) a cage or well, and multiple ladder sections, each ladder section not to
exceed 50 feet (15.2 m) in length. These ladder sections must be offset from adjacent
sections, and landing platforms must be provided at a maximum interval of 50 feet (15.2 m).

The bottom of the cage must be between 7 feet (2.1 m) and 8 feet (2.4 m) above the point
of access to the bottom of the ladder.

The top platform the cage must be a minimum of 42 inches (1.1 m) above the top of the
platform, or point of access at the top of the ladder.
xii. Using of All Ladders:

When portable ladders are used for access to an upper landing surface, the side rails must
extend at least 3 feet (0.9 m) above the upper landing surface.

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Ladders must be maintained free of oil, grease, and other slipping hazards.
Ladders must be used at an angle where the horizontal distance from the base of the
supporting structure to the base of the ladder is approximately one-quarter of the working
length of the ladder.

Ladders must be used only on stable and level surfaces unless secured to prevent
accidental movement.

Ladders placed in areas such as passageways, doorways, or driveways, or where they can
be displaced by workplace activities or traffic must be secured to prevent accidental
movement, or a barricade must be used to keep traffic or activity away from the ladder.

The area around the top and bottom of the ladders must be kept clear. Ladders must not be
moved, shifted, or extended while in use.

Ladders must have non-conductive side rails if they are used where the worker or the ladder
could contact exposed energized electrical equipment.

The top or top step of a stepladder must not be used as a step.

Cross-bracing on the rear section of stepladders must not be used for climbing unless the
ladders are designed and provided with steps for climbing on both front and rear sections.

Keep three-points of contact with the ladder at all times.

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When ascending or descending a ladder, the worker must face the ladder.

A worker on a ladder must not carry any object or load that could cause the worker to lose
balance and fall.

The length of single ladders shall not exceed 30 feet.

Two section ladders shall not exceed 48 feet and over two-section ladders shall not exceed
60 feet in length.

Each section of a multi - section ladder shall overlap the adjacent section by at least the
number of feet as follows:
1.Length up to 36 feet: 4 feet overlap
2.Length over 36 feet up to 48 feet: 5 feet overlap
3.Over 48 feet, up to 60 feet: 6 feet overlap

xiii. SCAFFOLD SAFETY: -

To establish safe working procedures for the use of scaffolds

 Legs or uprights of scaffolds shall be securely and rigidly braced to prevent swaying
and displacement.
 Overhead protection shall be provided for personnel on a scaffold exposed to
overhead hazards.
 Special precautions shall be taken to protect scaffold members when using a heat
producing element.
 Tools, materials, and debris shall not be allowed to accumulate in quantities to cause
a hazard.
 Standard planking shall be scaffold grades or equivalent as recognized by approved
grading rules for the type of wood used. Toe boards should be at least 150mm high.
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 Standard scaffold planks shall extend over their supports at least 50mm and not
more than 4 x the thickness of the board. All standard platform planking, when
overlapped, shall be overlapped a minimum of 12 inches and secured from
movement with wire or nails. Do not use duplex type nails.
 Scaffolding shall be erected, moved, dismantled, or altered by qualified personnel
working under the supervision of a Designated Competent Person.
 Employees that are required to perform work off scaffolds shall be trained be Third
Party Certified Scaffold erector or trained and certified in-house to a standard
acceptable.
 The footing or anchorage for scaffolds shall be sound, rigid, and capable of carrying
the maximum intended load without settling or displacement. Unstable objects such
as barrels, boxes, loose brick, or concrete blocks shall not be used to support
scaffolds or planks.
 Scaffolds shall be provided with a screen, between the toe board and the guard rail
extending along the entire opening and consisting of 1/2-inch mesh, when placed
where pedestrian traffic must pass underneath.
 Scaffolds or their components shall be capable of supporting without failure at least 4
times the maximum intended load.
 Scaffolds shall not be loaded in excess of the working load for which they are
intended.
 Inspect all scaffold components before erecting scaffolds. Never use any scaffolding
that is damaged or defective in any way. Defective scaffolding including planks will
be returned to the scaffold yard and removed from the project.
 Do not work on scaffolds if one's physical condition is such that one feels dizzy or
unsteady.
Notify The Supervisor of Condition:

 Scaffolding components shall be used only for the purposes for which it was

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intended.
 Before climbing any scaffold, clean mud build-up from work boots to prevent slipping.
 All scaffolds working platforms shall have steel tubing handrails 1.1 meters high and
0.6 meters high coupled to hand rail post and 15 cm minimum toe boards rigidly
secured.
 Scaffolds shall be inspected prior to use and daily by a Designated Competent
Person. The Competent Person shall complete an inspection tag and secure it to the
point of access. The inspection will be recorded in a register.
 Obtain approval from the project electrical and safety representative prior to erecting
scaffolds adjacent to electrical power lines.
 All scaffolds shall have a ladder installed or an equivalent means of safe access to
the working platforms.
 Do not use ladders or make shift devices on top of scaffolds to increase the height.
 Retractable lifelines shall be used while ascending or descending vertical access
ladders with a fall exposure greater than 4 meters.
 All working platforms shall be completely decked. The Planks must be secure from
movement by tying planks to the bearers with #9 wires.
 Only the Scaffold Department/Competent Person(s) will be allowed to build, tear
down, or modify scaffolds.
 Personnel shall not be on any scaffolds on other temporary elevated work
area during storms on high-wind, unless the scaffolds or working level is
indoors or otherwise unaffected by the weather conditions. Outdoor scaffolds
or elevated work platforms shall not be used during thunderstorms or when
there is likelihood of lightning.
xiv. Scaffold Inspection Tags:

 Scaffolds shall be inspected before each shift prior to use by a Designated

Competent Person. The Competent Person shall fill out the inspection tag (Green

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Tag- READY FOR USE, Yellow Tag- WORK WITH FULLBODY HARNESS and Red
Tag-DO NOT USE) and attach it to the point of access.
 Scaffold tags shall be updated daily prior to work or immediately following any repairs
or alterations.
 The Competent Person will be required to sign off on the tag.

xv. PERSONAL FALL ARREST SYSTEMS: -

 The top edge height of top rails must be 42 inches (1.1 meters) plus or minus 3
inches (8 cm) above the walking/working level.
 Screens, mid rails, mesh, intermediate vertical members must be installed between
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the top edge of the guardrail system and walking/working surface (at least 21 inches
(53 cm) high.
 The guardrail system must be capable of withstanding a force of at least 200 pounds
applied on the top from both directions, mid rail shall be capable of withstanding a
force of at least 150 pounds applied in any downward or outward direction.
 Guardrail systems shall be surfaced to protect workers from punctures or lacerations
and to prevent clothing from snagging.
 Distance between Vertical Posts should not be more than 2.8 Ft.
 If no mid rail is installed, the distance between the vertical posts should not be more
than 19 inches.
xvi. Full Body Harness:

These consist of an anchorage, connectors, and body belt or body harness. It must do the
following:
 Limit maximum arresting force on an employee to 900 pounds when used with a
body belt.
 Limit maximum arresting force on an employee to 1800 pounds when used with a
body harness.
 Be rigged so that an employee can neither free fall more than 6 feet (1.8 meters) nor
contact any lower level.
 Bring an employee to a complete stop and limit maximum deceleration distance an
employee travels to 3.5 f (1.07 m). (shock absorber)
 To keep at least 3 feet clearances from the ground.

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 Have sufficient strength to withstand twice the potential impact energy of an

employee free falling a distance 6 feet or the free fall distance permitted by the
system, whichever is less.
 The use of body belts for fall arrest is prohibited (1/1/1998) and a full body harness is
required.
 The anchoring point must withstand a force not less than 5000 pounds.
xvii. Safety Monitoring Systems:

 Used when no other alternative fall protection has been implemented.

 Competent person to monitor the safety of workers.
 The employer shall ensure that the safety monitor is competent in the recognition of
fall hazards.
 Is capable of warning workers of fall hazard dangers and in detecting unsafe work
practices.
 Is closed enough to work operations to communicate orally with workers and has no
other duties to distract from the monitoring function.

xviii. Safety Net Systems:

 Safety nets must be installed as close as practicable under the walking/working

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surface and never more than 30 feet (9.1 m) below such levels.
 Installed with sufficient clearance underneath to prevent contact with the surface or
structure below.
 The maximum size of each safety net mesh opening shall not exceed 36 square
inches nor be longer than 6 inches (15 cm) on any side. Each Safety net or section
shall have a border rope for webbing with a minimum breaking strength of 5000
pounds.
Safety nets must extend outward from the outermost projection of the work surface as
follows:
Distance between work level and the Distance of extension outside the
net work level

Up to 5 ft (1.5m) 8ft (2.4m)

More than 5ft to 10ft 1 Oft {3m)

More than 10ft 13ft{3.9m)

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1.14 WELDING AND CUTTING

i. Health Hazards of Welding:

Welding “smoke” is a mixture of very fine particles (fumes) and gases. Many of the
substances in welding smoke, such as chromium, nickel, arsenic, asbestos, manganese,
silica, beryllium, cadmium, nitrogen oxides, phosgene, fluorine compounds, carbon
monoxide, cobalt, copper, lead, ozone, selenium, and zinc can be extremely toxic.

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Generally, Welding Fumes and Gases Come from:

 The base material being welded or the filler material that is used;
 Coatings and paints on the metal being welded, or coatings covering the electrode;
 Shielding gases supplied from cylinders;
 Chemical reactions which result by the action of ultraviolet light from the arc, and
heat;
 Process and consumables used;
ii. Health Hazards:

Heat

The intense heat of welding and sparks can cause burns. Eye injuries have resulted from
contact with hot slag, metal chips, sparks, and hot electrodes.
Visible Light and Ultraviolet and Infrared Radiation:

The intense light associated with arc welding can cause damage to the retina of the eye,
while infrared radiation may damage the cornea and result in the formation of cataracts,
Invisible ultraviolet light from the arc can cause “arc eye” or “welder ‟s flash” after even a
brief exposure (less than one minute). The symptoms of arc eye usually occur many hours
after exposure to UV light. And include a feeling of sand or grit in the eye, blurred vision,
intense pain, tearing, burning, and headache.

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iii. Safety Hazards of Welding:

Electrical Hazards:

Even though welding generally uses low voltage, there still a danger of electric shock. The
environmental conditions of the welder (such as wet or cramped spaces) may make the
likelihood of a shock greater.
Dry gloves should always be worn to protect against electric shock. The welder should also
wear Rubber-soled shoes, and use an insulating layer, such as a dry board or a rubber mat,
for protection on surfaces that can conduct electricity.

The piece being welded and the frame of all electrically powered machines must be
grounded. The insulation on electrode holders and electrical cables should be kept dry and
in good condition.
Fire and Explosions:

The intense heat and sparks produced by welding, or the welding flame, can cause fire or
explosions if combustible or flammable materials are in the vicinity.
Welding or cutting should only be performed in areas that are free of combustible materials,
including trash, wood, paper, textiles, plastics, chemicals, and flammable dusts, liquids and
gases.
Never weld on containers that have held flammable or combustible material unless the
container is thoroughly cleaned or filled with an inert (non-reactive) gas.
Fire Prevention and Protection:

 If the object to be welded or cut cannot readily be moved, all movable fire hazards in
the vicinity shall be taken to a safe place.
 If the object to be welded or cut cannot be moved and if all the fire hazards cannot be
removed, then guards shall be used to confine the heat, sparks, and slag, and to
protect the immovable fire hazards.

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 If the above requirements cannot be met, then welding and cuttings shall not be
performed.
 Suitable fire extinguishing equipment shall be maintained in a state of readiness for
instant use. Such equipment may consist of pails of water, buckets of sand, hose or
portable extinguishers depending upon the nature and quantity of the combustible
material exposed.
 Fire watchers are required whenever welding or cutting is performed in locations
where other
 than a minor fire might develop, or any of the following conditions exist:
 Appreciable combustible materials, in building construction or contents, closer than
35 feet to the point of operation.
 Appreciable combustibles more than 35 feet away, but are easily ignited by sparks.
 A fire watch shall be maintained for at least a half hour after completion of welding or
cutting operations to detect and extinguish possible smoldering fires.
 Fire watchers shall have fire extinguishing equipment readily available and be trained
in its use. They shall be familiar with facilities for sounding an alarm in the event of a
fire. They shall watch for fires in all exposed areas, try to extinguish them only when
obviously within the capacity of the equipment available, or otherwise sound the
alarm. A fire watch shall be maintained for at least a half hour after completion of
welding or cutting operations to detect and extinguish possible smoldering fires.
 Floors. Where combustible materials such as paper clippings, wood shavings, or
textile fibers are on the floor, the floor shall be swept clean for a radius of 35 feet
(10.7m). Combustible floors shall be kept wet, covered with damp sand, or protected
by fire-resistant shields. Where floors have been wet down, personnel operating arc
welding or cutting equipment shall be protected from possible shock.
 Cutting or welding shall not be permitted in the following situations:

In the presence of explosive atmospheres (mixture of flammable gases, vapors, liquids, or

dusts with air), or explosive atmospheres that may develop inside an unclean or improperly
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prepared tanks or equipment which have previously contained such materials, or that may
develop in areas with an accumulation of combustible dusts.

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iv. Welding or Cutting Containers:

No welding, cutting, or other hot work shall be performed on used drums, barrels, tanks or
other containers until they have been cleaned so thoroughly as to make absolutely certain
that there are no flammable materials present or any substances such as greases, tars,
acids, or other materials which when subjected to heat, might produce flammable or toxic
vapors. Any pipe lines or connections to the drum or vessel shall be disconnected or blank.
v. Welding in Confined Spaces:

When arc welding is to be suspended for any substantial period of time, such as during
lunch or overnight, all electrodes shall be removed from the holders and the holders
carefully located so that accidental contact cannot occur and the machine be disconnected
from the power source.
In order to eliminate the possibility of gas escaping through leaks or improperly closed
valves, when gas welding or cutting, the torch valves shall be closed and the gas supply to
the torch positively shut off at some point outside the confined area whenever the torch is
not to be used for a substantial period of time, such as during lunch hour or overnight.
Where practicable, the torch and hose shall also be removed from the confined space.

Combustible walls. Where cutting or welding is done near walls, partitions, ceiling or roof of
combustible construction, fire-resistant shields or guards shall be provided to prevent
ignition.

Noncombustible walls. If welding is to be done on a metal wall, partition, ceiling or roof,

precautions shall be taken to prevent ignition of combustibles on the other side, due to
conduction or radiation, preferably by relocating combustibles. Where combustibles are not
relocated, a fire watch on the opposite side from the work shall be provided.
Personal Protective Equipment:

 A welder or helper working on platforms, scaffolds, or runways shall be protected

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against falling through the use of railings, safety belts, lifelines, or some equally
effective safeguards.
 Welding cable. Welders shall place welding cable and other equipment so that it is
clear of passageways, ladders, and stairways.
 Helmets or hand shields shall be used during all arc welding or arc cutting
operations, excluding submerged arc welding. Helpers or attendants shall be
provided with proper eye protection.
 Helmets and hand shields shall be made of a material which is an insulator for heat
and electricity. Helmets, shields and goggles shall not be readily flammable and shall
be capable of withstanding sterilization.
 Helmets and hand shields shall be arranged to protect the face, neck and ears from
direct radiant energy from the arc.
 Welders should always select clothing materials which will provide maximum
protection from sparks and hot metal. Protective eyewear, safety shoes, fire-resistant
clothing, and fire-resistant gauntlet gloves are recommended. Additionally, the shirt
should have full sleeves, no pockets and should be worn outside the trousers with
the collar buttoned. The trousers should have no cuffs and should extend well down
to the safety shoes.
 Goggles or other suitable eye protection shall be used during all gas welding or
oxygen cutting operations. Spectacles without side shields, with suitable filter lenses
are permitted for use during gas welding operations on light work, for torch brazing or
for inspection.
 All operators and attendants of resistance welding or resistance brazing equipment
shall use transparent face shields or goggles, depending on the particular job, to
protect their faces or eyes, as required.
 Helmets shall be provided with filter plates and cover plates designed for easy
removal.

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Health Protection and Ventilation:

 Mechanical ventilation is required when welding or cutting is done with materials not
specifically mentioned in this section. These materials – fluorine compounds, zinc,
lead, beryllium, cadmium, mercury, cleaning compounds, and stainless steel are
partially hazardous and have specific control requirements.
 Screens. When welding must be performed in a space entirely screened on all sides,
the screens shall be so arranged that no serious restriction of ventilation exits. It is
desirable to have the screens so mounted that they are about 2 feet (0.61m) above
the floor unless the work is performed at so low a level that the screen must be
extended nearer to the floor to protect nearby workers from the glare of welding.
 Mechanical ventilation shall be provided:
 In a space of less than 10.000 cubic feet (284 m3) per welder.
 In a room having a ceiling height of less than 16 feet (5m)
 Minimum rate. Such ventilation shall be at the minimum rate of 2.000 cubic feet
(57m3) per minute per welder, except where local exhaust hoods and booths, or
airline respirators. Natural ventilation is considered sufficient for welding or cutting
operations where restrictions are not present.
 Hoods. Freely movable hoods intended to be placed by the welder as near as
practicable to the work being welded and provided with a rate of airflow sufficient to
maintain a velocity in the direction of the hood of 100 linear feet (30m) per minute in
the zone of welding when the hood is at its most remote distance from the point of
welding.
 Oxygen for ventilation. Oxygen shall never be used for ventilation.
vi. Gas Welding and Cutting:

General Requirements:

 Maximum pressure. Under no condition shall acetylene be generated, piped (except

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in approved cylinder manifolds), or utilized at a pressure in excess of 15 psi (pounds

per square inch gauge) or 30 psi (pounds per square inch absolute).
 Apparatus. Only approved apparatus such as torches, regulators or pressure-
reducing valves, acetylene generators, and manifolds shall be used.
 Using acetylene at pressures in excess of 15 psi gauge pressure (or about 30 psi
absolute pressure) is a hazardous practice. Free gaseous acetylene is potentially
unstable at pressures above 15 psi and could decompose with explosive violence.
Experience indicates that 15 psi is generally acceptable as a safe upper pressure
limit.

 The decomposition characteristics of acetylene gas are avoided by keeping the gas in
liquid solution and storing it in cylinders of unique construction.
 Internally, acetylene cylinders are not designed like other kinds of compressed gas
cylinders. Acetylene cylinders are never hollow. These cylinders contain porous,
calcium silicate filler and a suitable solvent, usually acetone, because, under
pressure, acetylene by itself is unstable. Acetone is used because it has the ability to
absorb over 400 times its own volume of acetylene at 70F.
 Millions of microscopic pores make up the calcium silicate filler. Although it appears
to fill the steel shell, approximately 90 percent of the filler ‟s volume consists of “pore
space” for holding and evenly distributing the acetylene/acetone solution.
Protective Equipment, Hose, And Regulators:

 The operator must use the proper hose. Fuel gas hose is usually red (sometimes
black) and has a left-hand threaded nut for connecting to the torch. Oxygen hose is
green and has a right-hand threaded nut for connecting to the torch.
 Hose and hose connections shall be clamped or otherwise securely fastened in a
manner that will withstand, without leakage, twice the pressure to which they are
normally subjected in service, but in no case less than a pressure of 300 psi. Oil-free
air or an oil-free inert gas shall be used for the test.

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 Hose showing leaks, burns, worn places, or other defects rendering it unfit for service
shall be repaired or replaced. When inspecting hoses, look for charred sections close
to the torch. These may have been caused by flash-back. Also check that hoses are

not taped up to cover leaks.

 Pressure-reducing regulators shall be used only for the gas and pressures for which
they are intended.
 All gas welding and gas cutting equipment must be fitted with flash arrestors to
minimize the risk of injury to workers or damage to equipment if and when the
flashback occurs.
vii. Using Oxyacetylene Equipment:

An oxyacetylene welding outfit is basically made up of the following: cylinders of oxygen and
acetylene, regulators, hoses, and a torch.

Oxygen and acetylene are stored in separate cylinders. A great deal of gas is forced into
each cylinder, this result in very high pressures. The high pressures are controlled and
adjusted by the regulators.
Hoses carry the gases from the cylinders to the torch. The green hose carries oxygen. The
red hose carries acetylene.
The gases are mixed inside the torch. When burned, they produce a very hot flame. The
flame is regulated (adjusted and controlled) by interchangeable torch tips and by the torch
valves.
viii. Oxyacetylene Cutting:
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To cut steel using an oxyacetylene outfit, use a cutting torch instead of a welding torch.
Adjust the regulators for the torch tip and the thickness of the metal to be cut.
 Light the torch, and adjust it to a neutral flame.
 Locate the inner core of the flame just above the work surface.
 Tilt the tip slightly, and preheat the metal in a single spot. Keep heating until it is
cherry red.
 Push down on the oxygen cutting lever. A jet stream of oxygen burns through the
metal.
 Position the torch at a 90-degree angle to the work surface, and continue cutting
along the desired line. Move the torch smoothly.
ix. Arc Welding and Cutting:

The electric arc welder remains one of our most useful and time-saving pieces of shop
equipment. Most of these welders are typically AC/DC, 240-volt transformer types using
electricity as the energy source. Portable welders are of the diesel/gasoline engine powered
type. Properly installed and used the arc welder is very safe, but if used improperly the
operator can be exposed to a number of hazards including toxic fumes, dusts, burns, fires,
explosions, electric shock, radiation, noise, and heat stress. Any of these hazards can
cause injury or death.

Arc welding uses the heat from an electric arc to melt and fuse base metals and welding-rod
metal into one piece. The heat from the arc melts the flux (cleaner) coating on the rod.

There are two basic kinds of arc welding machines. Some provide direct current (DC).
Others provide alternating current (AC).
x. Selecting The Arc Welder:

When purchasing an arc welder, you can be assured of design safety and safety standards
for arc welders as determined by standards. Be sure that the welder you purchase carries
the seal of approval.
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Voltage

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The following limits shall not be exceeded:

Alternating Current (AC) Direct Current

(DC)

Manual 80 Volts 100 Volts

Automatic 100 Volts 100 Volts

For AC welding under wet conditions or warm surroundings where perspiration is a factor,
the use of reliable automatic controls for reducing no-load voltage is recommended to
reduce the shock hazard. Some of the older AC machines do not have an automatic control
and are on load all the time. It is easy to receive an electric shock when the equipment is
not handled properly.
Installing The Arc Welder:

Prior to installing the arc welder, you should determine if your present electrical system is
adequate to handle the increased load required by the welder. Your local power supplier or
a qualified electrician can assist you in determining this. It is very important for your safety
to install the welder by a qualified electrician. Failure to do so could cause fire, a ground
fault, or equipment failure. The following rules are not a complete list, but are especially
important guidelines which should be adhered to:
 The frame or case of welder shall be properly grounded.
 A safety-type disconnecting switch or controller shall be located near the machine.
 The welder or welders shall be protected by a properly sized fuse or circuit breaker
on an independent circuit.

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Ventilation:

The welder should be located in an area with adequate ventilation. In general, when welding
is being done on metals not considered hazardous, a ventilation system that will move a
minimum of 2000 cubic feet per minute (CFM) of air per welder is satisfactory.

However, many materials are considered very hazardous and should be welded only in
adequately ventilated areas to prevent the accumulation of toxic materials or to eliminate
the possible oxygen deficiency not only to the operator but to others in the immediate
vicinity. Such ventilation should be supplied by an exhaust system located as close to the
work as possible.

When welding or cutting metals with hazardous coatings such as galvanized metal the
operator should use a supplied-air type respirator or a respirator specially designed to filter
the specific metal fume. Materials included in the very hazardous category are welding rod
fluxes, coverings, or other materials containing fluorine compounds, zinc, lead, beryllium,
cadmium, and mercury.

1.15 Fire Prevention:

The arc welder is capable of producing temperatures in excess of 10.000 degrees F;

therefore, it is important that the workplace be made fire safe. This can be accomplished by
using metal sheets or fire resistant curtains as fire barriers. The floor should be concrete or
another fire resistant material. Cracks in the floor should be filled to prevent sparks and hot
metal from entering. When work cannot be moved to a fire safe area then the area should
be made safe by removing or protecting combustibles from ignition undetected until the
welder has finished the job.

Suitable fire extinguishing equipment such as buckets of sand or a dry chemical

extinguisher of the ABC type should be readily available.
Personal Protective Equipment:

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It is essential that the operator and helpers be properly clothed and protected because of
the heat, ultra- violet rays, and sparks, produced by arc welder. For body protection, a pair
of fire retardant long sleeved coveralls without cuffs is a good choice. Always avoid clothing
with tears, snags, rips, or worn spots as these are easily ignited by sparks. The sleeves and
collars should be kept buttoned. The hands should be protected with leather gauntlet
gloves. A pair of high to leather shoes, preferably safety shoes, is good protection for the
feet. Eyes should be protected by transparent goggles if the person wears prescription
glasses or safety glasses if not A welding helmet or hand shield with filter plate and cover
plate is mandatory for eye protection from the harmful rays of the arc. A flameproof skull
cap to protect the hair and head as well as hearing protection in noisy situations is
recommended.
 Plastic disposable cigarette lighters are very dangerous around heat and flame. It is
important that they not be carried in the pockets while welding.
 Filter Lens (Shade Numbers):
Safe Operation of the Welder:

 It is important that anyone operating an arc welder be instructed on its safe use by a
qualified person or welder.
 Because of their potentially explosive nature, we strongly recommend that no
welding, cutting, or hot work be attempted on used drums, barrels, tanks, or other
containers under any circumstances.
 The welder cables should be positioned so that sparks and molten metal will not fall
on them. They should also keep free of grease and oil and located where they will
not be driven over.
 Only use cables that are free from repair or splices for 10 feet (3 m) from the
electrode holder.
 Electric welders can kill by electric shock. If the welding operation must be done on
steel or other conductive material an insulating mat must be used under the operator.
If the welding area is wet or damp or the operator is actively perspiring, then he/she
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should wear rubber gloves under the welding gloves.

 It is easier and safer to establish an arc on a clean surface than a dirty or rusty one.
Therefore, metal should always be thoroughly cleaned by wire brushing or other
method prior to welding. When chipping slag or wire brushing the finished bead the
operator should always be sure to protect his eyes and body from flying slag and
chips. Unused electrodes and electrode stubs should not be left on the floor as they
create a slipping hazard.
 Hot metal should be handled with metal tongs or pliers. When quenching the hot
metal in water it should be done carefully to prevent painful burns from the escaping
steam.
 Any metal left to cool should be carefully marked “HOT”.
 When welding is finished for the day or suspended for any length of time electrodes
should
 be removed from the holder.
 The holder should be placed where no accidental contact could occur, and the
welder should be disconnected from the power source.
Safety Precautions for Engine Powered Welders:

 Always operate in an open well-ventilated area or vent the engine exhaust directly
outdoors.
 Never fuel the engine while running or in the presence of an open flame.
 Wipe up spilled fuel immediately and wait for the fumes to disperse before starting
the engine. “Never” remove the radiator pressure cap from liquid cooled engines
while they are hot to prevent scalding yourself.
 Stop the engine before performing any maintenance or troubleshooting. The ignition
system should be disabled to prevent accidental start of the engine.
 Keep all guards and shields in place.
 Keep hands, hair, and clothing away from moving parts.

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First Aid:

The welding area should always be equipped with a fire blanket and a well-stocked first aid
kit. It is desirable that one person be trained in first aid to treat the minor injuries that may
occur. All injuries, no matter how minor they may seem can become more serious if not
properly treated by trained medical personnel.
Key Points to Remember:
 Be sure the welder is properly installed and grounded.
 Never weld without adequate ventilation.
 Take proper precautions to prevent fires.
 Protect your entire body with fire retardant clothing, shoes, and gloves.
 Wear eye protection at all times.
 Weld only in a fire safe area.
 Never do any welding, cutting, or hot work on used drums, barrels, tanks, or other
containers.
 Mark metal “HOT” with a soapstone.
 Keep a well-stocked first aid kit.

1.16 HEARING CONSERVATION PROGRAM (NOISE)

Conservation of hearing is an important preventive measure. To reduce occupational

hearing loss, all employees, who work in potentially noisy areas, are provided hearing
protection, training and annual hearing tests.
Sound Measurements:

Sound pressure levels are measured in Decibels (commonly abbreviated to dB) which is a
logarithmic measure of sound pressure levels. It is a scale of ratios and not units of
measurements.

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Sound level meters measure the sound pressure waves in decibels, and to relate this to the
hearing response of the human ear, a filter is introduced to compensate for natural
protection factor found in the organs of the against low and high frequencies.

An (A) weighted filter is that which most closely resembles the human ear responses, and it
is now accepted practice to express industrial noise levels in dB (A)'s.

OSHA identifies 90 decibels based on an eight - hour time weighted average (TWA) as the
absolute "safe" level of noise exposure (PEL).
OSHA also recognizes an 85 dB TWA as its action level.
Permissible Noise Exposures:

Duration Per Day

Sound Level dBA
(Hours)
8 90
6 92
4 95
3 97
2 100
1½ 102
1 105
¾ 107
½ 110
¼ 115

When the daily noise exposure is composed of 2 or more periods of noise exposure of
different levels, their combined effect shall be considered, rather than the individual effect of
each. If the sum of these fractions: C1/T1 + C2/T2 + ……. +Cn/Tn exceed unity (1), then the
mixed exposure shall be considered to exceed the limit.

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(C: time of the exposed noise) & (T: time of the same noise level from the table)
i. Decibel Values for Some Typical Sound
Decibels Example
20 Studio for sound pictures
30 Soft whisper (5 feet)
40 Quiet office

50 Average residence

60 Conversation speech (3 feet)

70 Freight Train (100 feet)

74 Average automobile (30 feet)

80 Very noisy restaurant

80 Average factory

90 Subway

90 Printing press plant

100 Looms in textile mill

100 Electric furnace area

120 Hydraulic press

120 50 hp siren (100 feet)

140 Jet plane

180 Rocket launching pad

ii. Hearing Conservation Program:

Exposure to high levels of noise causes hearing loss and may cause other harmful health
effects as well. The extent of damage depends primarily on the intensity of the noise and
the duration of the exposure. Noise-induced hearing loss can be temporary or permanent.
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Temporary hearing loss results from short term exposures to noise, with normal hearing
returning after a period of rest. Generally, prolonged exposure to high noise levels over a
period of time gradually causes permanent damage.
The Following Summarizes the Required Component of Hearing Conservation Program:

iii. Monitoring:

The hearing conservation program requires employers to monitor noise exposure levels in a
manner that will accurately identify employees who are exposed to noise levels at or above
85 decibels (dB) averaged over 8 working hours, or an 8-hour time-weighted average
(TWA).

The exposure measurement must include all continuous, intermitted, and impulsive noise
within an 80 dB to 130 dB range and must be taken during a typical work situation.

Two basic types of instruments are available to monitor noise levels: Sound Level Meters
and Noise Dosimeters.

Sound Level Meters: are direct reading instruments that provide a "snap shot" measurement
of noise levels at a particular time. They do not average noise levels to provide the eight-
hour TWA on which OSHA bases its exposure levels.

Noise Dosimeters: measure employee's TWA exposure, they are physically worn by
employees for an entire work shift in order to record exposure levels.

Instruments used for monitoring employee exposures must be carefully checked or

calibrated to ensure that measurements are accurate.

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iv. Hearing Protectors:

Hearing protectors shall be made available and shall be worn by all employees exposed to
an 8-hour TWA of 85 dBA or greater.

 Ear muffs
 Ear plugs
 Ear canal
Hearing protectors will always have an assigned Noise Reduction Rating (NRR), which
should be printed on the packaging for each hearing protector.
NRR is the amount of decibels by which a given device will reduce noise exposure, by
subtracting the NRR value from the noise exposure levels.

1.17 ELECTRICAL SAFETY: -

i. Hazards of Electricity:
The primary hazards of electricity and its use are:
 Shock
 Burns
 Arc-Blast
 Fires and Explosions
ii. Shock:
Electric currents travel in closed circuits through some kind of conducting material. You get
a shock when some part of your body becomes part of an electric circuit. An electric current
enters the body at one point and exits the body at another location. High-voltage shocks can
cause serious injury (especially burns) or death.
You Will Get a Shock If You Touch:
 Both wires of an electric circuit
 One wire of an energized circuit and ground
 Part of a machine, which is “Hot” because it is contacting an energized wire and the
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ground Don’t take any chances with electricity. One mistake can cost you your life.
The severity of the shock a person receives depends on several factors:
 How much electric current flows through the body?
 What path the electric current takes through the body?
 How much time elapses while the body is part of the electric current?

The effect of an electric shock on a body can range from a tingle in the part touching the
circuit to immediate cardiac arrest. A severe shock can cause more damage to the body
than is readily visible.
Relatively small burn marks may be all that are visible on the outside. However, a severely
shocked person can suffer internal bleeding and severe destruction of tissues, muscles, and
nerves. Finally, a person receiving an electric shock may suffer broken bones or other
injuries that occur from falling after receiving a shock.
iii. Burns:
Burn can result when a person touches electrical wiring or equipment that is improperly
used or maintained. Typically, such burn injuries occur on the hands.
iv. Arc-Blast:
Arc-blasts occur when high-amperage currents jump from one conductor to another through

air, generally during opening or closing circuits, or when static electricity is discharged. Fire
may occur if the arcing takes place in an atmosphere that contains an explosive mixture.

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v. Explosion:
Explosions occur when electricity provides a source of ignition for an explosive mixture in
the atmosphere. The Ignition can be due to overheated conductors or equipment, or normal
arcing (sparking) at switch contacts.
vi. Fire:
Electricity is one of the most common causes of fire both in the home and workplace.
Defective or misused electrical equipment is a major cause, with high resistance
connections being one of the primary sources of ignition. High resistance connections occur
where wires are improperly spliced or connected to other components such as receptacle
outlets and switches.
Heat develops in an electrical conductor from the flow of current. This heat raises the
temperature of the conductor. As a result, resistance in the conductor increases, further
raising
the temperature. Thus, circuits conducting a high rate of current and generating more
resistance than it can handle, may create enough heat to cause fire.
vii. Causes of Electrical Accidents:
As a power source, electricity can create conditions resulting in bodily harm, property
damage, or both. It is important to you to understand how to avoid electrical hazards when
you work with electrical power tools, maintain electrical equipment, or install equipment for
electrical operation.

Accidents and injuries in working with electricity are caused by one or a combination of the
following factors:
 Unsafe equipment and/or installation
 Unsafe workplaces caused by environmental factors.
 Unsafe work practices.

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viii. Preventing Electrical Accidents:

Protection from electrical hazards is one way to prevent accidents caused by electric
current. Protective methods to control electrical hazards include:
 Insulation
 Electrical protective devices
 Guarding
 Grounding
 PPE
 Good Work Practices
ix. Insulation:
Insulators of glass, mica, rubber, or plastic are put on electrical conductors to protect you
from electrical hazards. Before you begin to work on any piece of electrical equipment, take
a look at the insulation (on electrical cords, for example) to be sure there are no exposed
electrical wires. Also use insulated tools.
x. Grounding:

Grounding is necessary to protect you from electrical shock safeguard against fire, and
protect against damage to electrical equipment. There are two kinds of grounding:

Electrical circuit or system grounding, accomplished when one conductor of the circuit is
intentionally connected to earth, protects the circuit should be lighting strike or other high
voltage contact occur. Grounding a system also stabilizes the voltage in the system so
expected voltage levels are not exceeded under normal conditions.

Electrical equipment grounding occurs when the equipment grounding conductor provides a
path of dangerous fault current to return to the system ground at the supply source of the
circuit should the insulation fail.

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When a tool or other piece of electrical equipment is grounded, a low-resistance path is

intentionally created to the earth. This path has enough current-carrying capacity to prevent
any buildup of voltages in the equipment which could pose a hazard to an employee using
the equipment. Therefore, never remove the ground prong from a plug because the
equipment no longer protects you from short circuits. If you’re touching an ungrounded tool,
you will become the path of least resistance to the ground.

Grounding does not guarantee that an employee will never receive a shock, or be injured or
killed by electricity in the workplace. However, this simple procedure will substantially
reduce the likelihood of such accidents. Be sure any equipment you work on is properly
grounded.
xi. Lockout/Tag out:

Words to qualified employees about de-energizing electrical equipment before you do any
repairs on it or make an inspection. Common sense dictates that electrical equipment be
de-energized before working on it, when feasible. (Circumstances where it might be
infeasible to de-energize circuitry or equipment before working on it would include
hazardous location ventilation equipment or the testing of fire alarm systems, for example,
that can only be performed when the system is energized. Qualified persons are only
permitted to perform this kind of work.)

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Having electrical current unexpectedly present when you are working on a piece of
equipment is no joke! Before any repair work or inspection of a piece of electrical equipment
is begun by an authorized person, the current should be turned off at the switch box, and
the switch padlocked in the OFF position.

The other step in this procedure is the tagging of the switch or controls of the machine or
other equipment which is currently locked out of service. The tag should indicate which
circuits or pieces of equipment are out of service

1.18 EXCAVATION SAFETY:

 Prior to excavation, drawings shall be checked by contractor/sub‐contractor to

determine if there are any underground installations pipes, cables exist. These shall
be protected against damage.
 Maintain sufficient angle of repose. Provide slope not less than 1:1 and suitable
bench of 0.5m width at every 1.5m depth of excavation in all soils except hard rock.
 As far as possible, excavated material should not be placed within 1 m from the edge
of excavation or depth of excavation whichever is greater.
 Drainage system shall be provided to control storm water entering the excavation.
Ground water running into the excavated area is controlled. Dewatering Pumps shall
be kept ready in case of emergency.
 Barricades, warning lights shall be erected at 1 m from the edge of excavation
adjacent to pedestrian or vehicular traffic.
 Two safe access / exits shall be provided by means of ladders, stairs ramps for
excavation beyond 1.5m.
 Where vehicles or Equipment’s operate near excavations, the side of the excavation
is made to withstand the forces exerted by the superimposed load.
 Each excavation is checked daily. If there is any cave‐in or slide, all the work in the
excavation is stopped forthwith.
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 Don’t allow vehicles to operate too close to excavated area. Maintain at least 2m
distance from edge of excavation.

1.19 CONFINED SPACE:

Confined space means that:

 Is large enough and so configured that an employee can bodily enter and perform
assigned work; and
 Has limited or restricted means for entry or exit (for example, tanks, vessels, silos,
storage bins, hoppers, vaults, and pits are spaces that may have limited means of
entry.); and
 Is not designed for continuous employee occupancy.

Typical confined spaces that may be encountered include, but not limited to: Storage Tanks,
Chambers, Manholes, Excavations exceeding 1.2 meters deep, pump wells, covered
reservoirs, tunnels, boreholes, pipelines, boilers, vessels, sewer manholes, etc.

1.20 Fire Protection and Prevention

i. Fire Prevention Measures:

The best way to fight fires is to prevent them. The following measures are to be taken into
consideration to help preventing Fires:

 Good housekeeping is the key. Trash should always be placed in appropriate

containers and emptied daily. Clean work areas are safer than cluttered or dirty one.

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 For those who smoke, smoke only in designated areas and never leave lit cigarettes
unattended. Also never smoke in bed.
 Good storage and handling of materials, especially Flammable materials.
 Store all flammable liquids in tightly, closed containers.
 Store flammable liquids in areas away from sources of flame, heat or sparks.
 Never smoke around flammable materials.
 Dispose of all flammable wastes in covered metal containers.
 Only use flammable liquids in well - ventilated areas.
 Clean up all spills of flammable liquids immediately

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ii. Types of Fire Extinguisher:

iii. PASS

 Pull (Pin) Pull pin at the top of the extinguisher, breaking the seal.
 Aim. Approach the fire standing at a safe distance.
 Squeeze the handles together to discharge the extinguishing agent inside.
 Sweep

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1.21 EMERGENCY RESPONSE PLAN

Emergency response procedures form part of the project documentation and shall be kept
readily accessible at all times throughout the project duration. The procedures interface with
existing emergency procedures of the Client and contain the telephone and contact
numbers of the nearest medical treatment facilities. Preparedness for dealing with
emergencies shall be ensured through:
 Implementing the Emergency Preparedness Procedures and confirming those
procedures are adequate by performing drills and exercises with reviews.
 Identifying foreseeable emergency situations and assessing their potential impact.
 Developing project specific emergency information covering:
i. FIRST AID & MEDICAL SUPPORT

In the event of a serious injury or illness the patient may require go to the nearest hospital.
Even of a minor nature, that shall be reported to the person's immediate supervisor and
patients should present themselves to the first aid officer for treatment. A confidential record
shall be made of all such visits.

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All emergency telephone contacts are to be verified by HSE coordinator prior to start
of activity:
ii. Emergency Response Procedure:
Although the focal point of CEG safety program is prevention, should an emergency
situation arise, follow the appropriate emergency response procedures detailed bellow.
Emergencies are defined as any incident which places or is capable of placing human life
into immediate danger or causing massive property damage and which requires immediate
and urgent action.
iii. Emergency Telephone Numbers:

Name Designation Contact Number

ABC Site Supervisor 1245678

iv. Severe Injuries Requiring Urgent Medical Treatment:

Never move an injured person unless he is in further danger. If electrical power is involved,
do not touch the injured person. Immediately switch off power, and then offer assistance.

Any employee witnessing an accident which threatens human life or massive property
damage is responsible for immediately notifying the area site engineer or supervisor, who
should:
 Proceed directly to the accident site.
 Assign someone to call for medical assistance.

Dial CEG Construction Manager and/or Safety Department for help and communicate
the following:
 Location of the accident
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 Number of injured persons

 Brief description of injured/condition of injured person.
 Any further relevant information.
 Assign a second person to notify the Safety Officer/Site Manager.
 Secure the accident area leave all equipment, materials and tools in position. This
will assist in subsequent investigation of the accident
v. EMERGENCY EVACUATION PROCEDURES: -
Emergency procedures have been developed or updated for all potential incidents including
fire, explosion, toxic gas leaks, weather disturbances and civil unrest. Procedure included
details on communications, firefighting, medical, security, and evacuation, resumption of
operation or other as required by the situation. In additional each subcontractor is
responsible to contractor for determining its own requirements.
Responsibilities:
Site Manager:
Responsible for maintenance of the emergency action plans and for ensuring adequate
resources are made available

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Site HSE Incharge:

Responsible for developing the details of each plan including communication, medical
services, etc., Also responsible for the orientation and training of all employees and
supervisors in the plans. All supervisors, employees and visitors Responsible for
understanding their role in each emergency and for complying with emergency instruction to
evacuate promptly
vi. Evacuation Procedure:
 Identify the direction of the wind and evacuate cross or upwind of the affected area to
a designated assembly area.
 If the designated assembly area is not accessible or safe due to wind direction,
proceed to an alternate assembly area.
 Personnel must assemble at the designated assembly areas.
 All engine-driven equipment must be shut down and engines turned off.
 Vehicle must be parked clear of traffic lanes so emergency equipment has access to
the location of the emergency. Keys should be left in the ignition and engines
switched off.
 Any permit voided due to an emergency must be properly reissued prior to
employees returning to their work activities.
 No one shall return unless an „„ALL CLEAR‟‟ signals has been given and CEG have
cleared personnel to return to work.
vii. ASSEMBLY AREA LOCATIONS

Assembly points will be designated for all employees.

All assembly points are marked with a letter of the alphabet and are highly visible.
The accounting procedure should proceed as follows:
 A count of all employees.
 A count of all CEG/supplier/subcontractor employees and visitors.

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Duties of Assembly Warden:

Assembly wardens appointed by the Safety Officer are responsible for following these
procedures in an emergency evacuation:
 Make sure the area / building is clear of persons other than fire fighters
 Go to the assembly area
 Report all persons unaccounted for to the Safety Officer
Handling Non-Emergency Accidents:
Non-emergency accidents are incidents in which human life is not perceived to be in
immediate danger nor are massive property/environmental damages at risk. These
accidents range from very minor injuries to severe injuries that do not appear to be an
immediate threat to life.
viii. ACCIDENT RESPONSE PROCEDURE: -
Upon occurrence of non-emergency accidents, immediately report the accident to the Site
Manager/Safety Officer who should Proceed to the accident site
IN CASE OF ACCIDENT: -
Any accident takes place, inform site In-charge, time office and Site Safety Coordinator
Assess the extent of injuries and /or damages If the Injury is minor, shift the victim to First-
aid center. {For minor injuries not perceived to require professional medical treatment (such
as minor cuts or burns) administer first aid using the supplies in the site first aid box. Notify
the Safety Officer of the accident injuries requiring professional medical treatment.} If the
Injury is major, shift the victim to the designated hospital. Then inform Project Manager /
Site Accountant / Regional Safety Coordinator /Employer’s representative
ix. Accident/Incident Investigation, Reporting and Analysis:
ln the event of an incident, the most important immediate actions are those to provide the
best assistance possible to employee(s) who may need it, and to ensure the safety of
others who may be affected or acting as emergency responders. lt is necessary to report,
record and investigate incidents to establish facts, detect trends and determine actions to
prevent recurrence. It is imperative that all incidents be reported immediately to the Safety
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Officer/Site Manager recorded and investigated as soon as practical. CEG supervision shall
immediately notify client representatives. CEG Incident Reporting Standard Form must be
used for reporting incidents and in compliance with Project incident notification
requirements.
x. Notification:
 Incidents, which result in medical treatment, restricted work cases and lost time,
require immediate notification to the project management.
 Incidents which result in a medical evacuation or hospitalization, requires notification
to the project management.
 Near miss and first aid incidents, which have the potential to severely injure, cause
damage or have a high severity, shall be reported to the project management
immediately.
 All injuries, illnesses, HSE incidents, and near miss incidents, regardless of severity,
must be promptly reported to Project Management.
 Investigations to determine contributing and mitigating factors must be initiated
immediately following the report of an incident. Formal investigations to be conducted
at the earliest to prevent recurrence
 Lessons learned shall be communicated through "Safety Alerts" to all CEG
personnel.
 Root because analysis will be utilized and form an Integral part of the
 Incident investigation and analysis process.
All incidents and accidents including near misses will be reported to WSP/RAC. The
investigation report (including the root cause as well as mitigation) will be shared with
WSP/RAC.
xi. Accident Statistics and Analysis:
The company overall accident statistics and analysis will cover at least the following
aspects:
 The total number and accident in a certain month
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 The type/nature and cause of each individual accident

 The seriousness of each accident
 Government prosecution
The accumulated number of accidents since the commencement of the project for any
accident involving property damage, type and amount of property damage
The Safety Officer should prepare a safety monthly report including accident statistics and
analysis and report to the Project manager The computed and classified results of the
accident statistics, analysis and investigation results should be analyzed by both the Site
Safety Management Committee and the Site Safety Committee for the sake of identifying
problematic areas, and subsequently devising remedial- actions and possibly proactive
safety measures to prevent the recurrence of similar accidents in the future.
The accident statistics and investigation results should be noticed on the safety bulletin
boards for the attention of all employees on no injury records frequent causes of accidents
simple tables comparing other site records unusual accidents charts showing reduction in
accidents chemicals or hazardous materials, if related to ill health, indicating accident trend
workload conditions (increased or unchanged) worker’s attendance or absence from work.

Non-conformance register that includes the assessment of corrective and preventive

actions to be effective or not length of time delay

1.22 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH)

It is a law that requires employers to control substances that are hazardous to health. You
can prevent or reduce worker’s exposure to hazardous substances by:
 Finding out what the health hazards are;
 Deciding how to prevent harm to health
 Providing control measures to reduce harm to health;
 Making sure they are used;
 Keeping all control measures in good working order;
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 Providing information, instruction and training for employees and others;

 Providing monitoring and health surveillance in appropriate cases;
 Planning for emergencies.
i. Chemical hazards
Write the full chemical name as identified on the Material Safety Data Sheet (MSDS).
Include CAS number if likely to be confused with other chemicals. If a commercial product,
write commercial name followed by chemical constituents. If relevant to the hazard, list
concentration of chemical (e.g. an acid may be corrosive, irritant or non‐hazardous
depending upon concentration).
Use the risk phrases from the MSDS e.g. Irritating to eyes, respiratory system and skin.
Ecological information (e.g. toxic to aquatic organisms) need not be included but will
inform your choice of disposal.
ii. Biological hazards
Use scientific name of organism/agent wherever possible, together with common or
commercial name if appropriate. For biological hazards, list ACDP hazard category. Other
hazards may include information on e.g. flammability, radiation safety, heat, cold and
sharps.
iii. Workplace exposure limits
Workplace Exposure Limits (WELs) are occupational exposure limits designed to help
protect the health of workers. WELS are concentrations of hazardous substances in the
air, averaged over a specified period of time referred to as a time‐weighted average. Two
time periods are used: long‐term (8 hours) and short‐term (15 minutes). Short‐term
exposure limits are designed to reduce effects such as eye irritation that may occur
following exposure for a few minutes.
iv. Control measures
When controlling exposure to a hazardous substance consider whether:
 The process can be changed to eliminate the need for the substance,
 The substance can be replaced with a safer alternative,
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 The substance can be used in a safer form e.g. pellets instead of powder,
readymade buffers or gels etc.
If prevention is not reasonably practicable, you must adequately control exposure e.g. by
one or more of the following:
 Totally enclose the process (e.g. glove box),
 Partially enclose the process (e.g. fume cupboard),
 Improve general ventilation,
 Use systems of work that minimize the chances of spillage etc.,
 Reduce the number of persons exposed.

List all engineering measures appropriate for the control of exposure to the hazard. This
should be indicated by the MSDS and the risk phrase (e.g. if toxic by inhalation then use in
a fume cupboard). Fume cupboard, glove box, safety cabinet (for biological) and local
exhaust ventilation are examples.
v. Communication
A well-documented project HSE plan loses its value when it is not properly communicated
to all concerned parties. All project staff shall ensure that HSE plan is well communicated
to all site personnel. Additionally, communications shall be designed to encourage
employees to inform their superiors of hazards in the workplace without fear and reprisal.

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2.0 MATERIAL & PROCUREMENT

2.1 General

Procurement is a term describing the purchasing process for goods and services. In building
construction, material procurement is the process by which the materials required to
construct a building are selected, ordered, invoiced, paid for and delivered to the site.

2.2 Frequently use Terms and Definitions

I. Material Requisition (MR):

A notification received from a user organization requesting the purchase of materials
and related services. (for inspectable items)
II. Material Approval Request (MAR):
A notification received from a user organization requesting the purchase of non-
inspectable materials.
III. Request For Quotation (RFQ):
A written document issued by Procurement inviting bidders to submit a quotation for
the items described in the quotation request.
IV. Competitive Bid:
A price/service offering by a supplier that must compete with offerings from other
suppliers.
V. Single Source:
The choice to use one supplier to provide a product or service, even though there are
other suppliers available.
VI. Purchase Order (PO):
A written document creates a binding contractual relationship between the buyer and
seller. A PO is used to purchase materials on a one-time basis.
VII. Purchase Agreement:

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A purchase agreement creates a binding contract between the buyer and vendor.
Generally, a purchase agreement contains the conditions which apply to purchases
made over a stated period of time (usually two years).
VIII. Non-Material Requirement (NMR):
Documents and drawings required from the vendor for the purchased equipment.
IX. Incoterms:
The Incoterms are a set of 11 individual rules issued by the International Chamber of
Commerce (ICC) which define the responsibilities of sellers and buyers for the sale of
goods in international transactions. Primary importance is that each Incoterms rule
clarifies the tasks, costs, and risks to be borne by buyers and sellers in these
transactions. i.e. CIF, FOB, DDP etc.
X. Inspection Assignment Package (IAP):
The Inspection assignment package is a set of documents that include details of
purchased material/equipment and their quality requirements needed to perform full
inspection at the vendor/sub-vendor facility.
XI. Inspectable Materials:
Deemed Critical based on Reliability, Quality, Safety, & Effect on Project. Product and
vendor approval are required Examples: Pipes, Transformers, HVAC, Valves. etc.
XII. Non-Inspectable Materials:
All items procured by JCD which are not considered inspectable, but still need to meet
minimum quality, reliability and safety requirements Examples: Glass, Lights,
Furniture. etc.

2.3 Selection & Approval of Vendors

The Procurement Incharge along with store actively seeks vendors to provide suitable
products and services. As per requirement, potential vendor evaluation is being done to
fulfil a specific need. The Procurement Incharge along with his Quality Checker/Supervisor
evaluates such vendors without bias.

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As Procurement Incharge and Quality Checker/Supervisor team evaluated the vendor,

final approval is being given by the Project Manager. Upon approval, the vendor is added
to the approved supplier list. Vendors are approved by one or more of the following
methods:

 Supplier assessment survey

 Audit/on-site review

 Satisfactory history

 Customer specified

 Specified by manufacturer

After approval of the material supplier or subcontractor an award will be made using the
standard format terms and condition for the supply. The award precise program dates will
be discussed in detail with the supplier or subcontractor.

Where require; subcontractor will prepare shop drawings relevant to his scope of work.
Once an order is placed, regular follow‐ups with the supplier/ subcontractor are carried out
to ensure compliance with the delivery schedule.

2.4 Surveys & Audit

When requested, a vendor assessment survey is delivered to the vendor by the

Procurement Incharge & Quality Checker/Supervisor. Once the vendor has completed the
survey:

 The Technical Managers or Supervisor reviews it for compliance

 Where require, audits may be conducted on-site visit by the Technical and
Quality Inspection Team

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 Results of this audit are recorded on the vendor assessment survey

 Survey results are stored in the vendor file held by the Document Controller

 Passed vendors are being listed in approved vendor list.

2.5 Special Cases Vendor Selection

In some cases, vendor/contractors selected based on the bid. In such case, purchase
committee consist of at least one member from procurement, quality & technical department
makes decision. Special cases include suppliers’ selection based on the bids, tender,
emergency basis etc.

In such cases, final approval is granted by Project Manager but incoming inspection and
continuous evaluation of such vendor is being carried out by Quality Team. In case, where
vendor provides non-conforming products so purchase committee and Project Manager
decide in procurement meeting about the continuation or discontinuation of business with
such vendor.

2.6 Procurement Process

The Procurement (Purchase) department reviews all purchase orders received from
Technical or Store team for adequacy as appropriate. Against the purchase order,
procurement department takes quotation from the approved vendors if it is available in scope
otherwise new vendor evaluation is being done.

After selection of vendors whom the product/services are in scope, copies of purchase
orders for materials, hardware or service are forwarded to the vendor. These purchase
orders are reviewed before being shared with vendor; purchase order is being reviewed by
procurement team and Procurement Incharge approve the purchase order after being verified
with the requirement received.

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Reviewed being carried in order to reduce to the risks related to out of specification
requirements send by company. Where requires; vendors are provided with appropriate
drawings, specifications and other requirements at the time of ordering. Purchase orders may
be generated manually or electronically through system but must typically contain:

 The vendor’s contact details

 The vendor’s approved supplier reference number

 Quantity, type, class/grade of goods, service purchased

 Special requirements, e.g., material certifications, inspections and packaging

requirements

2.7 Verification of Purchased Products

The progress of procurement will be measured on each requisition of equipment, major

bulk material or services. Where applicable the weight point of each requisition of equipment
and bulk materials will be determined in proportion to the estimated cost for the equipment or
the material covered by the requisition or purchase order

All the items / services to be procured for Client as part of the Project are listed in
“Procurement List" which is a controlled document and updated every week to show the
physical status of the deliverables planned along with the dates for different stages. The
physical progress on these deliverables will be shown in this register and procurement
schedule in the planning package. The progress monitoring and the tract of the procurement
items I packages for each deliverable will be monitored through this list

Quality Department ensure that the purchased product must according to the invoice
description matches that of the Purchase Order so that out of specification material is not
used in project and store team verifies those quantities are equal to what was ordered so that
material should not be short. Material is inspected as per requirement and Material Inspection

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Request is prepared. The receiver of the goods also stamps the invoice with the Goods
Received and signs on the space provided and indicates the date of receipt.

Verification of the purchased product is carried out through inspection of the supplied
product by the end user upon delivery. Any products or services supplied wrongly, damaged
or not in accordance with the purchase order requirements are documented onto a Non-
Conformance Report and processed accordingly.

3.0 Inspection, Thorough Examination and Testing of Lifting Appliances and Lifting
Gear

3.1 Introduction

This Guidance provides practical guidance on inspections, thorough examinations and tests
of lifting appliances and lifting gear as prescribed under the Factories and Industrial
Undertakings (Lifting Appliances and Lifting Gear) Regulations (hereinafter referred to as
LALGR) to ensure their safety and reliability.

This plan applied to all concerned parties, including owners of lifting appliances and lifting
gear, competent persons and competent examiners involved in carrying out inspections,
thorough examinations or tests of lifting appliances and lifting gear. It should be applied in
conjunction with relevant national/international standards, codes of practice and
manufacturer's instructions in order to ensure the quality of inspections, examinations and
tests.

To start with, this guidance gives a brief account on the main frame of legal requirements of
inspections, examinations and tests of lifting appliances and lifting gear. It then lists out the
key elements and components of ‘inspection’, ‘thorough examination’, and ‘test and thorough
examination’. The co-relationship between ‘thorough examination’ and ‘test’ has also been

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elaborated. It recommends certain criteria in the scale-down of safe working loads of lifting
appliances and a proper way in the tabulation of safe working loads in the current certificates
after the tests and thorough examinations. Finally, it advises that, under the general duty
provisions, the employer should provide and maintain safe systems of work to ensure the
safety of personnel engaged in the job in addition to the carrying out of good quality and
accurate inspections, thorough examinations and tests.

For the purposes of this GN, the following interpretations which are extracted from the
LALGR apply:

“competent examiner, in relation to the carrying out of any test and examination required
by the aforesaid regulations, means a person who is

(a) appointed by the owner required by these regulations to ensure that the test and
examination is carried out;

(b) a registered professional engineer registered under the Engineers Registration

Ordinance (Cap.409) within a relevant discipline specified by the Commissioner for Labour;
and

(c) by reason of his qualifications, training and experience, competent to carry out the test
and examination;

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As at the date of issue of this Guidance, mechanical engineering and marine engineering
are two disciplines specified by the Commissioner for Labour for the purposes of these
regulations;

“competent person” in relation to any duty required to be performed by him under the
aforesaid regulations, means a person who is

(a) appointed by the owner required by these regulations to ensure that the duty is carried
out by a competent person; and

(b) by reason of training and practical experience, competent to perform the duty;

“crane” means any appliance equipped with mechanical means of raising and lowering a
load and for transporting the load while suspended; and also all chains, ropes, swivels, or
other tackle (down to and including the hook) used in the operation of a crane; but does not
include

(a) a hoist block running on a fixed rail or wire;

(b) a stacker or conveyor whereby a load is moved by means of a belt or platform; or

(c) an earth or mineral moving or excavating appliance not fitted with a grab;

“lifting appliance” means a crab, winch, teagle, pulley block or gin wheel used for raising or
lowering, and a crane, sheerlegs, excavator, pile driver, pile extractor, dragline, aerial
ropeway, aerial cableway transporter or overhead runway, and also any part of any such
appliance;

“lifting gear” means a chain sling, rope sling, ring or similar gear, and a link, hook, plate
clamp, shackle, swivel or eyebolt;

“owner”, in relation to any lifting appliance or lifting gear, includes the lessee or hirer
thereof, and any overseer, foreman, agent or person in charge or having the control of
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management of the lifting appliance or lifting gear and, in the case of a lifting appliance
situated on or used in connection with work on a construction site, also includes the
contractor responsible for the construction site;

“safe working load” ﹙hereinafter referred to as SWL in relation to a lifting appliance or to

lifting gear, means either

(a) the appropriate safe working load for operating the lifting appliance or lifting gear as
specified in the current certificate of test and thorough examination delivered in the approved
form by a competent examiner in respect of that lifting appliance or lifting gear for the
purposes of the LALGR; or

(b) where no such certificate is required, the relevant safe working load shown in the table
referred to in regulation 18（1）（b) of the LALGR.

3.2 Legal Requirements

Inspections, thorough examinations and tests are particularly important for ensuring the
safety and reliability of lifting appliances and lifting gear. Statutorily, there are three types of
duties as follows:

• inspection by a competent person;

• thorough examination by a competent examiner; and

• test and thorough examination by a competent examiner.

The legal requirements of ‘inspection’, ‘thorough examination’ and ‘test and thorough
examination’ of lifting appliances and lifting gear are summarized in Table 1 and Table 2
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respectively. Table below tabulates the types of Forms used for inspections, examinations
and tests of different lifting appliances or lifting gear.

Types of Thorough Test and thorough

Inspection
appliance examination examination

Lifting appliance at least once in the before use for the first time or after
within the preceding 7
except crane, winch, preceding 12 substantial repair, re-erection,
days
crab. months failure, overturning or collapse (Reg.5
(Reg.7A of LALGR)
(Reg.5 (1) of LALGR) (2) & 5 (4) of LALGR)

Crane within the preceding 7 at least once in the within the preceding 4 years or after
days (including the preceding 12 substantial repair, re-erection, failure,
automatic safe load months overturning or collapse
indicator) or before erection (all
or after each erection and removal to a
of the devices used
new location or any adjustment which
for the anchoring and
involves changes in the arrangements for
ballasting of
the crane) anchoring or ballasting the crane

or after exposure to weather likely

to have affected the stability of the
crane

(Reg.7A & 7B(1)(c) of (Reg. 5 (1) & 7E (1) of (Reg.5 (3), 5 (5), 7B(1)(b), 7E(2) &
LALGR) LALGR) 7G(2)(a) of LALGR

Winch and within the at least once in within the preceding 4 years or
crab preceding 7 days the preceding 12 after substantial repair, re-erection, failure,
months overturning or collapse

(Reg.7A of LALGR) (Reg.5 (1) of LALGR) (Reg.5 (3) & 5 (5) of LALGR)

3.3 Inspection

The safety and reliability of a lifting appliance or lifting gear cannot be ensured unless it has
received regular inspections. Regular inspections are particularly important because they
provide a useful means of detecting potential hazards which could contribute to accidents.
Regular inspections can also forewarn the owner of necessary preventive maintenance or
repair, the lack of which can lead to serious deterioration of the lifting appliance and
expensive replacement or repair charges.

An inspection means a visual and physical checking usually supplemented by a functional

check to examine the states of individual items of a lifting appliance or lifting gear. The

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purpose of an inspection is to find out whether there is any item having abnormal wear and
tear, malfunction, oil leakage, overheating, corrosion, unusual noise, dislocation, visual
cracks, misalignment, overloading, abnormal slackening or elongation, and excessive
vibration, etc. and if necessary to arrange for subsequent remedial actions such as repair and
replacement of the defective parts, or to stop the lifting appliance or lifting gear from further
use if a critical condition exists.

The key elements of regular inspection are:

• frequency and coverage of inspection;

• competence of persons engaged in inspection; and

• report by competent person.

Frequency and Coverage of Inspection

For Lifting Appliance

Weekly Inspection

This is a statutory requirement for the lifting appliance to be inspected within the preceding 7
days prior to use by a competent person. In fact, nearly in every preventive maintenance
schedule, weekly inspection is recommended by the manufacturer's operation and
maintenance manuals.

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The coverage of a weekly inspection should be as broad as possible. Every lifting appliance
has its own specifications. Reference should be made to the manufacturer's operation and
maintenance manuals and if necessary the professional advice from the manufacturer should
be sought before determining the inspection items.

In general, a weekly inspection should cover but not limited to the following:

• the hoisting mechanism, including wire ropes, pulley blocks and end fastenings;

• the functional mechanisms such as sheaves, brakes, locking mechanisms, hooks,

limit switches, control switches and buttons;

• the safety devices such as automatic safe load indicators;

• the fixing and anchorage arrangements;

• the connecting hardware such as bolts and nuts, hooks, wire grips and shackles;

• the electrical systems including earth conductors and circuit protectors;

• the lubrication and cooling systems such as lubricating oil and coolant;

• the hydraulic and fuel supply systems such as oil reservoirs; and

• the configuration such as straightness of the boom or jib, etc.

Daily Inspection

At the beginning of each shift or working day, the operator, if competent for the purpose, or a
competent person, should carry out an inspection to ensure that the lifting appliance is in a

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serviceable state without any defect. All components that have a direct bearing on the safety
of the lifting appliance should be inspected on daily basis. Typical examples are the control
mechanism, control switches, levers, hydraulic hoses, oil level of hydraulic and fuel systems.

Other Regular Inspection

In many cases, manufacturers require other regular inspections such as monthly/quarterly

inspections to be conducted on some components. These inspections are intended to
determine the need for repair or replacement of parts as required to maintain the appliances
in serviceable condition insofar as safety is concerned. Reference should be made to the
manufacturers' operation and maintenance manuals.

For Lifting Gear

Inspection Before Use

This is a statutory requirement for each lifting gear to be inspected before use on each
occasion by a competent person. All lifting gear should be inspected to ensure that it is free
from any abnormal wear and tear, visual cracks, elongation or slackening, etc. In particular,
according to the legal requirement, it shall be checked that the total number of visible broken
wires for a wire rope, in any length of 10 diameters, shall not exceed 5% of the total number
of wires in the rope.

Competence of Persons Engaged in Inspection

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Inspection of a lifting appliance or lifting gear shall be carried out by a competent person who
may be an operator or a mechanic. A competent person is regarded as competent if he is
well trained and possesses adequate knowledge and practical experience in handling the
similar type of lifting appliances or lifting gear. He should be able to detect and assess
defects and potential hazards that could limit the safe performance of the lifting appliances or
lifting gear.

A competent person should be fully familiar with and apply the following aspects of
knowledge and skill:

• the operation or use of the lifting appliance or lifting gear that he has to inspect;

• the location and function of safety devices, master switches, on-off switches

• the safety rules, precautions, servicing and overhaul requirements and limitations as
defined in the operation and maintenance manual of the lifting appliances or lifting
gear that he inspects;

• the content and application of the LALGR;

• the skill of using hand tools, machine tools, measuring instrument and testing devices
to conduct simple functional checks;

• the maintenance record of the lifting appliances or lifting gear that he inspects; and

• the safe system of work to take care of himself and of other persons working with him
during inspection.

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Report by Competent Person

For Lifting Appliance

The use of an inspection checklist is recommended for carrying out the inspection of a lifting
appliances. A checklist, clearly listing out all inspection items, definitely systemizes and
facilitates the inspection work.

It is strongly recommended that the competent person should keep a logbook to record all
defects and comprehensive findings noted during the inspection. Details of all modifications,
repairs and maintenance should be entered in the logbook. The logbook should also bear the
lifting appliance's brand name, model, serial number and year of manufacture, etc.

The competent person shall issue a certificate in the approved form (Form 1) to record the
state of a lifting appliance after the inspection. A Statement whether the lifting appliance is in
safe working order should be entered by the competent person. He should deliver the
certificate to the owner of the lifting appliance as soon as possible. An example of a Form 1
that has been duly completed by a competent person after inspecting a mobile crane is
shown at Appendix I. It is important that the owner and/or the person in control of the lifting
appliance should be notified as soon as possible if it is found to be not in safe working order
so that appropriate action can be taken to repair or replace the lifting appliance or otherwise
ensure that the potentially dangerous lifting appliance is withdrawn from use as soon as
possible. A notice should be attached to the lifting appliance stating that it must not be used.

For Lifting Gear

As far as reasonably practicable, the use of a checklist listing out the identification markings
of all lifting gear to be inspected is recommended. The result of inspection should be
recorded.

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It is important that the owner and/or the person in control of a lifting gear should be notified
as soon as possible if the competent person has revealed any defect which renders the lifting
gear no longer in safe working order so that appropriate action can be taken to repair or
discard the lifting gear. It should also be noted that lifting gear awaiting repair or taken out of
service should be separately and suitably stored. Notices should also be attached stating that
they must not be used.

3.4 Through Examination

The objective of ‘thorough examination’ is to ensure that the lifting appliance or lifting gear so
examined is of good mechanical construction, made of strong and sound materials, free from
any defect and in the correct configuration and condition according to the manufacturer's
instructions. The examination shall be carried out as carefully as the conditions permit so as
to arrive at a reliable conclusion as to the safety of the parts examined.

The key elements of thorough examination include

• the period of examination;

• the coverage; and

• report by competent examiner.

The Period of Examination

The criteria to carry out a thorough examination as required by law depends on a time factor
which is either within a 6-month period or 12-month period.

6-month period

The owner of any chain, rope, or lifting gear used for raising or lowering or as a means of
suspension shall ensure that each chain, rope or lifting gear in use has been thoroughly
examined by a competent examiner in the preceding 6 months before it is used.
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12-month period

Lifting appliances shall be thoroughly examined by a competent examiner at least once in the
preceding 12 months. It is mandatory that a periodic thorough examination shall be carried
out by a competent examiner even if the lifting appliance or lifting gear is in serviceable and
good condition. In certain lifting appliances, the period of examination is also defined by the
manufacturer besides the legal requirement. Reference should be made to the operation and
maintenance manual for any additional requirement.

The Coverage

A thorough examination should cover those components of lifting appliances and lifting gear
which are subjected to certain degree of exposure to wear, deterioration, malfunctioning or
misalignment. Lifting appliances and lifting gear should be carefully examined to identify any
deficiencies that may constitute a hazard. To ensure that the lifting appliance or lifting gear is
safe to be used, a thorough examination not limited to the following should be conducted:

• visual examination;

• dimensional examination;

• functional or operational test;

• open-up examination;

• electrical test and examination; and

• non-destructive test.

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Visual Examination

Visual Examination includes the check and examination of the state of individual items of a
lifting appliance or lifting gear. The purpose of visual examination is to identify any problems
that are likely to affect integrity. Visual examination is usually supplemented by hammer test
so that concealed defects can be revealed. Visual examination should cover at least the
following aspects:

• the components of the hoisting mechanism, including all wire ropes, lifting attachment,
controlling devices and buttons;

• the items of any braking systems including the brake linings, pawls and ratchets of
clutch system;

• connecting hardware and joints such as bolts, fasteners, joints, of a hydraulic or

pneumatic system;

• mast or jib configuration, including jointing pins, welds of a structural mast or bases,
stoppers or clamps of a travelling system; and

• fixing and anchorage, and ballast arrangements of the appliance which may affect
stability.

Dimensional Examination

Dimensional Examination includes the check of the dimensional tolerances and distortions of
certain critical components and configuration that may affect the stability, performance and
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function of the lifting appliance or lifting gear. The purpose of dimensional examination is to
ensure that the dimensional tolerance and configuration alignment are within the limit as
specified by the manufacturer's specifications or relevant safety standards such as British
Standards or the equivalence.

The main areas of dimensional examination include:

• measurement of linear dimensions such as diameter, thickness, clearance of a

component, the diameter of a wire rope, the wear limit of a brake lining, wear and tear of
gearing;

• measurement of span limit, deflection, alignment to verify the structural stability of a load-
bearing fabrication such as deflection of a jib, alignment of the corner frame of the mast
of a tower crane; and

• dimensional clearance of safety limit switches.

In most cases, visual examination, hammer test and dimensional examination are carried out
simultaneously to increase the thoroughness and accuracy of a thorough examination.

Functional or Operational Test

Having finished the visual and dimensional examinations and there is no deficiency or
irregularity noted, an operational or a functional test should be conducted to check the
function of the various operating and safety systems of a lifting appliance. An operational or a
functional test consists of a no-load test and a SWL performance test.

A no-load test is first conducted before operating the lifting appliance in a loaded condition.
This is essentially a safety procedure to ensure that the appliance is capable to take up
safely the SWL performance test in the later stage.

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The no-load test consists of checks on the following elements if applicable:

• lifting and lowering mechanism;

• boom lifting and lowering mechanism;

• travelling mechanism;

• swinging or slewing mechanism;

• functions of all safety alarms, safety devices and indication lamps; and

• brake operation such as the fail-safe mode or free operation.

It is important to ensure the competence of the operator assisting the functional/operational

test, e.g. the operator of a crane shall hold a valid certificate under the LALGR. The operation
and maintenance manual should be made available for reference during the test.

When the lifting appliance is found in safe working order under the no-load test, a SWL
performance test is conducted to verify the performance of the appliance. With reference to
the load chart of the lifting appliance, the SWLs contained in the previous test certificate, year
of manufacture, maintenance record or accident history of the appliance, a correct amount of
proof load is selected to conduct the SWL performance test. The test should be conducted by
the same mechanic and operator who assist the no-load test.

In the case of a crane operating with various working radii, the SWLs at minimum and
maximum radii should be at least selected for the SWL performance test.

The testing elements of a SWL performance test should be the same as those of the no-load
test. In certain cases, a dimensional examination such as deflection measurement may be
incorporated into the SWL performance test to verify the deflection limit as stated in the
manufacturer's specifications or relevant safety standards.

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Opening Up Examination

Opening Up Examination includes the check of covered, concealed or encased components

such as gearboxes in the drive train, brake linings or brake discs of the braking system
whether they are within the limits as recommended by manufacturer's specification. It is
important that opening up examination should be conducted after abnormal conditions and
irregularities are observed during the functional test or as recommended by the
manufacturer. The opening up procedure stated in the assembly manual should be strictly
followed.

Electrical Testing and Examination

Electrical tests on the portable electrical lifting appliance should be carried out by a registered
electrical worker registered under the Electricity Ordinance (Cap.406) not limited to the
insulation resistance test, earth continuity test and functional test of the appliance.

For a fixed electrical installation (e.g. an over-head travelling crane), thorough examination
and testing should be carried out by a registered electrical worker registered under the
Electricity Ordinance (Cap. 406) to ensure that:

• the installation is properly protected from earth fault, short circuit and overload;

• the connection to the source of electricity supply is proper and safe;

• the electrical parts and the electric cables/wiring are in good order; and

• the electric cables/wiring are properly laid and protected against damages.

Non-destructive Test

Material defects of components such as fatigue cracks or corrosion cracks may be developed
during service. When a visual examination or an opening- up examination is insufficient to
draw a reliable conclusion as to the parts or components being examined, non-destructive
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tests should be engaged to further assess the integrity and reliability of those parts in
question.

The common non-destructive testing systems currently engaged in the examination of

components are:

• liquid penetrant inspection;

• magnetic particle inspection;

• electrical test methods;

• ultrasonic testing; and

• radiography.

There are standard procedures, precision equipment and technology to conduct a non-
destructive test. The decision to apply any of the above testing methods should be left to the
professional judgement of the competent examiner engaged in the thorough examination of
the lifting appliance. Non-destructive test has to be carried out by a qualified personnel only
with proper training and appropriate experience.

Conclusion of the Thorough Examination

Depending on the type, model and working capacity of the lifting appliance or lifting gear, the
competent examiner is to select the best type of examination that may assist him to
determine the safe working condition of a lifting appliance or lifting gear. No matter which
types of examinations that the competent examiner may select, it is important that the lifting
appliance or lifting gear so examined should be in safe working order under normal usage
and maintenance within a working period before the next examination.

The clause ‘in safe working order’ as concluded by the competent examiner in the certificate
after he has examined the lifting appliance or lifting gear bears a professional assurance that:
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• the lifting appliance or lifting gear is of good mechanical construction, made of strong and
sound materials, and free from patent defect;

• the arrangements for fixing and anchoring the lifting appliance are adequate to secure its
safety;

• every structure supporting the lifting appliance is of good construction and adequate
strength, of sound materials and free from patent defect;

• all safety devices, limiting switches, and safety arrestors are functioned properly;

• the appliance is electrical safe and free from electrical hazards should there be any
electrical components; and

• under normal operation condition and proper maintenance, the lifting appliance or lifting
gear is safe to use within the period either defined by the manufacturer's specification or
the statutory requirement.

Report by Competent Examiner

A competent examiner should keep an examination log book to note down the major
configuration details, performance characteristic, function of safety devices or warning
systems, electrical particulars, means of identification and the state of working condition of
the lifting appliance or lifting gear undergone thorough examination. Any deficiencies or
abnormal conditions detected during the thorough examination should be entered in the log
book. The owner of the lifting appliance or lifting gear should be informed of the findings for
immediate attention or repair.

Where the thorough examination shows that the lifting appliance or lifting gear cannot be
used safely unless certain repairs are carried out, the competent examiner should
immediately inform the owner of the lifting appliance of that fact and should, within 14 days

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after the thorough examination, deliver a report to the owner and a copy of it to the
Commissioner for Labour.

When an appliance is found to be in safe working order, a competent examiner should issue
a certificate of thorough examination in an approved form to the owner of the appliance as
soon as possible to allow the owner to use the appliance. The certificate should contain
enough details to indicate the identification, configuration, performance and capacity of the
appliance. A certificate not in the approved form (including a temporary certificate) does not
fulfill the requirement of the LALGR.

Sufficient number of entries and correct amount of SWLs should be entered in the certificate
for the lifting appliance. It is recommended that the number of entries of SWLs in the
certificate should be the same as the number of load ratings in the load chart supplied by the
manufacturer to provide sufficient data for an operator to operate the lifting appliance without
overloading the appliance. When the competent examiner has scaled down the capacity of
the lifting appliance, the original load chart of the lifting appliance is no longer applicable and
the competent examiner has a duty to ensure the original load chart if being posted or
marked on the lifting appliance is removed. The competent examiner also has a duty to list
out all newly allocated SWLs in the certificate.

3.5 Testing Through Examination

Under the LALGR, the owner of a lifting appliance or lifting gear shall appoint a competent
examiner to test and thorough examine his lifting appliance or lifting gear in the manner as
prescribed in the First Schedule of the LALGR which has been reproduced at Appendix II.

The said Schedule prescribes the following requirements:

• the amount of proof load to be adopted during the test;

• the greatest possible proof load for a hydraulic crane;

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• the test procedure and requirement of lifting gear; and

• after being tested with proof loads, each part of the lifting appliance or lifting gear
should be examined so as to ensure that no part of the lifting appliance and lifting gear
has been damaged during the test.

Test and thorough examination of a lifting appliance and lifting gear (except a fibre rope or
fibre-rope sling) shall be conducted within certain period and under specified conditions. For
example, crane, crab or winch shall be tested and thoroughly examined during the preceding
4 years by a competent examiner even thorough they are in serviceable states and good
conditions. ‘Test and thorough examination’ is also required under the following specified
conditions:

• before the lifting appliance or lifting gear is put into use for the first time,

• after undergoing substantial repair, re-erection, failure, overturning or collapse of the

lifting appliance, or

• after exposure to weather conditions likely to have affected the stability of the crane.

It is worthy to note that the replacement of a suspension rope of a crane also requires further
test and thorough examination as almost all replacements will involve lots of alignment and
adjustment of limit switches, brakes and end fastenings, etc.

Process of Test and Thorough Examination

A ‘test and thorough examination’ is composed of the following:

• a thorough examination,

• a test, and

• a re-examination.
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Thorough Examination

A ‘thorough examination’ shall be carried out to ensure the lifting appliance or lifting gear is
capable to withhold the proof loads of the test to be conducted. The degree of coverage of
such thorough examination should be the same as discussed in Chapter 4.

Test

A ‘test’ as required by law is a proof load test. The objective of the test is to demonstrate that
the lifting appliance or lifting gear is structurally sound and fit for the use for which it is
designed.

For a lifting appliance or lifting gear which is first put into use, the test is to verify the
specifications and performance as recommended by the manufacturer. In case of a wire
sling, a 'test' means a destructive test to find out the breaking load of the sling and hence to
deduce its SWL.

In the event of any alteration or repair which may affect the stability or the strength of a lifting
appliance, proof load test should be carried out to ensure that all parts affected by the repair
or alteration are structural sound and stable for further use. Where a periodic test is required
by regulations, a proof load test should be conducted to ensure that the performance and
capacity of the appliance are in safe working order.

The key elements of a proof load test are to select a particular test and a correct amount of
proof loads to verify the performance, stability and structural integrity of the lifting appliance.
The type and the amount of proof loads are different from one appliance to another. For lifting
appliances, the proof load is in the range of 110% to 125% of the previous or known SWL.
Reference should also be made to various relevant national/international safety standards,
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codes of practice or manufacturer's specifications to determine and select the most

appropriate type of test and the correct amount of proof loads.

The proof load test is conducted to cover the following:

• to verify the configurations of a lifting appliance such as the amount of deflection or

degree of inclination of a mast or a span of a lifting appliance. In general, the test is
collaborated with dimensional examination. The test is also known as confirmation
test; and

• to check the functions of the hoisting, slewing and travelling mechanisms of a lifting
appliance, with particular attention to the performance and efficiency of the braking
system for each of these motions. Any overrun or creep should be discernible. The
test is sometime called a dynamic test.

Re-examination

According to the First Schedule of the LALGR, an examination shall be conducted after the
proof load test with an aim to check whether there is any cracking, deformation or loosening
of or damage to structural connections developed during the test. Re-examination is to
ensure that the lifting appliance or lifting gear is still structural sound and stable for safe use
until the next cycle of test.

Adjustment and tuning of overload protection devices, safety devices and limiting switches
should be carried out and reset during the re-examination in accordance with the
manufacturer's specifications and a functional test of these switches should be conducted to
verify the correct operation of the lifting appliance or lifting gear.

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Report by Competent Examiner

Test certificates shall be issued to indicate the compliance with the appropriate regulations.
The certificates shall be in the approved forms and signed by the competent examiner who
carried out the test and thorough examination. A certificate not in the approved form
(including a temporary certificate) does not fulfill the requirement of the LALGR.

For the lifting appliance with various SWLs at different working radii, such as tower cranes or
mobile cranes, the certificate should tabulate all SWLs for which the lifting appliance is
certified, not just the ratings at the positions where the proof load was applied.

Every test certificate should be endorsed with all necessary information to ensure that there
is no ambiguity as to the appliance rigging at the time of the test, for example, all possible
variables such as jib length, counterweight, outriggers condition of a mobile crane, any
restrictions or specific conditions. In case the test and thorough examination shows that the
lifting appliance or lifting gear cannot be used safely, the competent examiner should report
to the owner and the Commissioner for Labour

3.6 Granting of Safe Working Loads and Scale Down of Load Ratings

It must be recognized that, while a lifting appliance or lifting gear is designed and
manufactured with a factor of safety, every lifting appliance or lifting gear begins to wear and
tear once it is put into service. This process will inevitably continue until the lifting appliance
or lifting gear is no longer capable to withstand its designed workload unless all parts subject
to wear or failure are regularly inspected, repaired or replaced, examined and tested to
ensure their conformity and fitness for the purposes.

Granting of Safe Working Loads

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Each lifting appliance or lifting gear would be accompanied with the manufacturer's
specifications and the operation and maintenance manual when it is newly purchased. For
the lifting appliance, there is a load chart in the manual specifying the rated (maximum)
capacities of the lifting appliance for every permissible configuration and situation. The load
chart also specifies the lifting appliance's operational limitations and the conditions necessary
for safe operation. These are essential information in connection with the extension of the life
cycle of the lifting appliance. In no circumstances should the lifting appliance be operated in
the manner that it is beyond the maximum safe working load. Provided that for the purpose of
enabling tests of any lifting appliance to be carried out, the safe working load may be
exceeded as required by the LALGR to carry out the proof load test and authorized by the
competent examiner appointed.

Even if a lifting appliance or lifting gear is new, prior to be put into service, a ETE should be
conducted on it in accordance with the LALGR before the appropriate SWLs are entered into
the test certificate. The capacities listed in the load chart also provide a reference for
selecting appropriate proof loads to be applied during the next ETE.

After the thorough examination or the ETE, the competent examiner should determine the
appropriate SWLs for operating the lifting appliance or lifting gear. It is important that the
numbers of SWLs so listed in the certificate for the lifting appliance should be equal to the
numbers of readings as shown in the load chart of the manufacturer's operations and
maintenance manual. Take a mobile crane for example, if the load chart supplied by the
manufacturer contains thirty load ratings for various jib lengths and working radii, there
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should also be thirty SWLs listed in the certificate issued by the competent examiner. A test
certificate issued by a competent examiner is illustrated at Appendix III. The item 6 of the
certificate is extracted to form an attached chart of the certificate that shows all SWLs.

Scale Down of Load Ratings

Occasionally, a competent examiner may scale down the load ratings of the lifting appliance
which has been put into service for a long period of years. He approves SWLs which are
about 50% to 80% of the original load ratings of the lifting appliance. The reasons behind the
scale down are complicated, including bad maintenance record, alarming accident history,
improper use and operation, and long year of service.

The scale down of the original load ratings of a lifting appliance should be allowed on
exceptional basis and provided that the following conditions are satisfied:

• the lifting appliance has been tested and thorough examined to ensure that all
components are made of strong and sound material and free from patent defect. The
test and thorough examination should accompany with a Non-destructive test to
confirm the structural integrity of load bearing components, joints and welds;

• approval has been obtained from the manufacturer to determine the amounts of scale
down, especially for those lifting appliances the load ratings of which drop in non-linear
scale;

• specified conditions should be imposed in the certificate to ensure the safe condition
of the lifting appliance before the next test and thorough examination; and

• all load ratings contained in the load chart are proportionally scaled down. The scaled
SWLs should be fully tabulated in the certificate.

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If the thorough examination or the proof load test revealed that the appliance should be
undergone a repair but genuine parts are not available for replacement, it is important to note
that scale down of load ratings to form new SWLs should not be allowed. The lifting
appliance should be put out of service until the proper repair has been done.

It is not applicable to any lifting gear for scale down of SWLs as the SWLs of lifting gear is
determined by the breaking load of the sample gear under a destructive test.

3.7 Safe System of Work for Inspection through Examination and testing

A safe system of work should be developed to ensure the safety of personnel engaged in the
job in addition to carrying out of a good quality and accurate inspection, examination or test.
Legally, every employer must ensure the safety and health at work of all his employees. He
should provide and maintain a safe system of work that is safe and without risk to health. The
safe system of work should be worked out under the advice of a registered safety officer. The
system should include the following main ingredients:

• site conditions;

• weather conditions;

• test weights;

• procedure and safety precautions;

• prevention from swinging or wheeling outwards of loads;

• competence of operator engaged in examination or testing;

• use of information;

• emergency procedure; and

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• administration of the safe system of work.

Site Conditions

When a lifting appliance or lifting gear is to be examined or tested in a site or inside a

workshop, due consideration should be given to the condition of the site or premises
where examinations or tests are to be conducted. Whenever possible, the lifting appliance
or lifting gear should be examined and tested in open area or workshop where no other
work activities are carried out concurrently.

The ground or structure for support the lifting appliance should be well consolidated,
structurally stable and capable of withstanding the loads that would be applied to it. Care
should be taken to ensure that there are no hidden hazards in the vicinity such as cable
ducts, drains, pipes, back-fill areas, cellars or other underground weakness when testing
of a lifting appliance is conducted. Lifting appliances should not be examined or tested in
the vicinity of overhead power lines. In general, brick or masonry work, metal or bamboo
scaffolding, or temporary structure or working platforms should not be used as a test site
during the proof load test.

The site where the test is conducted should be of sufficient area and have unrestricted
overhead clearance to allow the unobstructed movement of the lifting appliance and load
throughout all its appropriate test movements.

It should also keep in mind to ensure all personnel not involved in the test be kept away
from the test area. Particular care should be taken when a mobile crane or a tower crane
is tested near a public area, highway, or occupied buildings. Appropriate time and date
should be arranged with all relevant parties to keep away traffic and pedestrians during
the test.

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Weather Conditions

If the test site is situated in an open area, examinations or tests should not be carried out
in adverse weather condition. Gusting wind may introduce an additional adverse effect on
the safe handling of the load and the safe operation of the lifting appliance. Accident may
happen to the personnel involved in the examination or test as rainy weather may
increase the slipperiness of the frame structure of the lifting appliance on which they may
walk. Suitable safety precautions should be devised if examinations and tests in such
weather condition could not be avoided.

Test Weights

The test weights used should comply with the following requirements:

• weights of proven accuracy within +/- 1.0%,

• weights proven on a weighbridge, the weighbridge has been calibrated within the last
12 months, and

• weights suspended from a calibrated weighing device, the weighing device has been
calibrated within the last 12 months.

The suspended test weights should be kept as close to the ground as possible, such as in
the range of 100mm to 200mm above ground. Safety precautions should be taken to
ensure the work safety of the personnel involved in the proof load test if the test weights
are required to be hoisted or travelling along a path.

Test weights should be made up of concrete/metal blocks/plates, preferably with markings

to show their actual weights. Under no circumstances, should reinforcement bars, wooden
planks or life load be used as test weights.

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Procedure and Safety Precautions

A proper procedure should be worked out to clearly define the sequence and the
responsibility of each personnel engaged in the inspection, examination or test of a lifting
appliance or lifting gear. It should set out which tests to be carried out first and what follows a
non-destructive test. It is important to note down all safety precautions from relevant codes of
practice, national/international standards and the manufacturer's operation and maintenance
manual, and if appropriate, incorporate them into the safe system of work. The proper
procedure and safety precautions for manually handling heavy test weights, equipment and
lifting tackles should be laid down. If it involves working at height, relevant safety measures to
prevent fall of persons should be adopted, including the provision of safe access and egress,
proper working platforms and personal protective equipment such as independent life lines
and safety harnesses, etc.

A briefing session to explain and highlight the procedure and precautions should be
conducted to ensure that every personnel is fully familiar with this topic.

Prevention from Swinging or Wheeling outwards of Loads

When a lifting appliance operates with various SWLs at different working radii, adequate
precautions should be exercised during the proof load test to prevent the load from swinging
or wheeling outwards in order not to overload the lifting appliance. In case of a horizontal jib
crane with trolley, suitable device should be fitted at the maximum radius of the jib, e.g.
clamps to prevent the trolley from moving beyond this point.

Competence of Operator Engaged in Examination or Testing

The safe system of work should specify the competence of the operator who is engaged in
the functional test or proof load test. The operator should be familiar with the characteristics
of the lifting appliance, the safety precautions in handling overloading and the limitation of the

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lifting appliance in the brake test, functional test and proof load test. He should be able to put
the lifting appliance under control at any time during the examination and testing work.

The operator should hold a relevant certificate, if required under the law, to qualify him in
operating the lifting appliance. He should fully understand all signals given by the competent
examiner to operate the lifting appliance smoothly and accurately.

Use of Information

The length of time that a piece of lifting appliance or its component will last is important.
There are three engineering factors that influence the lifetime, namely deformation, wear and
corrosion.

Nearly everything wears, and wear will usually develop significantly on moving parts such as
bearings, gears, pistons, seals and on parts to which there are relative motions with other
components. Not every wearing part is required to be removed and replaced, but there is a
limitation to the degree of wear for each component. To use equipment with excessive wear
developed in certain components is dangerous. The equipment would fail unexpectedly at
any time if such situation exists.

Machine members will deform when they are subjected to loading. For example, when an
overhead travelling crane is used for lifting a load, its bridge span will deform. A maximum
vertical deflection of 1/750 bridge span is allowed when the crane is lifting its maximum SWL
at the centre of the bridge. However, undesirable excessive deformation may be resulted if
components or structure are irregularly loaded, excessively overloaded or the material of the
component has changed its normal working state.

Competent persons and competent examiners should assess materials, tolerances, and
assembly of moving parts, gaining an impression as to whether any undesirable conditions
exist which will produce unacceptable wear and deform rates. This is an area where it is

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necessary to rely heavily on manufacturer's specifications. No doubt, the party who is most
familiar with the characteristics, performance and limitation of equipment is the manufacturer.

Every lifting appliance comes with a manufacturer's specifications, and an operation and
maintenance manual when it is newly purchased. For thorough examination or an ETE of a
lifting appliance, the examiner has to make good preparation, and cannot finish the job simply
by just a proof load test. A thorough examination or an ETE needs good preparation. Access
to the right information is the most important first step for the job. Such information includes:

• the specifications of the lifting appliance as stated in the manufacturer's specification

sheets;

• the ‘Do’ and ‘Don't’ and the ‘Caution’ statements in the operation and maintenance
manual;

• the relevant documents such as standards or codes of practice;

• maintenance records; and

• accident history.

The safe system of work should therefore include such information to make an examination
and test complete and reliable to ensure that the lifting appliance can be used safely before
the next examination and testing.

Emergency Procedure

An emergency procedure should be developed and included in the safe system of work. The
procedure should specify the equipment for handling the collapsed lifting appliance, removing
of test weights, assignment of personnel in charge of the emergency procedure. It is also

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important to secure medical assistance within the shortest possible time for medical
treatment in case of a mishap.

Administration of the Safe System of Work

The safe system of work should be written in simple language. It should be passed to all
personnel engaged in the inspection, examination or testing job. It should be properly
executed and administered by a responsible person such as a registered safety officer, a
competent examiner, a plant/ factory manager or a site agent, who should also help to revise
and update it from time to time to meet the demand of the industry.

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4.0 Lifting Equipment - Inspection and Maintenance

PURPOSE

To provide standards for the inspection and maintenance of lifting system equipment on the
Certex Equatorial Guinea project sites to comply with legal and site requirements.

SCOPE

This procedure applies to all lifting equipment on the Certex Equatorial Guinea project sites.
It applies to Certex owned equipment and all equipment hired by Certex Equatorial Guinea.
Contractors using their own equipment on site will have a system in place of equal standing.

The procedure excludes the inspection and maintenance requirements for:

• Industrial rope access rescue equipment and systems (refer AS/NSZ 4488 series)

• Personnel Fall Protection Systems (refer P314.311 Work at Height)

• Queensland Fire & Rescue Service / First Response rescue lift equipment.

• Elevators – personnel

• EWP and Scissor Lifts (refer P314.311 Work at Height and P314.701 Operation of
Mobile Equipment procedures)
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• Towing Equipment

RESPONSIBILITIES

Basic Rigger

• Perform inspections of lifting equipment prior to use. Acknowledge on the Lift Plan
sheet or Critical Lift Plan

• Immediately tag defective equipment and take out of service

Crane Base Supervisor (or delegated representative)

• Perform inspections of lifting equipment prior to use

• Immediately tag defective equipment and take out of service

Crane Operator

• Perform inspections of lifting equipment prior to use. Acknowledge on the Lift Plan
sheet or Critical Lift Plan

• Immediately tag defective equipment and take out of service

Dogger

• Perform inspections of all lifting equipment, prior to use. Acknowledge on the Lift Plan.

• Immediately tag defective equipment and take out of service.

Engineering and Maintenance Services Manager

• Approve use of aluminum components in lifting equipment

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Intermediate Rigger / Advanced Rigger

• Perform an inspection of all lifting equipment, prior to use. Acknowledge on the Lift
Plan sheet or Critical Lift Plan

• Immediately tag defective equipment and take out of service.

Persons with no WHS Rigger/Dogger License

• Perform a visual inspection of all lifting equipment, prior to use. Acknowledge on the
Lift Plan sheet.

• Immediately tag defective equipment and take out of service.

Section Superintendent / Equipment Owner

• Maintain all lifting equipment items under their control in safe order, without risks to
health and safety of persons by ensuring that:

o A register of all lifting equipment items under their control is developed and maintained

o Lifting equipment items that require scheduled servicing / maintenance are recorded in
SAP and maintenance plans are in place for the inspection, maintenance and
servicing requirements.

o Inspection and testing programs are undertaken as stated within this procedure

o Inspection tagging systems are used correctly

o Lifting equipment items under their control shall be made available for inspection

o Adequate storage is provided for lifting equipment items

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o A documented risk assessment for each power operated lifting device has been
prepared and entered into the Certex Plant Risk Register.

• Approve the use of synthetic web / synthetic-fibre slings

DEFINITIONS

Competent Person – a person who is suitability qualified (whether by experience, training or

both) to carry out the relevant work or function.

Davit – a lifting beam that can rotate or move on a horizontal plane.

Dogger - a person holding a WHSQ Certificate of Competency for Dogging and a Certex
qualification imparted by completing PG177a and PG177b.

Lifting Attachment – an attachment designed to be used in conjunction with lifting devices

and similar lifting equipment to raise, lower or haul, arrest and sustain a load

Lifting Device – a device equipped with mechanical means that will raise, lower or haul,
arrest and sustain a load in any working position within the full range of hoisting or haulage
without adverse effects on any components. Cranes and mobile cranes are inclusive. The
lifting device may be manually, engine or power operated (electric, hydraulic, and pneumatic)

Lifting Equipment Register – details the current list of equipment including a description,
date of purchase, last inspection date and condition and WWL / SWL.

Lifting Equipment – lifting attachments and rigging equipment that will raise, lower or haul,
arrest and sustain a load or object.

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Lifting Point – An attachment to a structure, pressure vessel, tank or pipework used for
attaching lifting equipment for the purpose of raising or lowering some other piece of
equipment.

Rigger – a person holding a WHSQ Certificate of Competency for Basic Rigging and a
Certex Equatorial Guinea qualification imparted by completing PG177a and PG177b.

RPE Engineer – Register Professional Engineer

Workbox - a device designed to AS1418.17 to be suspended from a crane to provide a

working area for a person.

Workbasket - a device designed to be elevated by a forklift or similar having tyne

arrangements to provide a working area for a person. Use of a workbasket involving
personnel in the basket is restricted.

WHS - Work Health and Safety

WWL / SWL – Working Load Limit / Safe working load limit – equivalent meaning.

ACTIONS

New Lifting Equipment to site

All new lifting equipment brought to site must have the following identification and information
attached prior to being used in the field.

Lifting Attachments and Power Operated Lifting Devices

Lifting attachments and power operated lifting devices must have the following attached:

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• An Equipment Number must be attached in a prominent position and be designed to

last the life of the equipment.

• A Design load rating SWL must be attached in a prominent position and be designed
to last the life of the equipment.

• An Annual Inspection Punch Tag-must be punched with date next due for inspection.

Lifting attachments must have a Design Certificate from a RPEQ Engineer and Certificate of
Inspection and Test must be witnessed and attached to the SAP equipment number /
functional location.

A cyclic work order created in SAP for the required inspection frequency and maintenance
requirements.

Rigging Equipment and Manually Operated Lifting Devices

Rigging equipment and manually operated lifting devices must have the following attached:

• An Equipment Identification Tag - refer 6.8

• A Design load rating-SWL must be attached in a prominent position and be designed

to last the life of the equipment.

• A Color tag for current year of use.

Tackle and Slings less than 1 Tonne

These items are not registered prior to putting into service as they are treated as a
consumable item.

Slings less than 1 tonne shall have the following identification:

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• An Equipment Identification Tag

• A Design load rating-SWL must be attached in a prominent position and be designed

to last the life of the equipment.

Tackle must have the Manufacturer’s load rating clearly identified on the item.

Aluminum and alloy fixtures, fittings or attachments

All lifting equipment shall be manufactured from ferrous load bearing components.
Exceptions are by Engineering and Maintenance Services Manager approval only.

Pre-Use check of Lifting System Equipment

All lifting system equipment required to undertake a lift shall be inspected by a competent
person prior to use. The check will include:

• Current Inspection Tag

• Equipment ID tag is attached and legible

• Safe Working Load (SWL) is visible and appropriate to task

• Equipment is free of defects and safety latch fitted to all hooks.

Pre-use check identifies an item with no ID tag or inspection tag, tag is not current or
equipment is defective/damaged

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Any lifting system equipment component found to be non-compliant shall be taken out of
service immediately. An “Out of Service” Tag with information stating the date and why the
equipment is defective shall be attached.

If the Inspection Tag is not current or missing, a competent Intermediate Rigger may perform
the equipment inspection using the appropriate inspection sheet. The record of inspection
must be retained by the Section and the equipment register updated.

If the equipment is defective/damaged or the Equipment ID tag is missing, then an

assessment should be made if the equipment should be disposed of or repaired based on
cost. The lifting register will be updated based on any changes.

Tackle and sling < 1t are to be treated as a consumable item. If damaged, then a new
replacement should be procured and the damaged item discarded.

Synthetic Slings

Synthetic Slings are treated as a restricted item-with approval for use by Area
Superintendent. Slings shall be in new condition prior to use. Any sling with staining or
abrasion shall be destroyed.

Scheduled Annual Inspection and Testing

The equipment owner is accountable for ensuring their equipment is safe for use, this can be
achieved by ensuring scheduled inspections and testing are undertaken. Lifting equipment
used on site and identifies the frequency of scheduled inspections (inspection frequencies
have been established to align with legislative requirements).

Scheduled inspections and testing are to be performed by a qualified Competent Person who
is notified of inspection requirements via cyclic work orders established for the either the
individual item or groups of items (e.g. a work groups lifting equipment)

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Inspection of equipment will be conducted as per manufacturer’s recommendations or be risk

based and approved by the Process Integrity Superintendent.

Upon receipt of the cyclic work order, the Contractor will:

• Contact the equipment owner to arrange an inspection time/location.

• Check each item against some predefined inspection criteria

• Check inspection tag fitted

• Update the Lifting Equipment Register with inspection outcomes and attach a copy of
the inspection report for each item (Rigging equipment and manually operated lifting
devices only)

• Ensure a copy of the updated Lifting Equipment Register and all inspection reports are
forwarded to the Section Planner for uploading to the relevant SAP equipment number
or functional location.

If the equipment ID tag is not available/legible and the equipment cannot be identified as an
item on the register, then it will be treated as a new item

If the equipment fails, the inspection the item will be tagged “Out of Service” and the Owner
notified and provided with a copy of the inspection report. Depending on the severity of the
damage the equipment owner may decide to:

• Arrange for repair and load testing, or

• Release the item for destruction.

Maintenance

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Maintenance activities may be performed by a competent person in accordance with the

manufacturer’s recommendations or Process Integrity Superintendent Approval.

Repairs

Repairs shall only be performed by a competent external Contractor in accordance with the
manufacturer’s specification and regulatory requirements (i.e. Load test performed where
identified). The equipment owner will witness the repair certificate prior to attaching a current
Inspection Tag.

All repairs shall be documented and recorded in the Lifting Equipment Register. Unrepairable
items shall be destroyed and removed from the register by the Section.

Modifications and Alterations to lifting equipment or structures

Modifications or alterations to lifting equipment or structures used to support a load lift require
design approval by an RPE Certified Engineer. Approval is required prior to use.

The design shall be reviewed, approved and registered in accordance with Certex Equatorial
Guinea Procedure P774.008 "Registration of Design Calculations, Computational Models and
Reports" by the certifying engineer.

Approval may require load testing to be performed before use.

Lifting System Equipment Storage

All lifting system equipment must be correctly stored preferably off the ground or on a frame
in a clean designated area according to 5S principles.

Lifting System Equipment Identification/Inspection tags

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All lifting equipment on site will be fitted with:

Equipment identification tag or manufacturers unique ID tag

For rigging equipment and manually operated lifting devices (refer Attachment 7.1), use the
manufacturers unique ID or a unique Section identification number (e.g. the Work center
number followed by the next available number on the register

For lifting attachments and power operated Lifting Devices, the Identification number will
consist of the SAP Equipment number / Functional location imprinted on a metal tag securely
attached to the equipment.

Annual Inspection tags

There are two types of inspection tags:

• Color tag with the current year displayed, or

• Metal Stamped dog tag for lifting attachments only.

Dates marked indicate the expiry date.

Inspections may commence 2 weeks prior to and up to 2 weeks after the expiry date, with
tags changed over as equipment is identified as compliant.

Risk Assessments

A plant risk assessment will be conducted for each type of lifting equipment and device used
on site. The assessment process will involve equipment owners, operators, maintainers and
a safety representative.

The risk assessment will be housed in the Plant Risk Register on SAP and be reviewed at a
frequency reflective of the inherent risk, or as part of an incident investigation.

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Training and Qualifications

Any person who has completed PG277 and been deemed competent by their Supervisor can
undertake the pre-task inspection of the specific lifting equipment for the PPM or work
instruction.

If there is no PPM, the pre-task inspection can be performed by a Certex Equatorial Guinea
employee or contractor with:

• Dogger or Rigger (Basic, Intermediate or Advanced) qualifications issued by WHS,

and

• A Certex Equatorial Guinea qualification imparted by completing PG177a and PG177b

Lifting and Rigging training.

Qualifications must be recorded in SAP against the individual’s training records.

Lifting System Equipment Register

It is a legislated requirement that a register be establish and maintained for lifting equipment
for site. Lifting equipment will be registered by the Section Planner in one of two ways:

• As an individual item in SAP with its own unique SAP functional location or equipment
number. This method will be selected for lifting attachments and power operated
Lifting Devices

- Cyclic work order to be established for the inspection/testing of the item.

- Results of inspection/testing attached to the SAP Item

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• As an item listed on an excel register. Each item has its own unique ID number which
corresponds to the next available number on the register or manufacturer’s unique ID.
This method will be used for rigging equipment >1t and manually operated lifting
device.

- The register will have its own unique SAP equipment number

- A cyclic work order will be established for the register – not individual items

- Results of the inspection/testing will be documented in the excel register

- A copy of the register will be attached to the SAP equipment number once equipment
has been inspected

Work groups are not required to keep a hard copy of the register.

Records must be retained for the life of the equipment, and if the equipment is sold, then a
copy of the inspection records form part of the sale.

It is the equipment owner’s accountability to ensure appropriate items of equipment are

entered into the Area Lifting Register prior to use.

Manuals

Manufacturer supplied manuals and other service books and pre-start check books are to be
kept in situ or made easily accessible.

The maintenance manual, service record (log book) and parts book can be kept at the office
of the equipment owner.

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Attachment: ONSITE LIFTING EQUIPMENT & DEVICES INSPECTION FREQUENCIES

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5.0 GUIDELINES AND PROCEDURE FOR LIFTING EQUIPMENT AND LIFTING

OPERATIONS

INTRODUCTION - LIFTING EQUIPMENT PROTOCOL

Purpose

To ensure the integrity of Lifting equipment, Lifting Operations and to establish uniform set of
requirements for lifting which must apply to Certex Equatorial Guinea. The intent is to
guarantee safety, ensure compliance, zero damage to associated equipment and to protect
the life of personnel(s) involve in the lifting operations and Minimum life cycle costs for all
lifting equipment

Scope

This protocol covers all Lifting Operations both onshore and offshore and lifting equipment
used at project sites within Certex Equatorial Guinea. It is the responsibility of Operating
Companies & its Clients, Contractors and any other users working within Certex Equatorial
Guinea to ensure that all requirements stipulated in this protocol are fully complied with.
Exclusions:

 Requirements for rope access: This information can be found in Certex Equatorial Guinea
Guidelines and Procedure for Rope Access and also IRATA regulations for Industrial Rope
Access Systems: Specification, Selection, Use and Maintenance.

 Requirements for escape lines.

 Merchant Navy Vessel, Marine ropes, anchors etc.,

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DEFINITION

Load

This is the actual load or mass of any material, people or animals (or any combination of
these) that are lifted by the lifting equipment. In some circumstances, such as in the use of a
mobile crane, the weight of the lifting accessories including the hook block will need to be
considered as part of the load being lifted.

Lifting Equipment

Work equipment for lifting or lowering loads and its attachments used for anchoring, fixing or
supporting it. It includes any lifting accessories that attach the load to the machine in addition
to the equipment which carries out the actual lifting function. Lifting equipment encompasses
Lifting Appliances and Lifting Accessories.

Lifting Appliances

Any lifting machine, driven by manual or mechanical power that is able to raise, lower or
suspend loads, and includes the supporting structure and all plant, equipment and gear used
in connection with such a machine, but excludes continuous mechanical handling devices
(i.e. conveyors) such as but not limited to:

i. Cranes (tower, mobile etc.),

ii. Wall / Pillar Cranes, Derricks, Swing Jibs and Davits,

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iii. Runway Beams, Monorails, All Pad Eyes are lifting gears, Gin Poles and Gin Wheels,

iv. Winches, Hoists (air and electric), Crabs, Telfer Hoists,

v. Chain Blocks, Wire Rope Pulling Machines, Pull Lifts, Trolleys,

vi. Powered working Platforms,

vii. Elevators and Lifts,

viii. Forklifts, Self-Loader and Side Booms,

ix. Lifting Jacks (pneumatic or hydraulic).

Lifting Accessories or Loose Gear

Any item used to connect a load (connecting units) to the lifting appliances but which is not in
itself a part of the load or the equipment, such as:

i. Chains slings and Wire Ropes slings,

ii. Chain, Wire Rope repetitions see above and Webbing Slings,

iii. Rings, Links, Hooks, Shackles, Eye Bolts, Swivels, Blocks, Snatch Blocks,

iv. Beam Clamps and Plate Clamps,

v. Lifting Beams / Spreader Beams.

Competent persons

The Competent personnel carrying out a Thorough Examination (TE) must be deemed
competent by virtue of attaining the appropriate theoretical and practical knowledge, together
with experience that will enable them to detect defects or weaknesses in the equipment. This
will be a combination of experience; training and qualifications some of which are listed in
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Appendix. The competent personnel must be “independent and impartial”. This does not
prevent someone working for the same organization being the competent person but should
not be someone who is responsible for production/operation/profit. The competent personnel
must have a minimum of 3 years’ hands-on experience within a relevant engineering
discipline related to lifting equipment and appropriate knowledge of the relevant laws, local &
administrative orders, codes of practice and inspection techniques.

Inspection

Any physical activity, related to ensuring that an item of “Lifting Equipment”, in its entirety and
at a given location or environment, meets the specified design and operating Standards and
is safe to operate or utilize for a specified period. This includes, but not limited to, activities
such as measuring, testing, and recording, checking, analyzing, loading and charting one or
more characteristics of the equipment.

Periodic Inspection

This is the minimum, specified period, denoted in days, weeks, months or years, between

one “Inspection” and a repeat or next “Inspection”

Thorough Inspection

It means the following items shall be checked for compliance with manufacturers’

specifications and safe operation, as a minimum:

i. Oil levels, fuel level and lubrication.

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ii. Ropes, rope terminal fittings and anchorages, rope drums and sheaves for any
damage and wear.

iii. All water is drained from air reservoirs.

iv. Crane for any loose or damaged structural component including supports and
outriggers where fitted. Loose joints may be readily noticed by flaking or marking on
the paint surface or by rust marks. Similarly, cracks may often be detected by rust
runs.

v. Security of the counterweight. Where this is in the form of removable weights,

checking that the weights correspond to those shown on the counterweight chart for
the operating condition in use.

vi. Load moment system where fitted, is correctly set or fitted (or both) with the program
appropriate to the boom or jib length, and fly-jib lengths and falls or parts of rope.

vii. Indicator appropriate to the boom, jib or fly-jib length is fitted.

viii. Crane cabin is in a tidy condition and free from grease and oil, rags, tools and
materials other than those for which storage provision is made.

ix. Pneumatic systems and hydraulic systems including their safety devices.

x. Operation of the crane through all motions with particular attention to brakes.

xi. Operation of all limit switches or cut-outs and safety devices. Caution to be exercised
in making the checks in the event of non-operation.

Working Load Limit (WLL)

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This means the maximum load (mass), which any piece of lifting equipment may lift safely in
the most efficient configuration. For wire rope sling, chain slings and fibre rope slings, this is
in direct lift i.e. eye to eye in a straight vertical line/ hitch.

Safe Working Limit (SWL)

This means the maximum load (mass), which any piece of lifting equipment may lift safely in
a particular configuration, other than its most efficient configuration. e.g. for a wire rope sling
choked on a square load without any corner protection, its safe working load is approximately
50%; choker hitch should be 80% of its WLL.

Proof Load Test

This implies the application of a predetermined load excess of SWL to assess the ability of
the equipment to withstand operation requirements. This applied proof load shall never
exceed the elastic limit of the item being tested. The amount of Proof Load to be applied will
vary depending upon the type of equipment, its SWL, and the applicable Standard. On
completion of any proof load test, the “Lifting Equipment” is to be fully inspected to ensure
that the structural integrity of the equipment has not been impaired.

PROCEDURE FOR LIFTING OPERATION

General Requirements

Lifting equipment is so constructed or adapted as to be suitable for the purpose for which it is
used or provided, and to have regard to the working conditions and risks to health and safety
in the place in which that work equipment is to be used. The risk assessment must be carried
out as per the requirements of Regulation. The risk assessment will need to include:

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i. How often the lifting equipment will be used;

ii. Where the lifting equipment will be used;

iii. The nature and characteristics of the load that the lifting equipment will lift;

iv. Any limitations on use specified by the manufacturer or supplier;

v. It must cover means of access, ergonomic risks, weather conditions in open-air

operations, etc.;

vi. Every lifting operation involving lifting equipment shall be:

a. properly planned as Lifting Plan and this is to be done by a competent person,

b. appropriately supervised,

c. carried out in a safe manner.

vii. Look out for:

a. Suspended loads – where are people working? - If the load fell?

b. The continuing integrity of equipment

c. The attaching and detaching of loads

d. Proximity hazards

e. Pre-use check

f. DO NOT overload

g. Be aware of causes of over-turning and ensure this does not happen.

h. Visibility – ensure we can see what is happening

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viii. All lifting operations are ‘risk assessed’ Safe Working Load - SWL’s – must NOT be
exceeded.

ix. The status of all equipment should be known by all people using it and all who may be
affected by it. The status is to be clearly identified.

x. All checks are to be done by a responsible person trained in pre-use and in- service
inspection.

xi. Only trained people should be allowed in areas where lifting equipment is used

xii. The equipment in use is only to be made of material suitable for the conditions under
which it is to be used.

xiii. All fixing points and mountings are to be of adequate strength and capability

xiv. Environmental aspects need to be taken into consideration e.g. when out of doors,
high winds and temperature which may affect structural integrity

xv. Equipment that has been stored needs to be checked prior to use.

xvi. All Lifting Equipment must be stored and controlled to prevent accidental use of
damaged and worn equipment.

Crane on Hire

The crane hire company has a duty to ensure that when a mobile crane is hired out, a
physical evidence must accompany it (e.g. a copy of the last examination report issued by
Approved agency), and the user should ensure that this evidence is available. The user
should ensure that the crane is thoroughly examined by a competent person before it is put
into use, to make sure it is safe to operate.

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The user has the duty to manage the subsequent lifting operations in a safe manner. The
user (as an employer or a self- employed person) also has the duty to ensure that periodic
thorough examinations are undertaken at the frequencies laid down in this protocol. The user
may well come to an arrangement with the hirer under which the hirer carries out the
thorough examinations, but that does not alter the user's duty to make sure they are done.

Crane for Hire for Contract Lifting Operations

This refers to the situation where an Certex Equatorial Guinea enters into a contract with a
third party who will undertake the lifting operation on their behalf, i.e. the third party provides
the crane and the operator. In these circumstances the crane owner has the duty to ensure
that the crane is properly maintained, examined and has valid test certificate and safe to use
and that the lifting operation is carried out safely.

Strength and Stability

i. Lifting equipment should be of adequate strength and stability for each load, having
regard in particular to the stress induced at its mounting or fixing point.

ii. Every part of a load and anything attached to it and used in lifting it should be of
adequate strength.

iii. Account should be taken of the combination of forces to which the lifting equipment
will be subjected as well as the weight of any associated accessories used in the lifting
operation. A competent person should ensure that the strength and stability of the
lifting equipment continues to be adequate for the tasks that the equipment is intended
to be used.

iv. Where appropriate, suitable and effective measures must be taken to provide
sufficient resistance to overturning in order to ensure the adequate stability of the
lifting equipment. Where there is a significant risk of overturning and/or overloading

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arising from the use of the equipment, it should be provided where appropriate, with
equipment or devices such as rated capacity indicators and rated capacity limiters.
Such devices provide audible and/or visual warning when the safe lifting limits are
being approached.

Positioning and Installation

Lifting equipment should be positioned or installed and thereafter shall be examined

thoroughly in such a way as to reduce to as low as is reasonably practicable the risk of the
lifting equipment or a load striking a person; or from a load drifting, falling freely or being
released unintentionally. It should be ensured that there are suitable devices to prevent a
person from falling down a shaft or hoist way.

Requirements for Lifting Accessories

The main requirements relating to lifting accessories are as follows:

i. They shall be of good construction, sound material, and adequate strength and free
from patent defects.

ii. The safe working load (SWL) must be displayed or, for lifting accessories, plainly
marked on them; only items listed or marked may be used in a lifting operation.

iii. The safe working load must NEVER be exceeded.

iv. Before being taken into service for the first time all items must be tested and
thoroughly examined by a competent person, and at six-monthly intervals during
service.

v. Accessories exposed to harsh conditions and undue wear must be inspected at

intervals necessary to ensure their safety, this may be at periods less than 6 months in
accordance with an examination scheme.

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vi. Certificates must be issued for all items.

vii. The EC Declaration of Conformity or the Manufacturers Test Certificate and every
other subsequent report of thorough Examinations for each of the lifting accessories
must be kept in the technical file.

viii. Wrought iron equipment must be periodically annealed (i.e. subjected to heat
treatment which enables the wrought iron to revert to its "safer" crystal structure).

ix. Registers of equipment details must be kept.

Lifting Equipment for Lifting Persons

Lifting equipment for lifting persons used at any operational location is designed:

i. To prevent a person using it from, being crushed, trapped or struck, or falling from the
carrier.

ii. To prevent so far as is reasonably practicable a person using it, while carrying out
activities from the carrier, being crushed, trapped or struck or falling from the carrier.

iii. With suitable devices to prevent the risk of a carrier falling.

iv. So that a person trapped in any carrier is not thereby exposed to danger and can be
freed.

Lifting Equipment used for lifting person SHALL be labelled: PERSONNEL LIFT ONLY

The raising and lowering of people by work equipment, which is not specifically designed for
the purposes, should only be undertaken in exceptional circumstances, when it is not
practicable to gain access by less hazardous means. Where it is necessary to use such work

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equipment then all necessary precautions must be taken to ensure safety, including
appropriate supervision.

Examples of lifting machinery which is not specifically designed for lifting people but which
could be used if the necessary precautions are taken include a fork- lift truck, a telescopic
handler and a crane (fixed or mobile). When fitted with a suitably designed carrier or working
platform, these can provide a safer alternative to other means of access (such as a ladder).
However, such an arrangement will not provide the same level of safety as purpose- built
equipment such as a mobile elevated work platform (MEWP).

Marking of Lifting Equipment

1. Machinery and accessories for lifting loads are clearly marked to indicate their safe
working loads.

2. Where the safe working load of machinery for lifting loads depends on its configuration
then the machinery is clearly marked to indicate its safe working load for each
configuration; or

3. Information, which clearly indicates its safe working load for each configuration, is kept
with the machinery.

4. Accessories for lifting are also marked in such a way that it is possible to identify the
characteristics necessary for their safe use.

5. Lifting equipment, which is designed for lifting persons, is appropriately and clearly
marked to this effect.

Color Coding

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It is mandatory to ensure all portable, circulating and fixed lifting equipment are color coded
to give visual indication of its certification status.

The following color code cycle must be used to indicate the current lifting accessories in use,
such as: Chains and Wire Ropes, Webbing Slings, Hooks, Shackles, Eye Bolts, Swivels,
Blocks, Snatch Blocks, Beam Clamps and Plate Clamps, Lifting Beams / Spreader Beams
etc.

Thorough Examination and Inspection

Operators & Contractors and users must ensure that lifting equipment is thoroughly
examined after installation and prior to service. Also, it must be ensured that lifting
equipment, which is exposed to conditions that could cause deterioration and that can result
in dangerous situations is thoroughly examined –

i. In the case of lifting equipment for lifting persons or an accessory for lifting

- at least every 6 months.

ii. In the case of other lifting equipment - at least every 12 months or in accordance with
an examination scheme (Appendix); and for each time that exceptional circumstances
which are liable to jeopardize the safety of the lifting equipment have occurred; and

iii. If appropriate for the purpose, is inspected by a competent person at suitable intervals
between thorough examinations.

Educational Background and Qualifications:

The competent personnel carrying out a thorough examination must have appropriate
practical and theoretical knowledge and experience of the lifting equipment to be thoroughly

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examined to detect defects or weaknesses and to assess their importance in relation to the
safety and continued use of the lifting equipment.

The competent person must have a minimum of 3 years’ hands-on experience within a
relevant engineering discipline related to lifting equipment and appropriate knowledge of the
relevant laws, local & admin orders, codes of practice and inspection techniques. Nobody is
allowed to perform inspection independently without having appropriate qualification and
training.

Training

All persons who use lifting equipment must have received adequate training for purposes of
health and safety, including training in the methods which may be adopted when using the
lifting equipment, and be aware of any risk which such use may entail and precautions to be
taken.

Any person who supervises or manages the use of lifting equipment must have received
adequate training for purposes of health and safety, including training in the methods which
may be adopted when using the work equipment, and be aware of any risk which such use
may entail and precautions to be taken and methods of safely controlling the equipment.
Minimum training requirement as contained in Appendix II of these guidelines shall be strictly
adhered to.

Reports and Defects

A person making a thorough examination for an organization must:

i. Notify the organization of any defect in the lifting equipment which in his opinion is or
could become a danger to persons.

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ii. As soon as is practicable, make a report of the thorough examination in writing,

authenticated by him to the organization and any person from whom the lifting
equipment has been hired or leased.

iii. Owner/User of lifting equipment who has been notified of defects must ensure that the
lifting equipment is not used before the defect is rectified.

Use & Maintenance

This guideline is pursuant to Mineral Oils (Safety) Regulations 1997 and deals with the
maintenance of lifting equipment. In addition to the pre-operational checks to be conducted
by the operator before the commencement of the work, a system of regular maintenance by
competent persons must be in existence and records kept and logged. They should be
operated within defined safe operating limits, e.g. the maximum lift height and capacity.

Equipment should be properly maintained according to manufacturers’ instructions on

inspection, maintenance and servicing. In addition to these checks, which should be carried
out by a competent person on a routine basis, the operator should carry out a daily safety
check.

A record of all checks and repairs carried out should be retained.

Third Party Inspection Bodies

Third party inspection bodies must have valid accreditation from Certex Equatorial Guinea
and any other International certification body. The Inspection Body must have a management
system, which includes but not limited to the following:

Proper Documentation of its policies, procedures and operations starting from receiving the
request for an inspection, carrying out contract review, preparing for inspection,
performing inspections, recording results and up to the issuance of the final report/
certificate in accordance with the documentation requirements of ISO/ IEC 17020:1998
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“General criteria for the operation of various types of bodies performing inspections” and any
additional requirements set by the relevant authorities.

RECORD KEEPING

Operators, Contractors, Owner and Users of the lifting equipment must ensure that the
information contained in every report made to them is kept available for inspection:

i. In the case of a thorough examination of lifting equipment other than an accessory for
lifting; until they cease to use the equipment.

ii. In the case of a thorough examination of an accessory for lifting; for two years after the
report.

iii. Any EC conformity declaration received must be kept for as long as the equipment is
operated.

iv. The initial declaration must be kept until the equipment is disposed of.

v. Reports of thorough examinations and inspections should be kept available for

inspection at the place where the lifting equipment is being used. If this is not possible,
the information should be readily accessible.

vi. Reports must be readily available to the Certex Equatorial Guinea office as required.

vii. No lifting equipment should leave any undertaking unless accompanied by physical
evidence that the last thorough examination has been carried out and color coded as
per this protocol.

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APPENDICES

Lifting Equipment: Frequencies for Testing / Inspection & Certification

Lifting Equipment Type Frequency For

Proof Load Test Inspection (SWL)
All Lifting Accessories: • On initial supply Every six (6)
• Chains, slings and • After substantial alteration or Major repair months
wire ropes slings • At discretion of surveyor
• Rings, links, hooks,
shackles, eyebolts,
1. swivels, blocks,
snatch blocks
• Beam and plate
clamps, frames,
pallets, lifting
beams and cargo nets.
Lifting Equipment: • On initial supply Every twelve
• Pedestal cranes, • Every four (4) years (12) months
mobile cranes, • After reinstallation, substantial alteration or
forklifts, tower cranes major repair
• Overhead traveling • At discretion of surveyor
cranes, wall /
pillar cranes,
2
derricks
• Winches, hoist (air
and electric), crabs, Every Six (6)
Telfer hoist, powered Months*
working Platforms,
vehicle lifts
or hoists etc.
• Mobile or movable
jacks
and associated “Lifting
Equipment”
• Lifting Persons &
Suspended Baskets *
Runaway beams, pad eyes, • On initial supply Every twelve
gin pole and gin wheels. • After reinstallation, substantial alteration or (12) months
3 major repair
• At discretion of surveyor Every six (6)
months

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Chain Blocks, tirfors, pull • On initial supply Every six (6)

4 lifts, • Every four (4) years months
trolleys
• After substantial alteration or major repair
• At discretion of surveyor

5 Lifts – (passenger or goods) • On initial supply Every twelve (12)

• Every four (4) years month
• After substantial alteration or major repair
• At discretion of surveyor Every six (6)
months
6 Escalators and Elevators • On initial supply Every six (6)
• Every one (1) year months
• After substantial alteration or major repair
• At discretion of surveyor

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List of Required Training

S/N Course Application Target Group

1. Mobile Crane 1. Onshore crane operations for All Mobile Crane Operators,
Operation all cargo and construction industries Crane Supervisors, HSE
supporting Oil and Gas. Personnel in Lifting
2. For operators to gain Operations.
competency for changing career to
offshore rigs, vessels and Floating Truck and plant
Production Storage and operators developing
Offloading (FPSO)s. new careers
2. Safe Use of 1. Management, Supervisors, All Managers, HSE Engineers,
Lifting Workforce involved in cargo operations Lifting Supervisors,
Equipment shall have an introduction to lifting Roustabout, Roughnecks, Store
operations in general who have little or man, Crane Operators, Forklift
no knowledge. Operators, Riggers, Quayside
2. Encourage safe system of work supervisors,
for all cargo, supply, manufacturers,
production, exploration and construction
industries supporting Oil and Gas.
3. Forklift Operation 1. Yard personnel involved in All Forklift Operators,
loading unloading freight in relationship Supervisors,
with supply to oil and Gas Materials Controller, Assistant
2. Construction, production and Driller, Deck leader/Foreman,
offshore stores preventing extreme Roustabout/Roughneck
manual handling by mechanical force by
trained and
competent persons.
4. Offshore Crane 1. The heart of offshore cargo All Offshore Crane Operators,
Operation API RP 2D loading and offloading is crane operations Crane
and should also covers Vessels, Rigs, Supervisors, Deck Pushers,
FPSO and fixed units. Banksmen and Roustabouts
developing career change
2. A career move for Roustabouts
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and Banksmen alike as several years

working beside cranes from below
encourages good
operators given the opportunity.
5. Overhead Crane & 1. For Blow Out Preventer All Overhead Crane Operators,
Hoist (BOP) operations offshore. Crane Supervisors & HSE
Personnel in Lifting Operations.
2. Required to develop safe
systems of work in oil contractor’s in
supply, engineering and fabrication
warehouses

12. LOLER & PUWER To give an understanding of regulations Supervisors, Logistics Controllers,
associated with lifting operations that Team Leaders, Riggers,
have been adopted as industry best Scaffolders, foremen, Welders,
practice worldwide and is theoretical Lifting Superintendents, HSE
only. Engineers
13. Wire Rope Inspection To give Lifting Equipment Inspectors in Lifting Supervisors and Lifting
depth knowledge on thorough inspection inspectors
of wire ropes as a great percentage of
Crane accidents are caused by wire Rope
failures.
14. Competent Rigger API To help riggers in offshore environments All lifting Superintendent,
RP 2D to safely carry out their operations. It is in
Supervisors,
Compliance with API RP 2D. Logistics controllers, Crane
Operators, Rigger, Deck
Foreman,
Roustabouts/Roughnecks.
15. Safe Use of Cargo Common name is CCU a collective name for All QAQC Personnel’s,
Carrying Units tanks, containers, open tops, storage Lifting Superintendents,
boxes, modular units in accordance with warehouse Supervisors,
the 3 main standards of DNV 2.7.1, Riggers, Logistics controllers,
BSEN12079 BS7072 and ensuring prior to Quay Supervisors and
shipping from location they are packed, Mobile crane operators
documented, free from risk to meet the
requirements of the Nigeria
petroleum industry regulations
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16. Frog Basket and Swing To Ensure no harm to personnel being All Persons involved in personnel
Rope Training transferred by personnel basket at sea. transfer, Riggers, Supervisors,
This is a relatively new system to the and users by Management,
industry and may also be used as Supervisors and Workforce &
emergency carrier Medics
if someone is being transferred.
17. Deck Crane (Knuckle To provide skills for modern type of All Offshore Crane Operators and
Boom) crane that reduces load swing and can Crane Supervisors
be stowed in more confined areas
18. Man Ridding Tugger To provide skills for work within the Deck Crew Personnel’s, Drillers,
Operations Derricks and sub-sea areas of offshore Electricians, Mechanics, Coiled
installations that cannot be accessed by Tubing operators, Wire line
other means by persons either operators, Snubbing operators.
mechanically or by safe
ascend/descend
19. MEWP (Mobile To provide skills for onshore and MEWP Operators, Supervisors,
Elevated Work offshore access by mechanical aid either and
Platform) Operation scissor or articulated boom that is used All involved in working at
for maintenance, access, inspection, height Operations
survey,
dropped object checks, replacement
parts.

20. Lorry Loader(Hi Ab) To provide skills for onshore and offshore HIAB Operators, Supervisors,
smaller type boom crane usually telescopic Lifting Superintendent,
greater than 1 tonne. Logistics personnel.
This is used by store delivery onshore
and placed for change out of machines
and or smaller deck operations on smaller
water craft supplying and supporting
offshore and
land resources.
21. Manual Handling To helps to reduce the rate at which Lifting Superintendents,
employees get exposed with Supervisors, forklift Operators,
occupational Injuries. Statistics shows Riggers and Crane Operators
that most Injuries in the workplace is as
a result of lack of
Manual Handling training
22. Side loader Operations To provide skills for shore Side Loader Operators,
operations/ Laying of Pipelines. Supervisors
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and HSE Personnel’s involved

in
lifting
23. Cranes (Mobile, To improves the knowledge base of Inspection Engineers,
Offshore, Overhead & equipment inspectors such that the Supervisors and Managers
Tower) Integrity of Equipment can be
Inspections ascertained at any time. In compliance
to industry
standards.
24. Winches &Powered To improves the knowledge base of Inspection Engineers,
Hoists Inspection equipment inspectors such that the Supervisors and Managers
Integrity of Equipment can be
ascertained at any time.

6.0 INSPECTION

6.1 Introduction and Purpose

The purpose of this plan is to define the activities required to ensure that only quality
product or material is being used in the project. Any violation of un-authorized or out of
specification material usage in the project should be restricted by installing the controls in
the system. All 3rd party raw material purchased products or services conform to the
specified contract requirements; by assuring and controlling the quality of products or

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services. This project plan covers the control of material & work inspections of the
permanent works equipment, materials and services such as:

a) Raw material directly used in the project

b) Services taken from 3rd party contractors
c) A material supply contract from an overseas company
d) Sub contracted work

6.2 Inspection and Test of Material

The Inspection and Test Plan is a comprehensive list of activities based on the Project
Flow of Work that describes the type level and responsibility for inspection and testing that
is required for a satisfactory completion of the Works. It defines the related specification that
the work shall comply with, the Verification Criteria, and the level of inspection and control.

The Inspection and Test Plans as per Technical Submittal Plans to client provide the
framework within which Quality department. This is implemented as the work progresses
and each document are developed to take into account the detailed requirements of the
specification and the construction method employed.

6.3 Receiving, In-process and Final Inspection & Testing

An Inspection and Testing Schedule are developed based on the technical

specification. In the “Inspection and Test Plan” materials and works to be
inspected/tested are described, the inspected/tested parameters are analyzed along with
acceptance criteria, inspection/test plan and frequency. Responsible persons and
forms/records used are also stated.

The Inspection and Test Plans are developed by Quality Checker/Supervisor having
following detail in it:

 The works requiring inspection

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 The specification in relation to the works

 Drawings related to the works inspected
 The verification method for the inspection to be performed
 The Acceptance Criteria for satisfactory completion
 The Level and involvement of inspection for each executing Party (PM)

Quality Plan shall be developed, to the format approved by PM, detailing the
inspections, tests and surveys to be undertaken, when these will take place and the
acceptance criteria.

The Project Quality Manager having a status register of all individual included in the
Project Schedule. The Project Quality Manager maintain the original signed Project
Schedule, as described above. Each Inspection Party (PM - Contractor - Subcontractor),
involved in the inspection process have an inspection action code for every QCP item. It
should be one or more of the following:

C Designa Explanation
o
S tion
Surveilla Random attendance at site.
W nce
Witness Attendance at site is expected, signature is required on
check sheet or RFI form, but if the signatory is not present
to sign at the time, follow on work may proceed and the
H Hold Attendance
document(s)atsigned
site islater.
mandatory and signature is required
point on the Hold Point Release form in order to permit work to
proceed
R Review Documentation to be reviewed, no signature required. (R
may be in addition to any of the other codes).

The records to be generated by the inspection activity. As a minimum, each inspection

will include the following information:

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 Quality control requirements

 Location/Item Name/Tag Number as applicable

 Inspection Activity

 Applicable procedures

 Acceptance criteria

 Verifying documents

 Inspection Responsibilities (Review, Witness and Hold points)

Inspection form is being provided for approval of PM/TM prior to the submission of the
schedules within the specified period.

6.4 Internal Pre-Inspection Plan

In order to assist the plan for inspections, a pre-inspection checklist form is used. The
Quality Personnel identify the work not ready or not according to acceptable standards, if
any, during this internal inspection, prior to Project Manager (PM) Inspection and use the
following guidelines for handling non-conforming work.

The QC Engineer / Inspector will suitably tag the affected work to indicate its status. No
further work that could interfere with the correction of the non-conforming item will take
place until the internal non-conformance has been corrected. The tag classification is as
follows:

 Rework

A non-conforming item is changed to conform to specified requirements by further work,

e.g. reassembling, replacement of parts or other approved means.
 Repair

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The conforming characteristics are restored to a condition or situation acceptable to PM

though that item/items may still not conform to the original requirements.
 Reject

An action that will be taken to eliminate the non-conforming item from its specified use.
 Use as is

The action taken will be to obtain PM approval to accept a non-conforming item.

The responsible Quality Checker/Supervisor are confirmed that the approved corrective
action has been satisfactorily implemented. After the correction of the non- conformance,
the Quality Checker/Supervisor sign-off the relevant section of the Pre- Inspection form
and close out the form for the Site Manager’s Review Only after the case has closed the
Site Engineer may proceed to Request a Formal Inspection from PM with the standard
procedure, using form.

6.5 Material Inspection Request

A similar inspection plan is followed for the inspection of on-site materials. For each
material or item of equipment intended for the permanent Works. A document package,
comprising the form and relevant attachments such as a product data sheet and
Specification Comparison and compliance sheet, is prepared by the construction section
and reviewed by the Site Quality Checker/Supervisor.

It is understood that all materials arriving on site will be approved by PM as per a

corresponding plan initiated by the Quality Checker/Supervisor. A copy of the document
package for each approved material will be passed to the Safety Manager for action, if any,
such as the identification of Hazardous Materials. The above information will be submitted
to PM for approval.

When the submittal is returned from PM, approved or not, the Quality
Checker/Supervisor has the original records and compile and maintain the Register of
Materials and Equipment. The register will include the following information:
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 Material or equipment description and trade name Manufacturer

 Certification for Compliance or a compliance Statement for the supplier that the
submitted material complies with the relevant clauses of the technical
specifications,

 Approval or Rejection status and date approved by PM, if applicable

Copies of the Register of Materials and Equipment is circulated to the Project’s

management team.

For items of material and equipment that will require Inspection at the site prior to use or
at the Manufacturer’s or Supplier's Plant, these are submitted to PM on a MATERIAL
INSPECTION REQUEST FORM, [MIR] and will include the following:

 Country of Purchase/Fabrication.

 Description of Material or Equipment

 Purchase Order Number

 Date of Material Ordered

 Date due on site

 Pay Item Number

 Supplier Q.C. Requirements

Contractor’s in-plant inspection plan including items to be inspected, Hold Points, Tests
to be performed, Test and Documentation Report Formats, Frequency and Acceptance
criteria for inspection and testing. The Inspection Documentation and Testing Certificates
are submitted, when requesting payment for the particular item.

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On arrival of Approved Submittals, the Quality Checker/Supervisor inform the relevant

Q.C. Personnel as to what has been approved, so that they will be aware of what to inspect
on site.

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7.0 PROJECT SITE HANDOVER

7.1 General

The aim of the project handover process is to hand over a project to a new project
manager to ensure that it gets completed in time. A transition happens and the project is
assigned to another project manager. The project handover could happen as a result of the
current project manager having an emergency to take care of, or having to soon go for
retirement. The project manager could also have had a transfer to another department or
branch, and therefore need for a new project manager to see the project through.

The process of handing over a project is not an easy task, and shouldn’t be perceived to
be easy. It involves much more than handing over office keys and software access details. It
is therefore important to ensure that the person taking over the project is in the best condition
to continue the project and successfully accomplish its goals. The objects of project handover
process are to:

 To ensure the project yields the same results and achieved the goals set out.
 To ensure that the stakeholders and the clients are fully satisfied.
 To establish the project’s current status.
 To establish at which point the new project manager is to take over.
 To formulate the transition from the current project manager to the new project
manager.
 To introduce the new project manager to the project team, stakeholders and the
client.
The scope of the project handover process encompasses steps that ensure smooth
transitioning so that project activities continue uninterrupted even after a new project
manager takes over the project. Thus, the scope of the handover process entails:

 Preparing the project status report

 Filing in the project handover checklist
 Briefing new project manager on project details and introducing him to the project
team, the client, and project stakeholders
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 Completing outstanding documents and activities

 Handing over project document and files
 Signing off the project handover checklist
The Site Handover meeting shall be in the presence of the following:
 The Client’s and the End – User Representative
 PM, Area Manager with the Key-staff responsible
 The Contractor’s Project Manager or Site Manager representing him, together with
his Ley-Staff responsible.
During this meeting, the Contractor shall deliver ALL THE WORK TO PM and the site shall
be considered to be Preliminary handed over to the End – User. The particular date is
noted as the beginning of the one-year maintenance period as per agreement. PM shall
ensure that all related documentation has been signed by all parties’ representatives.

7.2 Instruction for Handover to new Project Manager

The instruction for handover to indicates the beginning of the project handover
process. It lays out the instructions to be followed during the transition process to a new
project manager. The project management office (PMO) evokes the project handover
process when the need for transition of the project from one project manager to another
arises. During this process, the project management office (PMO) establishes the
instructions to guide the transition of the project from the current project manager to a new
project manager.

7.3 Prepare Project Status Report

The aim of the prepare project status report process is to establish a status report for
the project up to the point of time where the handover is being carried out. It therefore
explains the status of the project in relation to the start-up documentation. The outgoing
project manager prepares the project status report so that the successor would know what
has so far been accomplished in relation to the set out objectives for the project, and

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where to pick up from. This helps the new project manager to know where to start, and
what goals he has to accomplish. Thus, the work of the project manager at this phase is to
prepare a project status report to show the current status of the project. Besides, the
outgoing project manager advises the new project manager on the next steps to be taken
on the project.

7.4 Fill In Project Handover Checklist

The purpose of the fill in project handover checklist process is to create a checklist of
all important things that are to be managed during the handover. This ensures that there is
nothing left out during the whole handover process. The project manager fills in the
handover checklist to ensure that everything is handed over at the right time to ensure a
smooth transition.
Checklists are always very useful as they summarize actions and timeline of events
that would have otherwise been complicated to explain. They are therefore a crucial
support in the handing over of a project between project managers. The project manager
fills in a checklist for all actions to be undertaken alongside their timelines in the project
handover process. The project handover checklist is the output document in this phase.

7.5 Brief new PM on Project Details

The brief new project manager on project details phase aims to debrief the new project
manager on all details in regards to the project. The project manager brings the new
project manager up to speed on all matters on the project to ensure that the new project
manager is well informed on all matters. This helps the new project manager to
understand the whole project better.
Several actions are required during this phase. The project manager lists all the
people working on the project alongside their roles, skills, and competencies. He informs
the new project manager on the work environment such as the passwords, keys, and key
card among others. The project manager informs the new project manager on the
technical or practical dependencies involved in the project. He informs the new project
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manager on how long the handover will take and gives a list of all important contacts for
the project, and the frequency of communication with each contact and their topics of
discussion.

7.6 Review Project Handover Checklist

The purpose on the review project handover checklist is to review the checklist
prepared by the project manager for the project handover process. The new project
manager reviews the project handover checklist to ensure that it incorporates all the things
required for the handover. This ensures that there are no important things left out during
the project handover. The new project manager goes through the project handover
checklist prepared by the project manager to ensure it includes all the necessary aspects.

7.7 Introduce new PM to Project Team

The purpose of introduce new project manager to project team process is to introduce
the new project manager to the project team as they are expected to work together. The
project manager introduces the new project manager to the project team. This ensures
that the project manager is well acquainted with the whole project team. Thus, during this
process, the new project manager gets to know the members of the project team that he
will be working with for the remaining phases of the project.

7.8  Introduce new PM to Client and Project Stakeholders

This is a critical phase in the project handover process because the new project
manager familiarizes himself with the client as well as the project stakeholders. This is
important because a project manager does not work in isolation during the project
lifecycle. Rather, he is in continuous communication and engagement with the
stakeholders to ensure their expectations and concerns are met and addressed
accordingly. Thus, the process ensures that the new project manager is well acquainted
with the clients and the stakeholders.

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7.9 Start the Transition Process Gradually

The purpose of the start the transition process gradually is to transfer the project
manager from the outgoing project manager to the new project manager. This transition
happens slowly with the new project manager taking up their new role step by step. The
project manager conducts the transition by gradually transferring the project to the new
project manager. Smooth transition is very important as it guarantees that nothing goes
wrong during the handover process.
The purpose of this phase is to determine when the transition has been completely
and successfully done. This is to ensure that everything is in order and nothing has been
left out. The new project manager determines when the transition process has been
successful.
If the new project manager finds the handover to be incomplete, he refers back to the
project manager so that the outstanding documents or activities should be completed.
If the handover process is complete, the process moves to the next phase. The new
project manager evaluates the whole handover process to determine whether that process
is complete or not. Besides, he identifies any outstanding activities for completion.

7.10 Requirements for Project Handover

Upon successful completion of the commissioning of the system(s) the Design Team are
formally notified that the system(s) are now ready for final handover and demonstration.

A Demonstration / Handover Schedule is prepared and issued to the Design Team for
comment / approval. The Clients representative(s) will be required to attend the
demonstration(s).

Final demonstration / Handover(s) commences upon approval of the schedule.

Where necessary, representatives of the vendor are required to demonstrate specialist

plant and equipment to the satisfaction of the Client.

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7.11 Monitoring Procedure

The Project Manager will ensure that the required commissioning has been completed in
accordance with design requirements, and that the relevant test certificates have been
submitted to the Consultant for review and approval. The Project Manager will also offer the
systems to the Consultant for acceptance and will demonstrate the systems to the Client’s
representative.

As part of the scheduled commissioning meetings, the Project Manager will issue a
Progress Report on the Schedule, Commissioning Programme, and the Commissioning
Documentation.

7.12 Use of System Handover certification

System acceptance will certify that the systems have been installed, tested, and
commissioned in accordance with the required specification, and

To verify the system, walk down, the Project Manager will use a System Acceptance
checklist. System Handover will be recorded using a project-related System Handover
Certificate. The Documentation of Handover / Acceptance of Systems will generally be
carried out in accordance with the Company.

7.13 Offer to Consultant for Acceptance

Following satisfactory installation, operation and testing of the systems by Winthrop, a

timetable will be agreed. The Demonstration Timetable, as stated above, will indicate the
relevant dates for demonstration and handover.

All specialist engineers will be in attendance prior to the demonstration, and each system
will be demonstrated fully to show its conformance with the project specification.

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The System Acceptance forms will be offered to the Consultant for signature following
system demonstration.

7.14 Offer to Client for Acceptance

Following satisfactory demonstration of the systems by Winthrop, a timetable will be

agreed for demonstration to the Client’s representative. The Demonstration Timetable, as
stated above, will indicate the relevant dates for demonstration and handover.

All specialist engineers will be in attendance prior to the demonstration, and each system
will be demonstrated fully to show its conformance with the project specification.

The System Acceptance forms will be offered to the Client for signature following system
demonstration. Instruction in the correct and proper use of the systems will also be
demonstrated to the Client, and attendance at the training will be recorded.

7.15 Acceptance

The system(s) is then walked down to provide a full working knowledge of the system in
question.

All keys, spare parts, ancillaries etc. for the various plant associated with the system are
issued to the Client at this time and the relevant documentation furnished proving issue of the
ancillaries to the Client. The Clients representative is required to sign the documentation.

All Demonstration / Handover documentation associated with the final handover of the
system(s) to the client are inserted in the Operation & Maintenance Manuals.

7.16 After Services

CEG believes to develop a long-term relationship with its customers, for this purpose as per
project agreement our after sales services department provides its services to the customer
in case of any query as per mutually agreed terms and conditions.
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8.0 CONTROL OF PROJECT QUALITY PLAN (PQP)

8.1 Review

This PQP is subject to amendment during the execution of the Works as a result of
periodic review and whenever circumstances require. A complete copy of the PQP will be
distributed to PM/CM after approval. Any revisions and/or additions will be signed by the
Project Quality Manager and the Project Incharge, as internal communication between the
two parties.

This procedure will ensure that all the involved parties will be kept aware of the
revisions and/or additions to the QA/QCP and in extension to the Project. It will be the
responsibility of the Project Quality Manager to follow up these revisions/additions.

8.2 Implementation

The Project Manager is responsible for the overall competency of the resources.
Responsibility for implementation of particular elements is assigned to the Project
management team. Non-Conformance Reports addressed from the Client will be treated as
top priority issues and as per the following procedure.

8.3 Allocating Human Resources

Project manpower requirements shall be determined, monitored and updated, if

required, based on the detailed construction schedule, so that sufficient manpower will be
available at site. Project crews consist of skilled and semi-skilled people of each work
discipline, supported and guided by experienced assistant foremen and well qualified
foremen.

Well-experienced employees will organize and guide the site activities as well as operate
the more complicated equipment in construction tasks. Indirect personnel managing the

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project and site activities will be selected based on their qualifications and previous
experience on similar projects.

8.4 Induction Training

It is mandatory for all personnel, supervisors and subcontractors, before being allowed
access to the Site and/or proceeding with the site work, to attend the Project Induction. In
addition, it will be mandatory for all personnel to attend safety orientation before entry into
and/or proceeding with any site work. All personnel will be requested to sign that the site
safety rules are understood, accepted and will be adhered to at all times.

8.5 Feedback & Improvement

For continual improvement in the manpower skills, Project implements a systematic

program of induction and ongoing training for employees and those who are transferred
between areas, departments, projects, sites, jobs or tasks within TD. Prior to implementing a
new or changed work process, all people affected will be properly trained. Training on new
tools, techniques and personal protective equipment will be provided to the work force prior
to application.

8.6 Revision

Revisions and/or additions will be proposed by the Project Quality Manager and following
review and approval by the Project Director, will be submitted to PM for approval. Upon
approval by PM, these revisions and/or additions will become an inseparable part of the
PQP. The Project Quality Manager will immediately inform the Site Engineers and all Quality
personnel, as well as any other person on the distribution and controlled copy list regarding
the revisions and/or additions to the PQP.

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8.7 Internal Audits

An Internal Audit Schedule will be Prepared by the QMS department subject to

amendment during the course of the Project to reflect the outcome of audits and whenever
circumstances require. Where non-conforming work is identified either by PM/CM or
through the Project’s inspection team, it will be dealt with as stated in Section of Non-
conformance.

Project’s management will from time to time review the performance of the QMS. This
may be done at formal or informal meetings with the staff, through the management of
nonconforming work, if any, and by review of internal audit reports. Review at corporate level
may also take place. In both cases, corrective and preventive action will be discussed.

Suppliers and Subcontractors quality plans will be submitted in separate documents once
they are recognized. These quality plans will include all the necessary information such as
third-party inspection and relevant certification.

Procedure

i. Internal quality audits will be performed during the Project against the documentation
applicable to the area under audit to verify that the QMS is being implemented and to
identify opportunities for improvement. A quality audit schedule will be drawn up for the
project. This schedule will take account of the relative importance of the applicable
documents and, the timing of activities within each document’s scope. The Site Project
Manager will receive a copy of the schedule. At least seven days before a scheduled
audit, the auditor will send the completed form

ii. Notification of an Internal Audit to the Project Manager.

iii. The auditor will ensure that the scope covers adequately the document to be audited.
Previous audits of the same or similar scope and the minutes of quality meetings will
also be reviewed, where available, to take account of any relevant findings. The auditor
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will always include in the scope the status of the system documentation, if any, held by
the person(s) who will be audited.

iv. At the appointed time, an entry meeting will be held between the auditor and the
responsible manager to outline the scope of the audit and to discuss any logistical
arrangements. The audit will proceed according to the prepared program, although
other aspects of the implementation of the QMS may arise during the audit and be
included in the scope.

QMS deficiencies will be reported by the following categories in order of descending

severity.

 A Non-Conformance
 An Observation.
 A Recommendation

v. In the case of a major deviation from QMS requirements, the auditor will raise a
Corrective Action Request.

vi. A cause for concern will be reported when a potentially serious deviation from
requirements has been observed or when trend of poor implementation has been
detected.

vii. An observation will be reported to address an issue of relatively minor significance, but
which nevertheless may adversely affect the satisfactory implementation of QMS
requirements.

viii. The auditor will hold an exit meeting with the Project Manager to discuss the outcome of
the audit and to explain any deficiencies and deviations observed which will be
documented. Where possible, corrective actions will be agreed at this meeting. In every
case, however, the date by which the deviation will be corrected will be agreed and
entered on the Corrective Action Request.
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ix. A copy of the Report will be passed to the QMS Representative, immediately as it is
issued for any Corrective Action Requests which have been raised.

x. When all of the corrective actions, if any, have been completed and the Corrective
Action Requests have been closed, the auditor will review the audit with the Project
Manager and close the Report. In case the Corrective Action Requests cannot be
completed within the review meeting, a follow-up meeting will be held to address these
issues in order to close non-conformances.

Subcontractor and Supplier Audits

i. Any of the responsible persons as mentioned above, may decide that an audit of a
supplier or subcontractor is necessary, regardless of the existence of an audit during
the assessment process. In co-operation with the QMS Representative an appropriate
auditor (or auditors) is (are) appointed and the supplier / subcontractor is notified in
advance of the exact audit date.

ii. Depending on the audit’s scope, the auditor(s) may conduct a full audit of the
Supplier’s/ Subcontractor’s processes or examine a part of them. Results from the
audit are recorded as required by the related Form, which is then communicated to
the relevant responsible person and a comment of the audit’s outcome. The audit
results are taken into consideration during the annual suppliers /subcontractors' review.

Audit Schedule

i. HSE/QAQC is responsible for preparing the audit schedule as direction of Project

Manager.

ii. 3rd party audits are occurred at least once in a year and supplier audits on pre-selection
or as per requirement.

Auditor Qualification

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i. The overall responsibility for implementation of the QMS on a project lies with the
Project Manager. Responsibility for the implementation of particular elements of the
QMS is assigned to members of the project management team.

ii. Quality Incharge is responsible for undertaking internal quality audits according to the
schedule. Individual audits are assigned to members of the Corporate Quality
Department on a case-by-case basis.

iii. HSE/QAQC report to their head of department or the Project Manager and are
responsible for assisting their superior to implement, develop and improve the elements
of the QMS applicable to their scope of work.

8.8 TRAINING

Training Needs

Any induction and/or training that may be required will be performed as per procedure.
Training requirements identification will be conducted by the Project Quality Manager.

All personnel involved in any Project Quality procedure will pass from a mandatory
induction course regarding the Quality process and procedures. These induction
courses will be designed in accordance to the participants and shall include but not
limited to the following items:

 Use of Project – Specific forms

 Registers
 The main Quality Procedures:
o Pre-inspection checklist
o Inspection Request [IR]
o Requesting information from PM/CM
o Dealing with and closing- up Non-Conformities [NCR]
o Document Submittals and transmittals
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o Material Approval and Inspection Procedures

o Subcontractors Approvals
 Communication with PM/CM
 Quality Records
o Control of Records
o Electronic handling of Records
Formal Quality System Training

Induction and Training for Quality Staff (Managers - Engineers – Inspectors)

In addition to the above training content the quality Staff and other affected
personnel will undergo intensive training for the Document Management System.
This training is to be conducted by the vendor of the Document Management
Software.
Training Duration and Frequency

Induction courses will have duration of twenty (20) hours and the subsequent
maintenance training will last for eight (8) hrs. repeated twice a year. Training
on quality matters and procedures should be discipline-oriented focusing on each
company sector and where the needs are identified.
Training for Quality Inspectors

This training will be performed by the Project Quality Managers and in

accordance to the discipline of the inspectors. Such Training shall include, but not
limited to the following:

 Study of Relevant Plans and Drawings

 Methods for Effective Inspection
 Quality procedures
The contribution of experts may be requested in any field related to the object of
training.
Quality Training for Tradesmen
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 The Training of Tradesmen has an informal manner, as it is provided in the

form of instructions and/or on-the-job training.
 Occasionally, if specific requirements arise (e.g. installation of a new type of
product) training may be in the form of Toolbox or Demonstration by the
suppliers
 Special Quality Toolboxes may be designed to address certain critical quality
issues.
Tool Box Talks

On regular basis (monthly) at least 4 hours training on occupational health safety,

construction methods best practices, environment safety will be conducted by
respective area executive level person as per training plan.

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9.0 RISK MANAGEMENT

9.1 General

The purpose of this plan is to define the activities required to ensure that all potential risks
related to quality management system are proactively identified and mitigated. This project
plan also covers the quality management system related opportunities.

9.2 Process

a. CEG considers and manages risks and opportunities related to all the processes
differently. All risks are managed with a focus on decreasing their likelihood, and
minimizing their impact if they should occur.

b. Opportunities are managed to increase their likelihood, and to maximize their

benefits if they should occur.

c. Where risks and opportunities overlap, the best appropriate method for managing
them shall be ascertained, given the situation at hand. Elements of such “blended”
uncertainties may require methods which both address the negative risk and positive
opportunity.

9.3 Risk Management Methodology

a. Following steps are followed while conducting risk assessment;

 Identifying the process for which the risk most likely dominates.

 Identifying the risk. While identifying the risk, following questions are
considered;

What could happen: what might go wrong, or what might prevent the
achievement of the relevant goals? What events or occurrences could threaten
the intended outcomes?
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How could it happen: is the risk likely to occur at all or happen again? If so,
what could cause the risk event to recur or contribute to it happening again?
Where could it happen: is the risk likely to occur anywhere or in any
environment/place? Or is it a risk that is dependent on the location, physical area
or activity?
Why might it happen: what factors would need to be present for the risk to
happen or occur again? Understanding why a risk might occur or be repeated is
important if the risk is to be managed.
What might be the impact: if the risk were to eventuate, what impact or
consequences would or might this have? Areas of impact to consider include:

b. Assigning a score to the likelihood (probability of occurrence) of identified risk. Each

element is given a score from 1 (lowest risk) to 5 (highest risk).

c. Likelihood is categorized into following categories;

Scor
Likelihood Description of Likelihood
e
Almost Highly likely to happen, possibly frequently
5
Certain (Frequent)
Will probably happen, but not a persistent issue
Likely 4
(Probable)
Possible 3 May happen occasionally (Occasional)
Not expected to happen, but is a possibility
Unlikely 2
(Uncommon)
Rare 1 Very unlikely this will ever happen (Remote)

d. Assigning a consequence rating if the risk were to be encountered; this consequence

is comprised of following elements;

 Impact on activities / operations

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 Impact on humans

 Impact on contract with customers, supplier or any other body

 Adverse impact on the reputation of CEG for failure to meet or achieve our
strategic objectives

 Financial consequences

 Compromise compliance of regulations or laws

e. Again, each element is given a score from 1 (lowest risk) to 5 (highest risk).
Calculating a final Risk Factor based on the equation:

Risk Factor = Likelihood Score x Consequence Rating

f. The risk is evaluated by plotting the likelihood against the consequences in the
following way.

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Risk Assessment Matrix

Level of Risk
CONSEQUENCES
Insignifica Modera
LIKELIHOOD Minor Major Extreme
nt te
(2) (4) (5)
(1) (3)
Almost Certain
5 10 15 20 25
(5)
Likely (4) 4 8 12 16 20
Possible (3) 3 6 9 12 15
Unlikely (2) 2 4 6 8 10
Rare (1) 1 2 3 4 5
Risk Rating - Management Action Required
Immediate attention & response needed; requires a risk assessment &
Extreme
management plan prepared by relevant Sections Heads appropriate
Risk
actions are taken
Risk to be given appropriate attention & demonstrably managed;
High Risk
reported to Section Heads
Assess the risk; determine whether current controls are adequate or if
Moderate
further action or treatment is needed; monitor & review locally, e.g.
Risk
through regular business practices or local area meetings
Manage by routine plans; report to concerned manager; monitor &
Low Risk
review locally as necessary

g. When the risks are evaluated, their cause is found out and then the control measures
are suggested and control measures are prioritized according to the magnitude of the
risk.

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h. When determining controls, or considering changes to existing controls,

consideration shall be given to reduce the risks as;

 Reduce the likelihood or possibility of the risk

 Reduce the consequence or impact of the risk

 Share the risk

 Eliminate or avoid it altogether

 Accept or tolerate the risk

i. A risk may be acceptable or tolerable in the following circumstances:

 No treatment is available

 Treatment costs are prohibitive (particularly relevant with lower ranked risks)

 The level of risk is low and does not require using resources to treat it

 The opportunities involved significantly outweigh the threats

j. The final column allows for entry of an estimated risk factor after mitigation, which is
an estimate on what the risk should be reduced to if the risk treatment is successful.

9.4 Risk Identification

a. Based on the risk identification methodology; risks are identified by Quality

Checker/Supervisor and his team as a part of Internal & External Issues and based
on the need and expectations of the interest parties.

Risks can be categorized as follows:

oInternal & External Issues
oMalfunction of equipment
oProject Delay
oContractor Issues

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oPersonnel – human error

oPurchase Process
oConstruction Process
oRisk of Fire & Explosions
oAny other that may affect operations

b. Risk associated with each process are identified by the concerned HOD and entered
in the Risk Assessment Form. This document includes the identification and
mitigation plans for risks associated with the defined process. Additional risks may be
identified by any employee at any time.

9.5 Risk Control

a. All high rating risks are controlled. The purpose of risk control is to reduce the risk to
an acceptable level. Risk control might focus on the following questions:

 Is the risk above an acceptable level?

 What can be done to reduce or eliminate risks?

 What is the appropriate balance among benefits, risks and resources?

 Are new risks introduced as a result of the identified risks being controlled?

b. Risk level is reduced to acceptable limit; by mitigating or avoiding of quality risk

when it exceeds up to specified (acceptable) level. It might be appropriate to revisit
the risk assessment to identify and evaluate any possible change in risk after
implementing a risk reduction process.

c. Risk acceptance is a decision to accept risk taken by Quality Checker/Supervisor

after discussing with PM & CM. This (specified) acceptable level will depend on many
parameters and should be decided on a case-by-case basis. It can be a passive
decision in which residual risks are not specified.

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d. Risk communication is the sharing of information about risk and risk management
between the decision makers and others. Output/result of the quality risk
management process should be appropriately communicated and documented.
Training and identification of required skills including coordination, communication,
discussion and leadership are also conducted by Quality Checker/Supervisor and his
team.

9.6 Management of Opportunities

a. CEG seeks out opportunities which could enhance its financial viability and market
position.

b. Opportunities are also identified as part of the context, described in the plan for
Context of the Organization.

c. Discussing and analysing opportunities shall be done by top management. All these
opportunities are discussed as a part of the management review activities, and
recorded in the management review records.

d. If an opportunity requires a risk assessment, this shall be done as defined above.

e. Analysis of any opportunity will generally result in one of the following possible
determinations:

 Pursue the opportunity

 Explore the opportunity in greater detail before proceeding

 Accept the opportunity, but under limited and controlled conditions

Decline the opportunity, typically based on a high expected risk

9.7 Risk Review

The effectiveness of the risk management process should be reviewed periodically based on
meaningful information “(e.g., results of contract review, inspections, audits, change control)
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or unplanned (e.g., root cause from failure investigations, recalls). The frequency of any
review may be changed upon the level of risk.

10.0 EQUIPMENT MANAGEMENT

10.1 Equipment Identification & Placement

All equipment’s / machines are placed at their designated places. Work instructions are provided
with all the equipment. Equipment manual (if any) provided by supplier (manufacturer) are readily
available to personnel as and when required.

All equipment’s are uniquely identified for effective traceability. If equipment is in parts, each of
its part is uniquely identified in a manner that it remains traceable to the main equipment.

Following scheme is used in order to relate equipment to their respective sections;

CEG-EQT-NNN

Where,

CEG Certex Equatorial Guinea

EQT Refers to Equipment
NNN A unique numerical figure only available with one equipment

10.2 Handling, Use, Transport and Storage of Equipment

Equipment is only allowed to be transferred / transported to an external location in following

cases;
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a. If equipment’s maintenance requires it to be taken to the supplier’s or manufacturer’s

premises
b. Equipment requires calibration services which require equipment to be taken to calibration
lab.
c. Staff ensures that equipment is properly working and operational when it is returned back
to CEG; in case found any problem organization does not accept equipment from third
party until and unless it is fully operational. After ensuring that the equipment is in
operational condition, it is accepted and placed at its designated place.
d. Visitors are restricted to offices and only authorized personnel are permitted to concerned
departments.

10.3 Equipment Maintenance

Equipment maintenance of following types is carried out in the CEG

Preventive Maintenance

All equipment will go through process of preventive maintenance at frequencies defined in

equipment manuals or maintenance plan. This process ensures that all the equipment is
periodically checked for their performance and parts, so that sudden and unforeseen problems
can be prevented.

Corrective Maintenance

In case of malfunctioning in any equipment it will go through the corrective maintenance process.
Concerned section in-charge will raise Maintenance Work Order, specifying the job nature,
which can be of two types;

a. Major: Maintenance is carried out according to the nature of problem and machine /
equipment is tagged as “UNDER MAINTENANCE” and time frame of machine
maintenance is given to user section. Maintenance will be carried out internally / externally
and machine / equipment will be transferred in the concerned section after completing the

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maintenance. After maintenance, signatures are taken on the Maintenance Work Order
from staff.

Minor: In case of minor issues, department (Electrical / Mechanical) fix the problems on the
spot.

Breakdown Maintenance

a. In case of any breakdown, the concerned section in-charge immediately notifies the
Admin department via maintenance work order/permit.
b. Admin department immediately sends Department Manager to the problem area along
with appropriate tools and he repairs that machine/ equipment.
c. If any part is to be replaced, then he takes part from store and if part is not available in the
store, then informed to Admin for purchase and a target date is recorded on the
Maintenance Work Order with delay reason. Under maintenance machine will be tagged
with “OUT OF ORDER” sticker.

OUT OF ORDER
Date:
Equipment Code:
Equipment Name:
Location:

d. On availability of resources, the Job is completed immediately.

e. Work Order/Permit form is signed and verified by the respective section in-charge.
f. The mechanic / electrician himself signs the Maintenance Work Order/Permit, write the
details of parts, and work done.
g. Respective Section Manager also signs the Maintenance Work Order/Permit.
h. Equipment Maintenance Log is filled against the Maintenance Work Order and kept in a
file as a record.
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i. In case of major break down or accident a Break Down / Accident Report, will be prepared
by concerned trade/section in-charge.
j. Concerned section shall survey on monthly basis to ensure that that all machines /
equipment are well maintained and that there is no equipment / tools lying un-serviceable
or pending repair.

Equipment Calibration

Equipment Calibration is performed minimum once each year. Calibration certificates of the all
equipment, calibrated from external calibration providers are kept by the by the concerned
section/ department in-charge.

Equipment Calibration is performed on yearly basis in case of external calibration and internal
calibration is performed twice a year. This activity in following ways;

a. Master equipment is calibrated from external calibration providers (Accredited Lab) and
rest of the equipment is calibrated against master equipment.
b. Equipment can also be verified by running the control samples or by written manuals of
machine internally.

Calibration service provider labels the equipment with their own sticker; in case they don’t,
Maintenance department shall label their equipment with calibration sticker as below;

Equipment Code:
Calibration Date:
LOGO
Due Date:
Performed by:
Section in-charge will ensure that calibration is performed before the due date actually arrives
and record maintained as document Equipment Calibration Program.

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Related Documents and Records

List of Machines & Equipment Appendix B

Equipment Calibration Program Appendix C

Preventive Maintenance Plan Appendix D

Machine Maintenance Order Appendix E

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