helmet - l&t construction .pdf · murali krishnan | p.v. kaliappan v. balaji | s. anantha prasanna...

Environment SafetyHealth

HelmetJan - Mar 2013 • Volume - 3 • Issue - 1

NEBOSH Accreditation

20 - TIPS to reduce Pollution

It happened - it can happen - Prevent it

Safe Synchronization of Power Transformers

Where should I use a ladder?

Protection from Heat Illness

Focus

Editor : V. S. Ramana

Editorial team : V. Ramesh Kumar | Gopi Kannan. S

Ashwin Chand | Mayura. K

Subha Anand | Shamala Nadendla

Content by : M. Kamarajan | P. Nagarajan

M. Nachiappan | R.N.Tripathy

Shaik Karimulla Sha Khadari

Mathivanan Palaniappan

Shailendra Kumar | Md Quaisar Imam

Sathyanarayana Seelamanthula

Murali Krishnan | P.V. Kaliappan

V. Balaji | S. Anantha Prasanna Venkatesh

Photography : V. S. Natanavelu

Design & layout : Global Print Design, Chennai

ContentsThis issue of Helmet covers more than the usual dose of safety related articles. The entire issue addresses various interesting areas right from occupational stress management to prevention of accidents while working at heights.

Being released during the hottest month of the year there are a couple of articles that cover heat related stress and how to safeguard oneself as well as the work force from such harsh natural elements. Apart from many thought provoking articles, this issue also covers and compiles significant EHS related events that have happened across the globe from each IC.

Hope that the articles are not only motivating, but also help in implementation of the good practices shared so that every project site becomes a safe work environment.

Happy reading

NEBOSH Accreditation .........for L&T’s Leadership Development Academy (LDA)

BUILDINGS AND FACTORIES .............................Message from B&F IC

INFRASTRUCTURE ................Safety while working on/ near Railway track

METALLURGICAL AND MATERIAL HANDLING ......Safe Synchronization of Power Transformers

POWER TRANSMISSION & DISTRIBUTION .......................Safety vs. Productivity: Friend or FOE?

WATER & EFFLUENT TREATMENT ...........................Protection from Heat Illness

35

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3HELMET Jan - Mar 2013

NEBOSH Accreditation for L&T’s Leadership Development Academy (LDA)

Academy (LDA), Lonavala. A tutorial team comprising of Mr.M Kamarajan, Mr.Josy John, Mr.Varatharajan Janardhanam, Mr.S.Selvaganapathy, Mr. Shailendra Kumar, Mr. Mathivanan Palaniappan, Mr. M. Nachiappan, Mr.R.V.Sudhakar, Mr. Krishna Nirmalya Sen; senior EHS executives from various ICs of L&T attended the meeting.

The objective of the meeting was to standardize the delivery of the course, to increase the effectiveness of the course and to achieve the overall objective of creating ‘Change agents’ who will inculcate a positive EHS culture in their respective place of work after attending this intensive culture building course. Mr. Neville Lobo, Vice President, Corporate HR and Director of LDA, set the context. He said that NEBOSH was the first step to address the critical aspect of creating a culture of Health, Safety, Security and Environment (HSSE) in the company. Mr. M Kamarajan, Head, HSE, B&F, who has delivered

National Examination Board for Occupational Safety & Health (NEBOSH), UK accredited L&T’s Leadership Development Academy (LDA) at Lonavala for delivering their International General Certificate (IGC) Course at a function organised in L&T’s Headquarters, Chennai on March 4, 2013. The formal agreement to this effect was signed by Ms. Teresa Budworth, Chief Executive, NEBOSH and Mr. Neville Lobo, Vice President, Corporate HR & Director, LDA, L&T in the presence of Mr. S.N. Subrahmanyan, Member of the Board and Sr. Executive Vice President (Infrastructure & Construction), L&T and Mr. Stuart Naylor, International Manager, NEBOSH. A formal accreditation certificate was also presented to Mr. S.N. Subrahmanyan by Ms. Teresa.

In order to launch the first batch of this course, which is scheduled during 15th April to 25th April at Chennai, L&T internal Tutors’ workshop was held on Friday, 22nd March at Leadership Development

4 HELMET Jan - Mar 2013

more than 30 batches of NEBOSH IGC courses, conducted the workshop. Some of the decisions that were taken during the meeting are:

y Safety Pledge will be administered at the beginning of all the training programs (in future) along with L&T Anthem; a pocket size multipurpose card will be printed and handed over to all the participants with the pledge printed on it.

y Attractive safety promotional materials shall be considered for publication in ATL (home page), which will be periodically changed

y HSSE module, (which is currently under development) will be launched in the ATL web site and will be used for giving safety induction to all levels of staff

y Participants of the NEBOSH course will be requested to share the knowledge gained during the program in their place of work to as many staff members as possible; this process will be facilitated by the concerned EHS head of the IC; peer review (of the participants) will be conducted (after 3 to 6 months of their participation in the NEBOSH program) to understand whether their approach to EHS has changed for the better.

After a lot of deliberations, it was decided to prepare a world-class course material (developed completely in-house) for the course and to use the NEBOSH training as a vehicle to bring a cultural transformation within the organization.


Message from B&F IC

It was a great opportunity to look at the current EHS

management system and the best practices that are

currently being implemented in the B&F sites after 18

years, since I was involved in the formation of the EHS

department during 1980s and maintaining/ monitoring the

EHS performance till 1995.

It is a pleasure to see that many of the fundamental

principles that were introduced (and practiced) in the

yester-years are being nurtured even today and a strong

growth in many best operational practices, particularly the

five critical SOPs (Lift Shaft & Floor Opening Protection,

Working on Peripheral Platforms, Builders Hoist Operation,

Temporary Electrical Distribution System & Barricades for

Excavation) and the related audits around those.

Safety Trophy Scheme (based on risk indices), The Helmet

magazine, Safety Month celebration are some of the

classic initiatives that were introduced many years before,

which have stood the test of time and is being practiced

even today, although it has gone through some cosmetic

changes!

Well, as is a normal practice, based on a gap analysis that

was performed after extensive discussions with various

levels of people across the length and breadth of our work

places, some of the initiatives that have been introduced /

being introduced are discussed below:

EHS Management System:

Scope of the management system is extended to the IC as a

whole, instead of restricting it the EHS function alone; in-line

with this requirement, Mr. K. Kannan (VP & Head for IT&IS

BU) was chosen to be the Management Representative

(MR). All the procedures are being modified with a single

line objective of bringing a positive EHS culture among all

the employees.

Competence Building Workshop:

One of the first and foremost need was to empower and

motivate the EHS team members to be self-starters/ self-

motivated; a well-designed Competence Building Workshop

(a one-day interactive program) has been designed and has

Buildings & Factories 5HELMET Jan - Mar 2013

6 HELMET Jan - Mar 2013 Buildings & Factories

been completed in all the Clusters; this will be continued

once in three months in all the clusters to serve as an

opportunity to rejuvenate them and to facilitate them to

function in a more focussed manner.

Pro-active EHS Performance Monitoring System:

EHS performance measurement was construed to be

the accident/ incident ratings only and there was a lack

of measuring the proactive EHS performance. Based

on this, an extensive and comprehensive proactive EHS

performance measures have been designed and launched

since April 2013, using which, individual EHS performance

of all the employees (staff members) at site is being tracked

down. This will help the management to recognize the top

performers on a monthly basis and to counsel the poor

performers so that they can be facilitated to perform better

during the subsequent months.

EHS Suggestion Scheme & Nearmiss Reporting:

Serious focus is being given to collect and capture all the

minor injury and no injury incidents, which ultimately lead

to serious injury incidents, if not taken seriously; all levels

of employees are being encouraged to report the hazards/

unsafe conditions at the work place either through the

existing suggestion scheme or by calling the safety engineers

over phone. Every deviation from the existing practice is

being looked at as an “opportunity to learn”, rather than

a violation being committed by an individual (and hence a

need to punish someone).

All the deviations are only symptoms and root cause analysis

(RCA) is being encouraged to find out the actual failure that

allowed the symptom to exist so that a permanent solution

can be worked out. All the EHS personnel are being groomed

to diagnose the causes of failures/ deviations (through RCA

techniques) so that they can prescribe correct medicines

(solutions), rather than treating the symptoms alone or

being policemen, (catching people doing wrong things).

Safety Improvement Slip

All the site engineers and managers have been provided

with a safety improvement slip (booklet) and have been

requested to issue it to all those who are not doing what

they are supposed to be doing in their respective area of

work towards EHS requirements; this has brought in a

culture of EHS being monitored/ nurtured by one and all

– not just by the EHS team members alone! “No blame”

culture is being brought in/ promoted in all the incident

investigations.

EHS Leadership Program

As the readers of “The Helmet” are aware, a two days’

training program on “Construction Safety” is being

organized for all the staff members for the past many years.

However, senior staff members (above the level of M2) are

excluded from this training program and hence a one day

workshop on “EHS Leadership” has been designed and in

fact is scheduled in the training calendar, released by HR

department. This is likely to create ownership / involvement of

project directors / managers and construction managers.

One day Workshop on Internal Audit Techniques

In addition, refresher training was organized recently for all

the internal EHS auditors to facilitate them to conduct audit

in a more comprehensive manner and to leave behind (with

the auditee) a set of “opportunity for improvement” rather

than a set of “Non-Compliances”.

One final, but an important cultural change being

promoted is to integrate the EHS requirements in the way

we do business in our IC. For ex: in all the training programs

(technical, behavioural, functional and managerial) being

organized by HR department, EHS requirements are

being built-in. Similarly, it is proposed to embed the EHS

requirements, while procuring materials / machinery / men,

right at the source, so that there is no need for ‘tinkering’ it

to make it safer (alright), after it is procured/ hired.

Well, we have set an ambitious goal for ourselves for the

year 2013-14, with a fond hope that all employees will

cooperate with us in all earnest in this drive. With folded

hands, all the readers of “The Helmet” (from B&F IC) are

requested to join this exciting journey and be a part of

this ongoing drive to eradicate the menace of incidents /

accidents v/ dangerous occurrences.

M. Kamarajan

Head EHS Buildings & Factories

___________________C

lusterSAFETY IMPROVEME

NT SLIP

Project Name :

Date:

Time:

----------------------------------

----------------------------------

----------------------------------

----------------------------------

-

Name of the person:

PS. No / Gate Pass No:ISSUED TO:

Designation:

Location:

----------------------------------

----------------------------------

----------------------------------

----------------------------------

-

Hazard (Unsafe Act / Uns

afe Condition) to be correc

ted & prohibited

Sl. No

Hazard (UA/UC)

Tick if applicable

Sl. No

Hazard (UA/UC)

Tick if applicable

1 Poor Housekeepin

g11 Not u

sing the required PPE

(Personal Protective Equ

ipment)

2 Working without p

roper access /

egress.

12 Found smoking in s

ite premises other

than the designated zone

.

3 Not providing hard

barricades in

floor edges

13 Found urinating in

site premises other

than designated toilets.

4 Unauthorized rem

oval of Lift Shaft

gate.

14 Using Short cuts

5 Unauthorized rem

oval of

protections, provided for th

e

openings

15 Unauthorized ope

ration of the

equipment’s / vehicles / p

ower tools.

6 Use of equipment’

s / vehicles /

power tools / scaffold / lad

der

without valid inspection ta

g.

16 Throwing materials

from / to higher

elevation

7 Using machineries

without guard

(all rotating / moving part

s)

17 Laid the power ca

ble in unsafe

manner

8 Not clearing the d

ebris at the end

of the shift

18 Electrical connecti

ons drawn from

socket without plug top.

9 Making safety devi

ces inoperative

19 Horse play in the jo

b

10 Doing jobs without

valid permits

as defined in EHSMS.

20 Leaving loose ma

terial in unsafe

location

10 a Other Unsafe cond

itions

____________________

_______

20 a Other Unsafe Acts

____________________

__________

----------------------------------

----------------------------------

----------------------------------

----------------------------------

-

Name of the person:

PS. No / Gate Pass No:ISSUED BY:

Designation:

Signature:

----------------------------------

----------------------------------

----------------------------------

----------------------------------

-



Helmet Congratulates the following sites for achieving

THREE Million and more LTI Free Safe Man-Hours

SafetyRoll o

f Honour

The Address - Wadhwa Housing Project, Ghatkopar Million Safe Man Hours, January 2010 to March 2013

Heidelberg Project, Damoh Million Safe Man Hours, July 2010 to March 2013

Vicat Sagar Project Million Safe Man Hours, July 2010 to March 2013

Rajashree cement plant Project, Malkhed Million Safe Man Hours, March 2011 to March 2013

Bengal NRI Housing Project, Kolkata Million Safe Man Hours, July 2011 to March 2013

NISER Project, Bhubaneswar Million Safe Man Hours, September 2011 to March 2013

Delhi ONE ProjectMillion Safe Man Hours, December 2011 to March 2013

Godrej Housing Project, Kolkata Million Safe Man Hours, July 2009 to March 2013

Grasim project, BharuchMillion Safe Man Hours, October 2011 to March 2013

ESIC Hospital Project, Kovai Million Safe Man Hours, March 2011 to March 2013

Torrent Pharmaceuticals Project, DahejMillion Safe Man Hours, October 2011 to March 2013

Manikgarh cement Plant Project, Chandrapur Million Safe Man Hours, March 2011 to March 2013

ESIC Hospital Project, KollamMillion Safe Man Hours, April 2010 to March 2013

TCS project, KochiMillion Safe Man Hours, October 2011 to March 2013

River View Apartments ph-II Project, LucknowMillion Safe Man Hours, March 2012 to March 2013

Mall of India Project, NoidaMillion Safe Man Hours, September 2011 to March 2013

Boeing MRO Project, NagpurMillion Safe Man Hours, March 2011 to March 2013

Maruti C-line Project, ManesarMillion Safe Man Hours, October 2010 to March 2013

CESC shopping Mall project, Kolkata Million Safe Man Hours, July 2010 to March 2013

Orchid Crown Project, PrabhadeviMillion Safe Man Hours, April 2010 to March 2013

Godrej Garden City ph-III project, AhmedabadMillion Safe Man Hours, July 2011 to March 2013

Seawoods project, Mumbai Million Safe Man Hours, July 2011 to March 2013

Godrej garden city ph I & II project, AhmedabadMillion Safe Man Hours, September 2011 to March 2013

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RMZ Galleria Project, Bangalore Million Safe Man Hours, February 2012 to March 2013

Cognizant Elcot IT Park Project, SholinganallurMillion Safe Man Hours, October 2012 to March 2013

Nestle Factory Project, SamalkhaMillion Safe Man Hours, May 2010 to March 2013

SNU Project, DadriMillion Safe Man Hours, October 2011 to March 2013

Wadhwa project, BKC MumbaiMillion Safe Man Hours, December 2010 to March 2013

Victory Valley Project, GurgaonMillion Safe Man Hours, April 2012 to March 2013

DLF-Mico project, EgmoreMillion Safe Man Hours, December 2011 to March 2013

M3M Golf estate project, GurgaonMillion Safe Man Hours, June 2011 to March 2013

Godrej one project, MumbaiMillion Safe Man Hours, February 2011 to March 2013

DIAL ATC Tower ProjectMillion Safe Man Hours, January 2012 to March 2013

Omkar Rehab project, MaladMillion Safe Man Hours, July 2011 to March 2013

CMRL Depot project, KoyambeduMillion Safe Man Hours, December 2010 to March 2013

Omkar Rehab building project, BhoiwadaMillion Safe Man Hours, June 2011 to March 2013

BMRCL R4 P2 package Project, BangaloreMillion Safe Man Hours, April 2009 to March 2013

TCS Garima Park projectMillion Safe Man Hours, August 2012 to March 2013

TCS Customer Care Centre, SiruseriMillion Safe Man Hours, April 2012 to March 2013

Construction of MSIL Proving Ground project, RohtakMillion Safe Man Hours, July 2011 to March 2013

IREO Rise project, MohaliMillion Safe Man Hours, March 2012 to March 2013

HONDA Ph-II Extension Project, Bhiwadi Million Safe Man Hours, April 2012 to March 2013

Minerva Tower Project, MumbaiMillion Safe Man Hours, July 2011 to March 2013

Lodha Fiorenza Project, GoregaonMillion Safe Man Hours, August 2011 to March 2013

Prestige Bella Vista Project, ChennaiMillion Safe Man Hours, April 2012 to March 2013

Kingfisher Tower Project, BangaloreMillion Safe Man Hours, October 2011 to March 2013

Atmosphere Project, KolkataMillion Safe Man Hours, July 2011 to March 2013

VGS Dulhera ProjectMillion Safe Man Hours, November 2011 to March 2013

Omkar Rehab project, WorliMillion Safe Man Hours, November 2011 to March 2013

8 HELMET Jan - Mar 2013 Buildings & Factories


Construction Safety

Safety and Me

Buildings & Factories

Safety is not a tick-box for various programs or actions taken (in various checklists), but it is to develop a proactive mindset. Being reactive is responding to a situation where a failure has occurred and the fallout has impacted on the operations. The enormity of the fallout can be as small as losing a few minutes of productivity to huge measurable losses including human lives. A pro-active approach to the management of safety, both on the job and off the job, supports the business and ensures that the interests of all stakeholders are protected.

A term that is commonly used across all sectors (but not fully understood by many) is ‘Safety Culture’. Safety culture is a sub-set of the overall culture of the organisation and will vary with the industry or activity. The safety performance of an organisation depends largely on the safety culture of the organisation. Safety culture comprises of the shared values, perceptions, attitudes, behaviour and a combination of knowledge, skills, aptitudes and the collective experience among the employees, who form the organisation.

Culture develops from the combined experience of the people within the organisation, not necessarily planned in advance and need not be the culture the organisation desires to have. The uniqueness of safety culture is that it is not stagnant; there are a whole lot of factors that influence changes to keep the momentum going. It (safety culture) reacts to experience, changes in the organisation’s philosophy and the impact of external and internal stakeholders. Technological advances resulting in process modifications and elimination of human interface are also critical to safety culture. In other words, the organization should keep a vigil on the likely changes in the safety culture due to the arrival of new employees, technological advances, process modifications and the influence of the stockholders and establish a course correction (in the culture) if found necessary.

The perception of safety will vary with people groups based on ethnicity, access to information, education and experience and bias towards recognizing safety comes first in real terms and not just remain as a


slogan within the organisation. Organisations with diverse ethnic and language groups forming part of its workforce have a greater challenge in moulding a common safety culture or in other words to have everyone read off the same page when it comes to safety. This challenge is real and the management has to take steps to counter this aspect of managing the workforce in a manner which will be acceptable to all who are employed. Safety culture is shaped by and has a direct relation to the individual, task and the organisation and these can have much variance.

Organisations are run by people and hence their psychological, behavioral and situational factors mould the work culture which the organisation will possess and this in turn will influence or create the safety culture of the organisation. Within the overall culture, a variety of sub-cultures will exist in the organisation depending on the nature of the business whether it is in a high risk sector like nuclear, oil/gas or an everyday office environment where the severity of the outcome of an unwanted incident will be lower.

The origin of the term Safety Culture is from the report published in 1987 by OECD Nuclear Agency (INSAG, 1988) on the 1986 Chernobyl disaster. A definition of safety culture widely used is ‘...the product of individual and group values, attitudes, competencies, and patterns of behaviour that determine the commitment to, and the style and proficiency of, an organisation’s Health & Safety programs. Organisations with a positive safety culture are characterised by communications founded on mutual trust, by shared perceptions

of the importance of safety, and by confidence in the efficacy of preventative measures’. – The Advisory Committee for Safety in Nuclear Installations, subsequently adopted by the UK Health and Safety Executive.

Developing a culture with safety as the core value is essential for a business to survive, since the key stakeholders are the individuals, organisation and the state as a regulatory body representing the interests of the larger society and everybody will have a win-win situation.

Management systems are much talked about and scrupulously followed in certain aspects like procurement, production and quality. Adopting the same approach to managing the safety aspects of the personnel and assets ensures that the delivery of quality products and services are ensured. Identifying the gaps in safety in the human and material capital employed in the organisation will be the first step towards building a safety culture.

Questions to ponder

What is the organisation culture at my workplace?

Why is the safety culture (within my workplace and beyond) not at par with best in its class?

What will be my contribution to enhancing safety culture?

Josy John Head-EHS, MIAL Project



Occupational Stress Management

Stress exists from time immemorial. Today with

modernisation, we have a mechanised world having

the sedentary, highly competitive jobs, alcohol abuse,

excessive smoking, imbalanced diet and total lack

of exercise, which has totally changed our lifestyle.

Stress is the greatest enemy of your health if allowed

to overcome you. Yet it can be a friend if managed

properly.

What is the stress?

Stress in Physics is defined as a “Force that deforms

bodies”. In human begins, stress does deform the

body, in the long run, in the form of stress related

diseases.

Human Responses to stress

The human body responds to stress with certain

temporary physiological changes. This response

depends on the vulnerability of each individual’s

system and personality. If a person’s gastro-intestinal

system is sensitive, he would have either hyperacidity,

loose motions or constipation. A particular stress may

cause no harm to one person,while being a high stress

to another.

Occupational stressors

A: Environmental (Physical) stressors

The environmental stresses are heat, light, noise,

chemicals and ergonomic stress. These are relatively

easy to manage by modification in the work

environment or re-design of work place.

B: Psychosocial Stressors

These are more difficult to manage as they cause

internal stress on the body. Psychosocial stress arises

from an individual’s inability to adapt to change.

Due to these higher responsibilities, white collared

employee’s experiences greater psychosocial stress.

Women employees are put to higher stress because

of their dual roles as bread winner and house wife.

With globalisation comes high competitiveness, high

targets and demands, inadequate qualifications,

limited growth opportunities, impersonal

relationships, which increase the stress.

How to identify stress effects?

Signs of stress effects

1. PHYSICAL: Intense exertion, manual labor, lack of sleep, travel

2. CHEMICAL: Drugs, alcohol, caffeine, nicotine and environmental pollutants such as cleaning chemicals or pesticides

3. MENTAL: Perfectionism, worry, anxiety, long work hours

4. EMOTIONAL: Anger, guilt, loneliness, sadness, fear

5. NUTRITIONAL: Food allergies, vitamin and mineral deficiency



6. TRAUMATIC: Injuries or burns, surgery, illness, infections, extreme temperatures

7. PSYCHO-SPIRITUAL: Troubled relationships, financial or career pressures, challenges with life goals, spiritual alignment and general state of happiness

Stress Related Diseases

Stress, if not managed properly can lead to p r e c i p i t a t i o n of following diseases or their aggravation if already existing.

Peptic ulcer, u l c e r a t i v e colitis, coronary artery disease, cerebro-vascular disease, Hypertension, diabetes, headaches/migraine, back pain, pain in the neck, bronchial asthma, psychosomatic diseases and sexual problems.

Management of Occupational Stress

y Plan your work well with proper time management.

y Don’t hide weakness and inadequacies,try to overcome them

y Avoid postponing things you are supposed to do now, a c c u m u l a t e d work can cause the stress

y Set reasonable/realistic goals

y A v o i d procrastination

y Set boundaries

y Listen to your favorite songs

y Place your stressors if you can ( e.g. m a r r i a g e ,

divorce, changing a house or changing a job)

y Don’t compromise your values/beliefs

y Do regular physical andyoga exercises

y Do regular relaxation exercises like breathing and guide imagery

y Make time for recreation and take vacations

y Take active part in family matters and spend time with family

y Maintain a proper balanced diet. Avoid excessive smoking and alcohol consumption.

y 30 to 40 minutes of aerobic exercises daily helps provide relaxation

y Have adequate rest and sleep

y Periodical medical check-up, helps early detection and corrective action against stress related diseases

y The key word is Balance

y Maintian balance with a POSITIVE ATTITUDE to mange the Stress

y

G. Madhav Kumar Cluster EHS Manager,

Hyderabad



Questions on Heat Stress

1. What is the correct definition for the heat stress index? Select from the following:

A. The ratio of relative humidity to absolute humidity.

B. The ratio of wet bulb temperature to dry bulb temperature.

C. The ratio of the evaporative heat loss required to maintain body temperature to the maximum evaporative heat loss.

D. The ratio of the dew point to 50% relative humidity.

2. The transfer of heat directly to objects through fluids contacting the body is known as:

A. Acclimatization

B. Metabolic heat transfer

C. Radiation

D. Convection

3. What is the convection heat load for employees working in a 20 mph wind at 85 F?

A. Minus (-) 11440 BTU/HR

B. Minus (-) 576 BTU/HR

C. 1760 BTU/HR

D. 11440 BTU/HR

4. A 35 year old man is shovelling sand in a construction site during a hot summer day.

The man takes 10-minutes break every hour. What is the maximum heart rate for him, after resting for 1 minute, which will not indicate he is becoming overstressed?

A. 90 bpm (beats per minute)

B. 125 bpm

C. 145 bpm

D. 180 bpm

5. Calculate the estimated radiant heat load from surrounding objects with radiant temperature of 1010 F.

A. 90 cal/min

B. 90 cal/hour

C. 90 BTU/min

D. 90 BTU/hour

6. A man,during the early morning hours, when his house is relatively cold (during the winter months in North India), feels the cold wooden floor through his woollen socks, as he stands at his computer table checking e-mails.

What type of heat loss is the man experiencing through his feet?

A. Conductive

B. Convective

C. Evaporative

D. Radiant

7. Which of the terms below correctly defines the heat load placed on the human body?

A. Thermal strain

B. Heat syncope

C. Metabolic work rate

D. Thermal stress

8. What is the outdoor wet bulb globe temperature (WBGT) on a sunny day, when the wet bulb temperature (WBT) is 750F, the dry bulb temperature is (DBT) is 820 F, and the globe temperature (Globe Temperature) is 840 F? Choose from the following:

A. 75.00 F

B. 77.50 F

C. 77.70 F

D. 80.30 F

9. The psychrometric chart provides information on which of the following?

A. Water vapor pressure

B. Dry bulb temperature

C. Relative humidity

D. All of the above are referenced on the psychrometric chart.

10. In extremely cold weather conditions, as the body loses heat, particular core body temperature marks the beginning of a condition called hypothermia; what is that temperature?

A. 37 Celsius

B. 35 Celsius

C. 33 Celsius

D. 31 CelsiusTurn over leaf for answers

13HELMET Jan - Mar 2013Buildings & Factories


Answers for Heat Stress Q&A

1. The heat stress index is the evaporative heat loss required to maintain body temperature divided by the maximum available heat loss through evaporation. If the required evaporative heat loss to maintain the correct body temperature is more than the maximum available heat loss through evaporation (which depends mostly on the body’s ability to perspire)

The correct solution is C.

2. Acclimatization is the process of gradually getting used to a much warmer environment.

Metabolism generates heat internally in the body.

Some heat is transferred through radiant energy.

Convection is the transfer of heat through direct contact with fluids such as air or water.

The correct solution is D.

3. Convection = 0.65V0.6 (T-95) is the equation to be used;

Where,

V = air velocity (in fpm)

T= temperature (oF) in Fahrenheit

Air velocity is given as 20 miles per hour; this has to be converted to foot per minute (fpm)

20 mph = 20X5280/60 fpm (1 mile = 5280 feet; 1 hour = 60 min)

= 1760 fpm

Convection = 0.65 (1760)0.6(85-95) = - 576 BTU/HR

The correct solution is B.

4. A person is probably becoming overstressed when their sustained heart rate exceeds(180– their age).180 – 35 = 145 bpm (beats per minute)The correct solution is C.

5. Radiant heat load is calculated using the following equation:

R = 15(tw – 95)

Where,

R = radiant heat load (BTU/hour)

tw = radiant temperature of surrounding objects (F)

R = 15(101 – 95) = 90 BTU/hour

The correct solution is D.

6. Conduction is the heat transfer through solid objects.

Convection is the heat transfer through contact with moving fluids. When we are dealing with heat stress, the moving fluid is usually the atmospheric air.

Evaporation is the heat lost through water (sweat) evaporating from the skin.

Radiant heat transfer occurs through infrared radiation between objects.

The man feels the cold from direct contact between the woollen socks and the floor.

Hence the correct solution is A.

7. Thermal stress is the heat load placed on the body. This can also be called as heat stress.Thermal strain is the body’s response to thermal stress. Heat syncope is the reduction of blood to the brain.Hence the correct solution is D.

8. The WBGT under a solar load = 0.7WBT + 0.2GT + 0.1 DBT

WBGT = 0.7(75) + 0.2(84) + 0.1(82) = 77.5

The correct solution is B.

PS: For cloudy days, DBT is ignored in the equation; it would be revised as: WBGT = 0.7 WB + 0.3 GT

9. The psychrometric chart provides a graphical relationship for water vapor pressure, dry bulb temperature, wet bulb temperature, relative humidity, and dew point.

Hence the correct solution is D.

10. 37oC - normal oral temperature (core body temperature)35oC – Body starts shivering

33oC - Severe hypothermia sets-in, below this temperature

31oC – Person becomes unconsciousness, blood pressure is difficult to obtain, shivering stops

Hence, the correct solution is C.

M. Kamarajan Head - EHS, Buildings & Factories

Buildings & Factories14 HELMET Jan - Mar 2013


Operation of Mobile Cranes Near Energized Transmitters or Electric Power Lines

It is recognized that operating mobile cranes where they can become electrified from electric power lines and transmitter towers is an extremely hazardous practice. It is advisable to perform the work to ensure that there is no possibility of the crane, load line, or load becoming a conductive path.

Operating Near a Transmitter Tower

Before initiating work near a transmitter tower(e.g., radio, microwave), where an electrical charge can be induced in the equipment or materials being handled, the transmitter shall be de-energized or tests shall be made to determine if electrical charge is induced on the crane. If an electrical charge is induced and the transmitter cannot be de-energized, the following shall be done:

a. The equipment shall be provided with an electrical ground directly to the upper rotating structure supporting the boom.

b. Ground jumper cables shall be attached to the materials that are being handled.

c. Combustible and flammable materials shall be removed from the immediate area before operations.

Operating Near Electric Power Lines (See Figure 1)

Any overhead wire shall be considered to be an energized line unless and until the owner of the line or the electrical utility authorities indicate that it is not an energized line. Do not rely on the coverings of wires for protection.

The following four conditions must be considered when operating a mobile crane near electric power lines:

a. Power lines de-energized and grounded.

b. Power lines energized, crane operating less than the erected/fully extended boom length away.

c. Power lines energized, crane within prohibited zone.

d. Crane in transit, no load and boom lowered.

Crane Operation Near De-energized and Grounded Electric Power Lines

This describes the preferred condition under which the operation can be performed safely. The hazard of injury or death due to electrocution can been removed.


The following steps shall be taken to ensure that de-energization of the power lines has occurred:

a. The Power Company or owner of the power lines shall de-energize the lines.

b. The lines shall be visibly grounded to avoid electrical feedback and appropriately marked at the job-site location.



c. A qualified representative of the owner of the lines or a designated representative of the electrical utility shall be on site to verify that steps (a) and (b) have been completed and that the lines are not energized.

d. If cage-type boom guards, insulating links, or other proximity warning devices are used on cranes, such devices shall not be used as a substitute for requirements of ‘working near energized power lines’. If such devices are used, due to the lethal nature of electrical hazards and to lessen the potential of false security, the crane operator, crew, and load handling personnel shall receive instructions and have an understanding of:

(1) The electrical hazard involved,

(2) Operating conditions for the devices,

(3) Limitations of such devices, and

(4) Testing requirements prescribed by the device manufacturer.

Power lines energized, crane operating within the erected/ fully extended boom length of the prohibited zone (see Figure 2).

a. An on site meeting between project management and a qualified representative of the owner of the power lines or a designated representative of the electrical utility shall take place to establish the procedures to safely complete the operations.

b. The specified clearance between the power lines and the crane, load line, and load shall be maintained at all times as specified in Table 1 and shown in Figure 3.

c. Load control, when required, shall utilize tag lines of a non conductive type. (Are commended choice

a. When operating near high-voltage power lines

Normal voltage (phase to phase)

Minimum required Clearance

To 50 kV 10 ft (3.1 m)

Over 50 to 200 kV 15 ft (4.6 m)

Over 200 to 350 kV 20 ft (6.1 m)

Over 350 to 500 kV 25 ft (7.6 m)

Over 500 to 750 kV 35 ft (10.7 m)

Over 750 to 1000 kV 45 ft (13.7 m)


for a non conductive tag line is dry rope, made of polypropylene or polyethylene fibre.)

d. A qualified signaller, whose sole responsibility is to verify that the required clearance is maintained, shall be in constant contact with the crane operator.

e. No one shall be permitted to touch the crane or the load unless the signaller indicates it is safe to do so.

f. Operation of boom and load over electric power lines is extremely dangerous due to limited perception of distance and multiple contact points as viewed from the position of the operator and/or position of the signaller. The operator should avoid operating the crane,with or without a load, in this area.

g. The horizontal and vertical distance of movement of long span lines due to the wind shall be added to the minimum clearance distance as specified in Table 1. A qualified representative of the owner of the power lines or a designated representative of the electrical utility shall be consulted for specific distances.

h. A qualified person should attach devices such as ribbons, balls, etc., to the power lines to improve visibility, or equivalent means employed to aid in location of the Danger Zone.

i. If cage-type boom guards, insulating links, or other proximity warning devices are used on cranes, such devices shall not be used as a substitute for requirements of ‘working near energized power lines’. If such devices are used, due to the lethal nature of electrical hazards and to lessen the potential of false security, the crane operator, crew, and load handling personnel shall receive instructions and have an understanding of the following:

(1) The electrical hazard involved

(2) Operating conditions for the devices

(3) Limitations of such devices

Figure 1. Operating Cranes Near Electrical Power Lines Not Within a Boom Length of Prohibited Zone.



Table1. Safe Working Distance from Power Lines.

b. While in transit with no load and boom or mast lowered

Normal voltage (phase to phase)

Minimum required Clearance

To 0.75 kV 4 ft (1.2 m)

Over 0.75 to 50 kV 6 ft (1.8 m)

Over 50 to 345 kV 10 ft (3.1 m)

Over 345 to 700 kV 16 ft (4.9 m)

Over 750 to 1000 kV 20 ft (6.1 m)


Crane operations within the prohibited zone and the power lines are energized.

CAUTION: Working in the prohibited zone with power lines energized requires very disciplined and extraordinary safety precautions, including direct involvement and support from the electric utility organization.

a. Before such operations take place, a qualified person responsible for crane operations and a qualified representative of the utility or an engineer qualified in power line transmission, after visiting the site together, shall determine whether operating the crane within the Prohibited Zone is the most feasible way to complete the job. Both persons shall set minimum required clearances and procedures for safe operations. These operations shall be under their supervision. Before crane operations within the Prohibited Zone, the following may be required:

(1) Crane/load grounding to a neutral line by the utility.

(2) Electrical system protective devices that automatically re-energize the circuit after a power line contact occurrence blocked or disengaged to inhibit this function.

(3) Insulated barriers, which are neither a part of, nor an attachment to the crane and which will not allow contact between the energized electric power lines and the crane, load lines, or load.

(4) Non conductive barricades to restrict access to the crane work area.

b. Load control, when required, shall utilize tag lines of a non conductive type. (Are commended choice for a non conductive tag line is dry rope made of polypropylene or polyethylene fibre.)

c. A qualified signaller, whose sole responsibility is to verify that the established clearances are maintained, shall be in constant contact with the crane operator.

d. The person responsible for the operation shall alert and warn the crane operator and all persons working around or near the crane about hazard of electrocution or serious injury and instruct those persons on how to avoid the hazard.

e. All non-essential personnel shall be removed from the crane work area.

f. No one shall be permitted to touch the crane or the load unless the signaller indicates it is safe to do so.

g. If cage-type boom guards, insulating links, or other proximity warning devices are used on cranes, such devices shall not be used as a substitute for requirements for working near energized power lines. If such devices are used, due to the lethal nature of electrical hazards and to lessen the potential of false security, the crane operator, crew, and load handling personnel shall receive instructions and have an understanding of the following:

(1) The electrical hazard involved

(2) Operating conditions for the devices

(3) Limitations of such devices


Crane in transit with no load and boom lowered

a. Cranes in transit with no load and boom lowered shall maintain the minimum clearance as specified in Table 1(b).

b. If during transit, there is a reasonable possibility of getting near a power line, a persons hall be assigned to observe the clearance and give warning before the crane approaches the minimum required clearance. It is important that this person not be distracted or assigned other duties while observing power line clearance.

c. When planning transit of the crane, the effect of speed and terrain on the boom and crane movement shall be considered.

Reference: Chapter 14 of the Book DOE-RL-92-36, Hanford Site Hoisting and Rigging Manual



HOW DID WE MANAGE HSE PERFORMANCE? A Report from Airport Project, Salalah, Oman


Throughout the world, it is stated that HSE is not considered as “First Option” or ‘First Priority’ but as “Great Value” for every one and to every establishment.

This is not just a ‘buzzword’ but a reality at Salalah Airport Project-Oman and the entire team takes it as a pride in implementing the Best International HSE practices. Of course, this is no easy task, but the result of Planning, Perseverance & Commitment.

This includes but is not limited to:

¾ Health: well-maintained workmen camp facilities, mandatory HSE induction for everyone before entering the project.

¾ Welfare measures: rest shed at each location, dining room, first aid, cool drinking water, smoking booth, prayer room facilities, and site clinic managed by qualified doctors.

¾ Safety: approved method statement for every task and implementation, HSE awareness training,Strict Permit To Work (PTW) System, special permits for extended working beyond normal hours, holiday / night works

and compliance to the standards & legal requirements.

¾ Plant & Machinery: traffic and logistics management and emergency preparedness & mock drills.

¾ Environmental: monitoring on continuous air quality, noise / dust, FOD control and housekeeping are mandatory.

Project Features:

y L&T’s First International Airport Project, consortium with Larsen & Toubro, India and Galfar Engineering & Contracting SAOG, Oman

y The Passenger Terminal Building with a gross floor area of approximately 66,000 sq.m

y Capacity: Stage 1: Handling ONE million passengers per annum & Two Million at later stage

y The airfield consists of a 4 km long runway with CAT II approach and guidance system

y Project has 250 plus staff and 6500 work force.


HSE Induction training mandatory for all personnel to work in MC5

MC5 - HSE “ZERO TOLERANCE “POLICY

Subject Issue Action

Welfare None or insufficient provisions Stop the work

PPE None or insufficient protection Stop the work of that person (s)

Driving rulesNot using seat belt, excessive speed,

using mobile phone

Record, report to employer for formal disciplinary action.

Repeated offenders will be removed from the project

Identification cardPeople who cannot produce / refuse

to show photo ID

Remove them from the project (either permanently or until they

can comply)

Code of conduct Aggressive Behaviour Remove them from the project and

escalate the issue

External works (Such as road diversions)

Any unsafe practices observed Stop the work

Drugs and AlcoholAny person working under the

influenceRemove from the project

Permit to work system Deviation & Unsafe practice Stop the work


HSE Procedure

In addition to the Monthly/Spot Motivational schemes, we have strict disciplinary procedures. All HSE / Security and Traffic Violations are dealt within the coverage of agreed Disciplinary procedure/ Zero Tolerance Policy.

This policy is approved by Client Engineer, is distributed / disseminated to all the site personnel and the defaulters are dealt with accordingly. Any penalty payment received from these violators is used for the Promotional/Motivational activities.


Scaffolding Stairs (Separate Entry / Exit)

Test for Height Work

Safety Awareness and Refresher Training

y Every week one critical activity is selected to create awareness to all concerned (on the associated risk & related controls to contain the risks).

y Monthly drivers’ forum is conducted in which the traffic violations and disciplinary actions taken are discussed.

y Safe drivers are rewarded with gifts and appreciation.

HSE Appreciation for 10 Million Safe Man hours

Environmental controls:

y Dust Noise, Birds and Animal monitoring (Day and Night)

y Waste Management and control at site

y Consumption of water (Personnel use, Dust suppression and Site construction activities)

y Consumption of Fuel versus the Equipment’s / DGs run at site

y Equipment / DGs Emission check and control

y Consultant’s Monthly environmental report to contractor and Quarterly Environmental reporting to MECA (Ministry of Environment and Climatic Affairs)

This Airport Project is Unique in its HSE compliance and commitment, which has led us to over 23 Million Man Hours without any significant incident and the journey

continues…

V. Balaji Head-HSE


Special Permits - In line with OMAN Labour law and MC5 General Contract Requirements (GCR)

y Working time per day per person (maximum hrs.) = 12hrs (including overtime)

y To work beyond normal Hours (9 hours), extended work permit shall be obtained in advance

y To work on holiday, holiday work permit and

To work at night, night work permit is required.

All the permits need to be applied in advance and approved by contract HSE and Client Engineer. The approved copy is shared to all concerned and copies sent to security / Time office / Site clinic and HSE- for Man power & HSE management.


20 - TIPS to reduce Pollution

1. Go paperless, Save environment: Sure you can’t stop advertisement leaflets coming in to your mail box (shouldn’t there be an environmental law to ban this practice, or at least, be made mandatory to use recycled paper?) but, you can control the statements, updates and notices which you get from your financial institutions.

Select ‘paperless’ as the mode of communication. Most people support this. It’s high time that all govt. agencies implement this too.

2. Stop using bottled water: This may be very hard for many, I understand. If it’s not that hard for you, start using re-usable materials and fill it up every time.

3. Stop smoking: Smoking creates pollution inside of your body and for the people around you. Even after hours of smoking, your kids can be recipients of harmful effects of your nicotine consumption.

“The pollution caused by cigarettes does not stop in our bodies or the air around us; it also affects the land we live on and the water that we drink. Millions of cigarette butts are discarded on to the ground every day“.

4. Use less electricity: There are various options to save on electricity. The easiest of all is to use a fan instead of an AC, if you can. Air drying clothes, letting sunlight come inside the home during winter and blocking it during summer are other easy options to try out at your home.

5. Use less gas: Bike to work, car-pooling are the easier options you can try. There are various other effective line.

6. Recycle: Don’t just throw your old electronics and batteries to trash. Make use of local free recycling facilities. Dispose your plastic containers as well by separating them out from normal trash.

7. Use reusable shopping bags: They are made of cloth and need cleaning once a week. This helps in eliminating a lot of plastics from our life.

8. Buy fresh local produce: Whenever you have option to buy from farmer’s market or local grocers, give it a preference. Processed goods take a lot of energy, first for processing part and later, the fuel consumption involved in transportation.

9. Save water: Sweet water is a scarce resource and it’s being depleted at a greater pace than earth is replenishing it. There are various ways to save water in everyday use from fixing leaky outlets to adjusting the timers on sprinklers.

10. Use emails and e-Greetings: Unless you are already using it, what’s preventing you from going ‘e’ route? Apart from being environment friendly, it also reduces effort required to pass your message across.

11. Use ceramic cups: Instead of plastic, paper or Styrofoam, the ceramic cups can be used over and over. This reduces the impact on the environment and on your budget.

12. Print less: Unless it’s absolutely necessary to print, refrain

from doing so. When you do have to print, consider printing on both sides of the paper.

13. Refuse receipts: I understand this is just a small savings of paper use here, but every little bit helps! Use credit/debit card to pay at the stores and decline the printing of the receipt. Your purchase is documented in your statements any way. If required for taxes, you can easily access the information.

14. Reuse and re-purpose: Whenever possible, re-use the containers, cartons and envelops. Oh, your tooth-brush as well! For cleaning sports shoes

15. Use energy-efficient bulbs: In the long run they save a lot of money and energy. Best are the LED bulbs, even fluorescent light bulbs consume 1/3rd (or lesser) of the energy of incandescent light bulbs.

16. Use clothes more than paper: Reduce paper usage by using cloths to wipe your hands or the things you normally wipe with paper towels.

17. Use microwave: Numerous dishes can be cooked in microwave. Use microwave more often to reduce your carbon footprints.

18. Leak proof your home: Ensure you are not losing warmth or cool through leakages, by having your home properly insulated and window and door seals checked. By doing so, you are saving energy and money.

19. Replace air filters: AC air filters for your home and car, if replaced regularly, can save a lot of energy which in turn can save you money.

20. Consume less: This is for your financial good as well. Live simple, use your furniture and clothes until they can’t be used any more. If possible, check out used items on Craigslist or garage sales.

Hemant Kadu

Cluster EHS Manager, Mumbai Cluster - RB&F



“It happened – it can happen – Prevent it”

Waiting for you

What happened?

An accident occurred while shifting of concrete slabs from ground level to the roof of a building (around 10 meters high). While lifting the concrete precast slabs of “unknown weight” using the mobile crane, the boom of the crane collapsed.

What went wrong?

y Lifting overload without assessing the weight and the associated risks.

y Pre-lift planning was not carried out.

y Lack of effective supervision.

How to prevent it

y Proper planning to be done prior to any lifting activity.

y Risk assessment must be carried out to identify the hazards and assess the risk before starting of the activity.

y Qualified and competent supervisor shall be assigned for all construction work, especially while dealing with critical lifting and working at height.

y Crane must be inspected for its fitness.

y Only trained workmen shall be engaged for lifting tasks.

y Proper communication to be made between crane operator and rigger team during lifting operation.

y Ensure adequate awareness (Pep talk) to all involved in lifting activity and ensure their capability to handle the required task.

Disclaimer: Accident details published in this magazine are collected from friendly sources, and being circulated with the only objective of learning from the incidents and to take preventive action. This does not represent incidents from any particular organization/site.

Hello Friends

Say, No more accidents.

Your Family is waiting for you,

Be Safe on your work and think of their view.

Smash out the shortcut

By your footstep

Tell the workmen

On your daily Pep.

Implement the Safety

On every of your work,

‘Tied-up’ with the System

To eliminate the dark.

It is indispensable

To live with your kin,

Arranging of food

To survive their being.Indrajit Sengupta

EHS Manager, ITC – Sonar Project

It is essential

Be Healthy and secure

Make friends with environment

Or you will be no more.

No one should allow

To misguide your act.

For the Sake of progress

To do deceiving act.

Be smart of your job

No ‘By-mistake’ any blunder

Make even, all the odds

Stop evils of the Clanger.

Buildings & Factories22 HELMET Jan - Mar 2013


Construction Safety Training Programme

DateName / Subject of the Training Programme

Faculty Coordinator Duration (days/hours)

No. of Praticipants

Location

10-11, Jan 2013 Construction Safety Program Mr. Shailesh A Patel, CEHSM, ABCL 2 19 Ahmedabad

24-25, Jan 2013 Construction Safety Program Mr. Shailesh A Patel, CEHSM, ABCL 2 32 Ahmedabad

15-16, Feb 2013 Construction Safety Program Mr. Shailesh A Patel, CEHSM, ABCL 2 29 Ahmedabad

02-03, Mar 2013 Construction Safety Program Mr. Shailesh A Patel, CEHSM, ABCL 2 26 Ahmedabad



21-22, Feb 2013 Construction Safety Program Dr. Sanjai Srivastava, CEHSM, BLCL 2 18 Bangalore

12-13, Mar 2013 Construction Safety Program Dr. Sanjai Srivastava, CEHSM, BLCL 2 18 Bangalore

12-13, Feb 2013 Construction Safety Program Mr. R.V. Sudhakar, CEHSM, CNCL 2 25 Chennai

13-14, Feb 2013 Construction Safety ProgramMr. Kumud Kumar Jha, Cluster EHS Manager, Delhi

2 35 Delhi

12-13, Mar 2013 Construction Safety ProgramMr. Kumud Kumar Jha, Cluster EHS Manager, Delhi

2 26 Delhi

18-19, Jan 2013 Construction Safety Program Mr. G Madhav Kumar, CEHSM, HYCL 2 25 Hyderabad

5-6, Mar 2013 Construction Safety Program Mr. G Madhav Kumar, CEHSM, HYCL 2 28 Hyderabad

17-18, Jan 2013 Construction Safety Program Mr. Sujit Saha, CEHSM, KKCL 2 19 Kolkata

15-16, Mar 2013 Construction Safety Program Mr. Sujit Saha, CEHSM, KKCL 2 25 Kolkata

13-14, Feb 2013 Construction Safety ProgramMr. Hemant Kadu, CEHSM, MBCL RB&F & Mr. V. Bhavani Shankar, CEHSM, MBCL - CB&A

2 33 Mumbai

7-8, Mar 2013 Construction Safety ProgramMr. Hemant Kadu, CEHSM, MBCL RB&F & Mr. V. Bhavani Shankar, CEHSM, MBCL - CB&A

2 32 Mumbai


2 36 Mumbai


2 24 Mumbai

13-14, Feb 2013 Construction Safety Program Mr. Josy John, Head EHS - MIAL Project 2 36 Mumbai Internal Airport Project

21-22, Feb 2013 Construction Safety Program Mr. Josy John, Head EHS - MIAL Project 2 28 Mumbai Internal Airport Project

28th Feb & 1st Mar 2013

Construction Safety Program Mr. Josy John, Head EHS - MIAL Project 2 37 Mumbai Internal Airport Project

2-3, Mar 2013 Construction Safety Program Mr. Josy John, Head EHS - MIAL Project 2 27 Mumbai Internal Airport Project




11-14, Feb 2013 Certified Scaffold TrainingMr. K.N. Sen, Head HSE, HCP & Mr. P.K. Singh, HSE Manager, HCP

4 32 Delhi

TRAINING PROGRAMMESSafety



Load Testing of Gantry CranesA gantry crane is particularly well suited for lifting and moving heavy objects in limited work area like PC yard and fabrication yard. We do use many gantry cranes with varying capacities ranging from 10 ton to 120 tons at our operations. Most of the incidents involving gantry cranes such as toppling, derailment,collision and overrun can be avoided by ensuring the fitness of the crane and track through pre-deployment, periodical inspections and strictly adhering to safe operating procedures.

Load testing of Gantry crane is therefore a critical requirement to ensure the fitness of crane. Load test shall be carried out as per the guidelines given below:

y All the gantry cranes shall be load tested during any of the below mentioned situations whichever occurs earlier:

¾ New Gantry Crane installation at site

¾ Relocation from one site to another site

¾ Working at a site for 12 months

y After installation and before commissioning, Gantry cranes shall not be used for any other activity without load testing other than for handling / arranging the loads for load testing.

y Load testing to be carried out at 110% of rated capacity of the crane.

y Tandem load testing to be carried out only if the job requirement is such that two cranes need to be used at the same time. In all other cases, the load testing to be carried out only for individual crane.

y Deflection to be checked with reference to the piano wire tied to both ends of the girder.

y Test to be conducted as per latest guidelines of IS807 and

IS3177 standards. Maximum deflection to be measured at rated load only. The maximum allowed deflection is 1/750th of span when measured in mm.

y Load to be kept in suspended condition for 10 minutes before checking the deflection in the center of the main girder.

y Load testing to be carried out with known weights, with pre-cast elements and additional concrete blocks cast for this purpose. Preferably, weights to be painted on loads for future references and to have a better clarity.

y During load testing, lifting hook to be kept at the center of the transverse travel on the main girder and load to be cleared from ground for about one feet.

y After the measurement of deflection at the rated capacity, the overloading of 10% to be added, further load testing to check the structural stability and to compensate possible jerk loads.

y With the complete load (i.e, with 10% extra load) crane needs to be marched for about a distance of 5 metres to check the stability of structures and long travel brakes.

y Record of deflection and tested procedure to be maintained immediately after completion of the testing.

y The complete load testing to be witnessed by P&M in-charge, EHS in-charge, Precast Yard in-charge and a third party competent authority.

Certificate of test should also be taken from the third party competent person (third party) as per the statutory requirements.

S.Sathyanarayana Head - EHS, Infrastructure IC

24 HELMET Jan - Mar 2013 Infrastructure


Kakrapar Atomic Power Project Million Safe Man Hours, February 2010 to

March 2013

Nashik Elevated Corridor Project Million Safe Man Hours, January 2010 to

March 2013

Beawar - Pali - Pindwara Road Project Million Safe Man Hours, December 2011 to

March 2013

Tapovan Vishnugad Hydel Project Million Safe Man Hours, May 2010 to

March 2013

Singoli Bhatwari Hydel Project Million Safe Man Hours, June 2011 to

March 2013

Krishnagiri Walaja Road Project Million Safe Man Hours, December 2011 to

March 2013

Vizag Vessels Project Million Safe Man Hours, November 2011 to

March 2013

Subansiri Hydel Project Million Safe Man Hours, May 2011 to

March 2013

DMRC – CMC1 Project Million Safe Man Hours, July 2010 to

March 2013

Kandla Mundra Road Project Million Safe Man Hours, April 2011 to

March 2013

27

16

10

8

Mumbai Mono Rail Project Million Safe Man Hours, September 2012 to

March 2013

Badarpur Faridabad DMRC Million Safe Man Hours, February 2012 to

March 2013

Bharuch Dahej RC Project Million Safe Man Hours, June 2009 to

March 2013

Panskura - Kharagpur RC Project Million Safe Man Hours, September 2009 to

March 2013

Ganjbasoda Sanchi RC Project Million Safe Man Hours, March 2010 to

March 2013

Hosurkrishnagiri Road Project Million Safe Man Hours, April 2012 to

March 2013

Chennai Metro-UG Million Safe Man Hours, August 2012 to

March 2013

DMRC CC-17 Project Million Safe Man Hours, August 2012 to

March 2013

DMRC CC-05 Project Million Safe Man Hours, January 2012 to

March 2013

10 MTPA Rail Siding, TATA JSR Project Million Safe Man Hours, July 2009 to

March 2013

5

5

4

4

8

8

7

6

6

5

4

4

4

3

3

3



SafetyRoll o

f Honour

25HELMET Jan - Mar 2013Infrastructure


APPRECIATION

• Best Safety Contractor Award for the year of 2012 – 2013 presented by Mr. Lokesh Kumar, Project Director (NPCIL) received by Mr.I.Chandran (Project Director,M/s L&T), Mr.Pradeep Khare (Project Manager, Main Plant), Mr.R.Sudharsan (EHS-In Charge, M/s L&T), & Mr.J.Dhinesh (Asst Manager - EHS, Main Plant).

• Best Housekeeping Contractor Award for the year of 2012 – 2013 presented by Mr. Lokesh Kumar, Project Director (NPCIL) received by Mr.M.Kannan (Project Manager, CSP), Mr.R.Sudharsan (EHS-In Charge, M/s L&T) and Team Members.

Kakrapar Atomic Power Project

Construction Safety

Road Safety WeekRoad Safety Week (1st to 7th Jan 2013) was celebrated across all projects by organizing awareness programs for employees as well as road users. Few glimpses of the event are given below.

Infrastructure


Two Days EHS Training


To raise EHS awareness among execution staff, two

day training programmes on “Construction EHS

Requirements” for Line management were organized

at different locations. Participants were exposed to

topics like EHS management system, P&M safety,

Fire prevention, Material handling, Excavation,

Work at height, Formwork, Electrical safety, Traffic

management, Environment requirements, Welding,

Grinding and Case studies.

Sl No. Location Date

1.Kolkata Cluster Office

30th & 31st January 2013

2.Delhi Agra Road Project-I

13th - 14th February 2013

3.Delhi Agra Road Project-II

22nd - 23rd February 2013

4. Delhi Cluster Office 26th & 27th February 2013

5. Mumbai Monorail 25th & 26th March 2013

Kolkata Cluster Office

Infrastructure


BBS Training

4-Day Orientation Program for the New Joinees

Behaviour Based Safety (BBS) workshops were organized

various areas to develop Mentors of Behaviour Based

Safety (MBBS) for working towards enhancing the

safety culture. These programs were organized through

expert faculty Dr. H.L. Kaila, Professor of Psychology, BBS

Trainer & Implementer.

An exclusive 4-day orientation program for the new joinees in EHS department was organized from

25th to 28th Feb ’13 at HQ Chennai. The program was aimed at familiarizing the participants with

the EHS management system elements and key technical areas including Plant & Machinery, Material

handling, etc.

SI No. Project Name Date

1. Kakrapar Project 25th Feb 2013

2. Delhi Cluster 14th & 15th March 2013

3. Lata Tapovan 18th & 19th March'1325th Feb 2013 @ Kakrapar Project

Delhi 14th & 15th March

Infrastructure


Competency Certificates Training Programme for Operators & Riggers

Online Health Card at Vizag Vessels project

With a view to have better tracking of the health

monitoring data of workers, online system was launched

at Vizag Vessels project that records and assists in

monitoring of critical health details of all workers

depending on the trade / activity. The online health

card, maintained through intranet portal, contains the

following vital health information pertaining to personal

health factors (B.P, Sugar, Vision, Pulmonary functioning,

chest radiography etc.), health ailments, family health

details, details of injuries (if any).

To increase EHS awareness among Operators and

Riggers, four day “COMPETENCY CERTIFICATION

TRAINING PROGRAM” for crane operators & Riggers

were organized at different locations through

External Agency. Participants were exposed to safe

operating process for operator, rigger safety, group

discussion and onsite practical training.

Sl No.

Site Name

Date External Agency

1.DMRC Project

18.02.13 to 21.02.13 M/S. Labour Net

2. HMRL 06.02.13 to 09.02.13 M/S. Labour Net

3. HMRL 27.02.13 to 02.03.13 M/S. Labour Net

DMRC

Infrastructure


In industries, Power Transformers are used for distributing electrical power to the shops and mills. One power transformer may not be sufficient to distribute power as per the load. Therefore, two transformers of same rating (Ex:1.6MVA for both the Transformers) are made parallel / synchronized to distribute the required Power to the consumers. During the parallel operation / synchronization of the Power Transformers, many fatalities have occurred in the past due to non-adherence of the conditions for synchronization. After the procurement of the Power Transformers they need to be checked for all the parameters mentioned in the brochure that accompanies the equipment.

The following conditions need to be ensured before connecting both the transformers to the power supply source:

1. V – Secondary terminal voltages should be same.

2. I – Percentage impedance must be same.

3. P – Polarities must be same.

4. S – Phase sequence must be same.

5. Group – The vector groups must be same.

Generally, the first four parameters (i.e. V, I, P and S) are ensured, but the vector groups are overlooked. The vector group plays a vital role for safe synchronization.

Example: The following diagrams indicate the phase angles of the transformers considering the example of clock.

Transformers-1 Transformer-2

DY4 DY11

*[D-Delta (Primary), Y-Star (Secondary)]

Since there is a phase angle difference of 210° and if the phases of transformer-1 is connected with the corresponding phases of transformer-2 with a phase angle difference of 210° there will be a huge flashover causing death to the people working nearby with damage to both the transformers. Therefore, attention is to be given during the synchronizing of power transformers for the above five conditions.

R.N.TripathyHead – EHS, MMH IC

Safe Synchronization of Power Transformers

Metallurgical & Material Handling30 HELMET Jan - Mar 2013




Vizag Steel Plant Expansion Project - BF # 3 Million Safe Man Hours, April 2009 to March 2013

Mahan Aluminum Plant (HINDALCO) - Singrauli Million Safe Man Hours, December 2010 to March 2013

UAIL – Rayagada Million Safe Man Hours, July 2011 to March 2013

Dhamra Port Project Million Safe Man Hours, April 2007 to March 2013

Wheel Manufacturing plant at Chhapra Million Safe Man Hours, February 2009 to March 2013

Can Mill Project Hirakud Site Million Safe Man Hours, July 2010 to March 2013

Coal Handling plant for NTPC - Barh Million Safe Man Hours, August 2006 to March 2013

SAIL-Burnpur Site Million Safe Man Hours, February 2010 to March 2013

Bhushan Steel Limited Site - Angul (M&M) Million Safe Man Hours, January 2013 to March 2013

Coal Handling plant, DVC – Koderma Million Safe Man Hours, March 2008 to March 2013

CHP-Mahan (HINDALCO), Singrauli Million Safe Man Hours, January 2011 to March 2013

NTPC – Simhadri (Vizag) Coal Handling Plant Million Safe Man Hours, May 2009 to March 2013

Civil and Structural works for BALCO, Korba Million Safe Man Hours, November 2011 to March 2013

NLC Thermal Plant Site, Tuticorin Million Safe Man Hours, September 2009 to March 2013

Engineering Workshop Limited, Kanchipuram Million Safe Man Hours, September 2011 to March 2013

JSW - Bellary Site Million Safe Man Hours, March 2012 to March 2013

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Bhilai Steel Plant Expansion Project - BF # 8 Million Safe Man Hours, August 2010 to March 2013

Coal Handling plant, Rajpura Million Safe Man Hours, December 2010 to March 2013

DCPM Project, Joda Million Safe Man Hours, June 2011 to March 2013

Aditya Alumina Lapanga Million Safe Man Hours, April 2011 to March 2013

Coal Handling plant, Amlohri Million Safe Man Hours, February 2012 to March 2013

Bhilai Steel Plant Expansion Project - SP # 3 Million Safe Man Hours, August 2010 to March 2013

JSPL Angul Million Safe Man Hours, August 2010 to March 2013

NTPC- Barh, Phase-II Million Safe Man Hours, August 2010 to March 2013

RMHS Project, TATA Steel Jamshedpur Million Safe Man Hours, June 2012 to March 2013

Pot Super Structure (HINDALCO), Mahan, Singrauli Million Safe Man Hours, March 2010 to March 2013

HZL (Roaster-V), Dariba Million Safe Man Hours, July 2011 to March 2013

DB Power CHP Project, Raigarh Million Safe Man Hours, December 2010 to March 2013

SSTPPL CHP Project, Khandwa Million Safe Man Hours, September 2012 to March 2013

EOL Project, Noamundi Million Safe Man Hours, January 2012 to March 2013

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Metallurgical & Material Handling 31HELMET Jan - Mar 2013


APPRECIATION • BALCO Korba site has received a certificate of appreciation from the client for their safe completion

of casting of corbels in 80 m tall stack chimney.

• ANNUAL EHS ROLLING TROPHY 2011-12 FOR HIL (Mahan) HIL Mahan site won “ANNUAL EHS ROLLING TROPHY 2011-12” In Safest Major Jobsite Category

• GMR CHP Project site, Raipur – MMH IC Hyderabad Cluster received the “GCEL Best Safety Performance Award 2012-2013” from the Client for its best Safety practices in the site during 42nd National Safety Day / Week (from 4th Mar’13 to 9th Mar’13).

• CHP GMR Team participated in various competitions during Client‘s Safety Week and Won the Best position in five categories among all agencies. 1. Safety poster -1st, 2. Safety Quiz - 1st, 3. Safety Extempore - 1st, 4. Safety Model - 2nd 5. Safety Nukkad Natak - 2nd

• Dhamra Port site - Mr. S.Ganguly & his team receiving the Best Safety Implementation Agency award from Mr. P. Sinha, VP – DPCL.

• Best Safety Concious Agency Awards received during 42nd National Safety week from client- Utkal Alumina, Rayagada

• UAIL Rayagada site has received a certificate of appreciation from the client for awarded the “Best Safety Conscious Agency” during the national Safety Week 2013.

• Dr. Vinod Nowal (Director & CEO), M/s JSW Steel Limited presenting award to Mr. R. Umasathiyan, Project Manager(L&T) for Excellency for Best Safety Practices at JSW Steel Limited, Bellary for the year 2012 on the occasion of 42nd National Safety Day.

• The award “Best Safety Conscious Agency Award for 2012-13” was presented during a glittering function on 4th March 2013 by Mr. R.D. Nirala, Fire & Safety Officer (Chief Guest) of Bajaj Power Generation Company Limited, Lalitpur District to Mr V.M.Maba Project Manager, CHP Lalitpur Site.

• Award for L&T-Smelter team on 42nd National safety Day Celebrated by AAP-Lapanga

• CHP Amravati site has received a certificate of appreciation from the client for achieving 2.107 Million safe Man-hours from 25th December 2010 to 02nd February 2013.

Metallurgical & Material Handling



A two day “EHS in Construction” training programme was conducted at CHP Lalitpur site during March 14-15. The programme was inaugurated by Mr.V.M Baba. Around 13 staff participated in the programme. Mr. Indranil Chakraborty (Cluster EHS Manager) Mr. P.K.Bhattacharjee (Cluster QMS Head) & Mr. M.Indu (Site EHS Incharge) were the faculty members for this program.

Safety Observation & Safety contact, training program was conducted at Bhushan Steel Project, Angul of MMH IC. The programme commenced with the administration of safety pledge. A total of 32 senior staff participated in the programme and committed to work towards the transformation of the safety culture by adopting proactive steps to ensure incident and injury free workplace. Mr.C.K.Sahoo (EHS Incharge – BSL Angul site) was the faculty member for this program.

2 Day Inhouse Safety in Construction Training program

Project Suraksha Jeet



Aditya Aluminium plant- Lapanga celebrated 42nd National Safety Day on 4th March 2013 On this occasion, L&T Smelter team has participated with two beautiful working models of Alumina storage Silo. Keeping in view of the gigantic storage Silos of 34 meter dia. and 45 meter height what we have already constructed at APP-Lapanga site, displaying the sequential Slip Form works as well as the 300 t single lift of roof Girder Erection.

The occasion was graced by Mr. B.B.Jha – Head- CPPC, Mr. B.P.Mishra – President and COO, Mr. A.Chugh – Sr. VP and Head Smelter, Mr. S.K.Guru - Sr. VP and Head CPP along with other dignitaries of AAP and dignitaries of all other agencies working at AAP project. During the demonstration, all safety aspects, followed during the execution of civil as well as structural roof girder, had been shown in the two working models. Among all other companies working at AAP-Lapanga, L&T Smelter team has won the award for Best safety model exhibition.

Safety Exhibition organized at GMR-CHP Raipur site, Mr. V.P.Singh – Head BMH - Power BU visiting

the exhibition

Safety Exhibition at BALCO – KORBA project site

Construction Safety

Model exhibition by L&T –Smelter at AAP-Lapanga site



Road safety

Road safety campaign at AAP-Lapanga site

Road safety campaign at JSPL Angul site

L&T(Smelter) of AAP- Lapanga site has organized a Campaign on “24th Road Safety week” on 07.01.2013. Mr. B.P. Mishra, President & COO of HIL has inaugurated the programme with other dignities of HIL in presence of PM Mr. K.K.Bhattacharya, senior staffs, Staffs & Workmen.

In this campaign all the drivers and operators were taught to follow the guide-lines of road safety. Every one of them were given driving guideline card in this awareness programme.

The campaign was very much successful when Mr. B.P. Mishra, President & COO-HIL joined hands in this campaign and expressed his happiness for the initiative taken from L&T Smelter team.

JSPL Angul site celebrated 24th National Road Safety Week from 1st January-2013 to 7th January-2013. The event was inaugurated by Mr .Hare Ram (Project Manager JSPL – Angul Site). The awareness programme started with the Road Safety Rally participated by all Staff members and workmen.



Safety vs. Productivity: Friend or FOE?

Friends of productivity can be the foes of safety and it reminds them to put Safety First. There are five foes of Safety, such as, Focus, Fatigue, Familiarity and Faulty Communication. In order to achieve high levels of Safety, Quality and Productivity, workers must have a conducive working environment.

The 5S Method of Improvement - Enhancing Safety, Productivity and Culture:

5S is a foundation for disciplined actions. It builds a culture of continuous improvement.

5S consists of:

y Sorting :- Sorting the activities aim to eliminate unnecessary items from the work area and to perform an initial cleaning.

y Simplifying:- This involves simplifying the arrangements in its place, keep it clean and ready for use.

y Systematic Cleaning:- Systematic cleaning and inspection of work areas and equipment help in understanding current conditions and determine if corrective action is required.

y Standardizing:- Developing common methods for consistency.

y Sustaining:- Sustaining is aimed at maintaining the improvements of 5S.

The benefits of 5S are:

y Neat and Clean Workplace:- When a work area is clean and organized, tripping hazards and other dangers are eliminated.

y Improves self-discipline:- The 5S system, especially its visual nature, makes abnormal conditions noticeable and makes ignoring standards more difficult.

y Improves culture:- It fosters better teamwork and enthusiasm

y Less wasted time:- When tools and materials are accessible and orderly, workers need less time

to access the same and no time is wasted on searching the items.

y Less space:- When unneeded items are eliminated and the needed ones are organized, required floor space is dramatically reduced.

y Improves:- Improves and increases smooth working, safety and productivity.

A clean and tidy workplace leads to greater well-being, increased motivation and enhances the company’s image. People like to work in a well-organized and clean environment. They feel better about themselves, better about their work, and they restore the self-discipline that is found in winning teams. Although 5S will not solve today’s competitive challenges, it does provide a solid foundation for achieving operational excellence. The teamwork and discipline built through 5S also improves worker-to-worker and worker-to-manager relationships.

A safety program won’t survive without accountability and ownership within the organization. In a successful safety culture, everyone is a stakeholder.

Kumar Shailendra Head-EHS

Power Transmission & Distribution (Domestic)

Power Transmission & Distribution

SAFETY FIRST


37HELMET Jan - Mar 2013Power Transmission & Distribution


ONE Million and more LTI Free Safe Man-Hours

MVPDS & SCADA, SAIL-RSP

Million Safe Man Hours, Apr 2010 to Mar 2013

RHhE Project in North 24 Parganas

Million Safe Man Hours, Feb 2011 to Feb 2013

765 kV Dharamjaygarh SS

Million Safe Man Hours, Jul 2011 to Jan 2013

220KV M/C & 132KV D/C HOWRAH- TL

Million Safe Man Hours, Jan 2012 to Dec 2012

3600 MW SEPCO Power Plant, Nariyara

Million Safe Man Hours, Mar-11- Mar-13

2 X 600 MW ebop DB Power Plant, Bharadhara

Million Safe Man Hours, Jan-11- Jan-13

400 KV Quad / Twin GCEL Transmission Line

Million Safe Man Hours, Oct-11- Jan-13

400 KV D/C (Quad / Twin) TL at Tamnar - JSPL

Million Safe Man Hours, Jan-12- Feb-13

Goa UG Cabling

Million Safe Man Hours, April- 10 to April 2012

765 Wardha Aurangabad TL

Million Safe Man Hours, Jan-12 to Feb 2013

Reliance – Sasan Power Limited

Million Safe Man Hours, March-12 to

March 2013

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Safety Month Exhibition

IE- Projects, RSP-SAIL, Rourkela

HWHTL-Project, Howrah, WB

IE- Projects, RSP-SAIL, Rourkela.

IE-UAIL Project, Raygada

HWHTL-Project, Howrah, WB

IE-UAIL Project, Raygada


APPRECIATION • Mr. Ramya has won 1st prize in Safety quiz competition during national Safety week 2013. He was

awarded from Client Utkal Alumina International Limited.

• Safety Performance Excellence from Jindal Power Limited 4X600 MW project during 42nd National Safety Week Celebration

• Mounda Super Thermal Power Project EHSO Mr. Partha Kumar Poddar was appreciated by

helmet - l&t construction .pdf · murali krishnan | p.v. kaliappan v. balaji | s. anantha prasanna...

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