Burmeister & Wain Scandinavian Contractor A/S Health and ... · PDF fileManual Doc....
Transcript of Burmeister & Wain Scandinavian Contractor A/S Health and ... · PDF fileManual Doc....
Burmeister & Wain Scandinavian Contractor A/S
Health and
Safety Manual Doc. 6000.QH.001.001
Health & Safety Manual
Part 1 General Safety Program
Chapter 01 How to use the Health and Safety Manual
Chapter 02 BWSC H&S Policy
Chapter 03 Safety Organization
Chapter 04 General Safety Requirements
Chapter 05 Site Layout
Chapter 06 Safety Induction and Site Rules
Chapter 07 Safety Meetings
Chapter 08 Site Safety Inspections
Chapter 09 Incident Reporting
Chapter 10 Emergency Procedures
Part 2 Specific Safety Instructions
Chapter 01 Common Activities
Chapter 02 Civil Works
Chapter 03 Mechanical Erection
Chapter 04 Electrical Erection
Chapter 05 Test & Commissioning
Chapter 06 Switching of LV, MV and HV switchgear
Chapter 07 Steam Systems
Appendices
Revision history:
2 18.02.2014 Manual used to project specific – it is now applicable for BWSC. Updated from revision 1 in its entirety. Main changes to part 1: Mandatory use of safety glasses and gloves, revised list of ‘site safety rules’, new incident report form, risk matrix. Main changes to part 2: new chapter ‘yellow rules for switchgear’, new chapter on steam. Update of some illustrations. Part 3 (generic risk assessments) removed.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of contents
3
Table of Contents 1 The Health and Safety Manual ........................................................................................................... 6
1.1 Scope of manual .............................................................................................................................. 6
1.2 How to use the Health and Safety Manual ............................................................................ 6
1.2.1 Access to the Health and Safety Manual ....................................................................... 7
1.2.2 Hierarchy of manuals ............................................................................................................ 7
2 BWSC quality, health, safety and environment (QHSE) policy ............................................. 8
3 Safety Organisation ............................................................................................................................... 9
3.1 BWSC Safety Organisation .......................................................................................................... 9
3.1.1 Typical Site Safety Organisation ..................................................................................... 10
3.2 The Safety Board .......................................................................................................................... 11
3.3 Responsibilities .............................................................................................................................. 11
3.3.1 Site Manager (Site Safety Officer) ................................................................................. 11
3.3.2 Supervisors (Safety Deputy) ............................................................................................ 12
3.3.3 Temporary Works Co-ordinator ....................................................................................... 12
3.3.4 Contractors .............................................................................................................................. 12
3.3.5 Workmen/Operatives ........................................................................................................... 13
3.4 Training and qualifications of personnel .............................................................................. 13
4 General Safety Requirements .......................................................................................................... 14
4.1 Construction, commissioning and semi-operation phases ............................................ 14
4.2 Transfer from construction to commissioning ................................................................... 14
4.3 Transfer from commissioning to operations ....................................................................... 15
4.4 Alcoholic beverage and drugs .................................................................................................. 15
4.5 Language difficulties .................................................................................................................... 15
5 Site Layout .............................................................................................................................................. 16
5.1 Purpose and contents .................................................................................................................. 16
5.1.2 Existing installations and site conditions ..................................................................... 16
5.1.3 BWSC temporary site installations ................................................................................. 16
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of contents
4
5.1.4 Traffic plan information ...................................................................................................... 16
6 Safety Induction and Site Rules ...................................................................................................... 18
6.1 Site safety induction .................................................................................................................... 18
6.2 General Site Rules ........................................................................................................................ 18
6.2 Fifteen fundamental safety rules ............................................................................................ 19
6.3 Health Information ....................................................................................................................... 19
7 Safety Meetings ..................................................................................................................................... 20
7.1 BWSC Safety Meetings ............................................................................................................... 20
7.2 Toolbox talks................................................................................................................................... 21
7.3 Other safety meetings ................................................................................................................ 21
8 Site Safety Inspections ....................................................................................................................... 22
8.1 Daily safety monitoring .............................................................................................................. 22
8.2 Formalised safety inspection .................................................................................................... 22
8.3 Work in shifts.................................................................................................................................. 23
8.4 Reporting from safety inspections .......................................................................................... 23
9 Incident Reporting ................................................................................................................................ 24
9.1 Reporting of incidents (injury, illness, dangerous occurrence) .................................. 24
9.1.1 Principles .................................................................................................................................. 24
9.1.2 Injuries ...................................................................................................................................... 24
9.1.3 Dangerous occurrences ...................................................................................................... 24
9.1.4 Potential severity .................................................................................................................. 24
9.2 Distribution of incident reports ................................................................................................ 25
9.3 Reporting to the local authorities ........................................................................................... 26
9.4 Incident statistics /Lost Time Injury Frequency ............................................................... 26
9.5 incident Summary Sheet ........................................................................................................... 26
9.6 Risk Matrix ....................................................................................................................................... 27
9.7 Dropped objects ............................................................................................................................ 27
10 Emergency Procedures ..................................................................................................................... 28
10.1 Emergency response plan ....................................................................................................... 28
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of contents
5
10.2 Certified emergency responders (First Aiders) ............................................................... 29
10.3 First aid equipment .................................................................................................................... 29
10.4 First aid response ....................................................................................................................... 29
10.5 Electrical accidents .................................................................................................................... 30
10.6 Burns ............................................................................................................................................... 30
10.7 Acid burns ..................................................................................................................................... 30
10.8 Poisoning........................................................................................................................................ 30
10.9 Accidents involving the back and the neck ...................................................................... 31
10.10 Fire protection and prevention ........................................................................................... 31
10.10.1 Fire evacuation plan ........................................................................................................ 32
10.10.2 Selection of fire extinguisher....................................................................................... 32
10.11 Oil spill contingency ................................................................................................................ 33
10.11.1 Oil spill hazards ................................................................................................................ 33
10.11.2 Oil spill controls ................................................................................................................ 33
10.11.3 Reporting ............................................................................................................................. 33
10.11.4 Reporting to the environmental authorities .......................................................... 33
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: BWSC Quality, occupational health, safety and environment policy
6
1 The Health and Safety Manual
The purpose of the BWSC safety program is to describe BWSCs requirements to a safe system
of work. By implementing this program work will be planned and carried out in a controlled
manner thereby preventing harm to people and to the environment.
The safety program shall be implemented from mobilisation of the site and remain in force
until demobilisation.
1.1 Scope of manual
The BWSC Health and Safety Program applies to all personnel on BWSC construction sites
including BWSC own employees, contractors and their sub-contractors, visitors and client
representatives.
1.2 How to use the Health and Safety Manual
The health and Safety Manual is divided into two parts and further supplemented with
appendices.
Part 1: General Safety Program
Part 2: Specific Safety Instructions for selected disciplines
Appendices: Standard forms and check lists (only with the electronic version to site
management)
Part 1 states the overall policies and principles guiding the BWSC Health and Safety work.
A chapter is devoted to each of the Health and Safety initiatives which will be implemented
at the construction site. The corresponding guidelines are also included here and
referenced to necessary forms and checklists where possible.
Part 2 provides specific and more detailed instructions for the various activities and areas
of work. This part 2 is divided into Common Activities, which are relevant for all technical
disciplines and separate chapters for Civil Works, Electrical Construction, Mechanical
Construction and Test & Commissioning activities.
Please note, that some activities, which are most commonly found in one technical field
may also be applicable in another. For example, the subject of ‘Work inside large
machinery’ will apply to work in for instance diesel engines and generators by both
mechanical, electrical and test technicians. Likewise is ‘hot work’ included under
mechanical work, although welding and soldering may be done by other disciplines also.
All staff with supervisory responsibilities shall familiarize themselves with this manual.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: BWSC Quality, occupational health, safety and environment policy
7
1.2.1 Access to the Health and Safety Manual
The H&S Manual is available in a printed as well as an electronic version. The electronic version
can be obtained on CD ROM media or accessed via BWSC’s Intranet portal. In the electronic
version all standard forms are included in original file formats (Word, Excel) to be used and
modified for specific projects.
1.2.2 Hierarchy of manuals
In addition to this manual health and safety work may be governed by rules and regulation or
other safety instructions, typically those issued by the client and already in force at the work
site.
In order to avoid conflict between safety rules the following hierarchy shall be used as a
guideline:
1) Local legislation, regulations and other national requirements shall be followed. Please
note that in some countries guidelines (in the UK known as Approved Codes of Practice
– ACoP) have a legal status and should be followed unless an alternative safe system of
work is deemed to provide the same or better results.
2) Client health and safety requirements will normally take precedence over BWSCs Health
and Safety Manual.
3) BWSC Health and Safety Manual will take precedence over contractors’ health and
safety manuals unless otherwise decided.
4) Contractors’ health and safety requirements will be applicable for the activities
performed by that contractor. In case of conflict with any of the above requirements
the more onerous will take precedence unless otherwise decided.
5) Sites may need to produce a list of site specific procedures or site specific decisions as
a consequence of work development or on the basis of review of procedures from the
contractors.
Normally this list of site specific procedures will form part of or be referenced in the Site
Health and Safety Plan (in the UK: Construction Phase Plan).
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: BWSC Quality, occupational health, safety and environment policy
8
2 BWSC quality, health, safety and environment (QHSE)
policy
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety organisation
9
3 Safety Organisation
3.1 BWSC Safety Organisation
The BWSC Construction Manager has the overall
responsibility in safety matters related to work on
BWSC construction sites.
The BWSC Site Manager has the overall responsibility for the safety on site.
He is directly involved in managing and coordinating the health and safety activities on site
ensuring that a safe system of work is in place. He will monitor the construction works and
take initiatives to ensure all required controls are in place. He reports to the BWSC
Construction Manager.
The Site Manager also has the role of Site Safety Officer; he may be supported by a Health
and Safety Officer and a Health and Safety Advisor if appropriate.
The Site Safety Officer or his appointed deputy will be on site at all times when work is being
carried out
The safety organisation shall be constituted as soon as the site is mobilized. The parties
representing the Client and BWSC are appointed as early as possible, while the rest of the
organisation, representing contractors and others, shall be assigned as and when they appear
on the site.
The safety organisation, including a list of names shall be kept updated and posted on the
bulletin board.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety organisation
10
3.1.1 Typical Site Safety Organisation
BWSC Site Manager Site Safety Officer Overall health and safety
Health and Safety
responsible
Responsible
Health and Safety
Advisor 1)
AdvisorAdOfficer
Health and Safety Officer 2)
Temporary Works Temporary Works Co-ordinator 1) 3) Supervisor 1) 3)
BWSC Subcontractors Safety Deputy Safety Officer Civil Works Civil Works Supervisor
Subcontractor Safety Deputy Safety Officer
Mechanical
Mechanical Works Mechanical
Supervisor
Subcontractor Safety Deputy Safety Officer Electrical works Electrical
Supervisor
Subcontractor Safety Deputy Safety Officer Test & Commissioning NN Manager Subcontractor
1) Depending on site
2) Position may be covered by the
Site Manager
3) Position may be
shared w/ other
supervisory responsibility
Please note that on some
BWSC sites the following
titles are used:
Site manager: BWSC Resident Project Manager
(NN discipline) supervisor: (NN discipline) Site Manager
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety organisation
11
3.2 The Safety Board
Safety coordination between BWSC and contractors on site will be organised through a Safety
Board consisting of the Site Manager, BWSC supervisors and the contractors’ site
management. Each subcontractor will ensure consultation with his workforce in accordance
with regulations.
The Safety Board will meet every second week as a
minimum. These meetings can be a part of normal
site meetings. Minutes of meeting shall be taken
and corrective and preventative action shall be
decided and followed up.
3.3 Responsibilities
3.3.1 Site Manager (Site Safety Officer)
It is the main responsibility of the Site Manager that the health and safety program is
implemented on site. Through actions and communication he shall ensure that safety
awareness is part of the work culture on site and that safety priorities are always given due
consideration in the planning and execution of the works. Specifically, the following duties can
be highlighted:
Understand the health and safety policy and the responsibility that follows.
Ensure that all personnel working on site, including all supervisory staff, has received a
Site Safety Induction.
Ensure that instructions are posted on bulletin boards in the working language as well as
other languages, where necessary.
Perform regular Site Safety Inspections to ensure that a safe system of work is in place
and that emergency facilities are adequate and maintained; report the findings in the
agreed format.
Investigate incidents and report findings; recommend changes to prevent re-occurrence.
Attend site meetings where safety is on the agenda.
Be aware of local laws regarding safety, health and welfare; become familiarized with any
parts of such laws and regulations that are relevant to the work being performed.
Prepare and publish an Emergency Evacuation Plan.
Ensure Fire Drills are carried out.
Publicize list of names and telephone numbers for emergency response.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety organisation
12
3.3.2 Supervisors (Safety Deputy)
Site Supervisors are responsible for the on-site implementation, execution and monitoring of
health and safety controls including the promotion of safety awareness in the work culture
within their disciplines. Specifically the following duties can be highlighted:
Be familiar with the Safety Program and any local regulations applicable to his field of
work.
Organise work places so that work can be executed with minimum risk for personnel and
environment.
Monitor contractors health and safety management systems to see that they are effective.
Ensure that risk assessed method statements are developed for all work and that these
are reviewed and revised if required during the construction period.
Ensure that contractors have systems to ensure that their operatives are competent and
able to perform their assigned duties in a safe manner.
Monitor and ensure that given instructions are followed.
Make sure that all permanent and temporary electrical supply is installed, used and
maintained correctly.
Check that equipment and tools are used and maintained properly.
Make sure that correct personal protective equipment (PPE) is used correctly.
Where necessary, make sure that proper signing is in place.
Be familiar with the emergency evacuation procedure.
Co-operate with the Site Manger in all safety matters.
3.3.3 Temporary Works Co-ordinator
Responsible for ensuring that the procedure for control of temporary works is
implemented including
o Co-ordination of all temporary works activities
o Ensuring that a temporary works register is established and maintained – the
temporary works register shall apply to all contractors on site
o Ensuring that design checks are carried out
o Issuing permits to load (permit to dig/permit to put into use) and permits to
unload (permit to take out of use) are issued.
3.3.4 Contractors
The Contractors’ responsibilities follow those of the Site Manager and Supervisors.
Specifically, the following points can be highlighted:
Fulfil the requirements in accordance with the BWSC Safety Program.
Ensure that all personnel under his supervision have been given a Safety Induction.
Make sure all his employees understand and follow the Safety Instructions.
Immediately report all incidents to the Site Manager in writing.
Ensure that operatives comply with the requirements of RAMS for their field of work.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety organisation
13
3.3.5 Workmen/Operatives
In general, the workmen shall understand that they have a responsibility for their own safety,
as well as the safety of their work colleagues. Specifically, the following duties can be
highlighted:
Understand and follow given safety instructions and working descriptions.
Notify their supervisor if they are aware of any issues which may influence the safety of
the work assigned to them – for example if work descriptions in RAMS are incorrect or
requirements cannot be achieved.
Use the required personal protective equipment (PPE).
Use correct tools and equipment for the work including protective clothing as required.
Prevent endangering themselves or colleagues.
Keep tools in good working condition and return broken/dangerous tools to the site
management.
Be familiar with the emergency evacuation procedure of the site.
3.4 Training and qualifications of personnel
The Site Manager and supervisory personnel shall attend training from recognized training
institutions in First Aid, including heart-lung resuscitation (cardio-pulmonary resuscitation
(CPR)), and Fire Fighting as soon as possible after their arrival on site.
All BWSC personnel shall attend training in accordance with the BWSC QHSE training
matrix.
All personnel working on energized electrical systems shall maintain valid training for
working with live systems (In Danish: L-AUS/AUS).
All BWSC personnel shall perform annual employee development talks with their line
manager at which time plans for development and further training is agreed. It is
important that the plan for development of the employee is reviewed in relation to the
requirements of BWSCs projects. Similarly that each project reviews the needs and follows
up on plans to meet the required skills and competences to successfully perform the
project.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: General Safety Requirements
14
4 General Safety Requirements
4.1 Construction, commissioning and semi-operation phases
BWSC’s Contracting Division is a turnkey supplier of power plants. It is important to be aware
that safety aspects are changing from the construction period to the commissioning period and
onwards into semi-operation stage. It may be the case that operational responsibility for one
or more units is taken over by the end-user, while construction and commissioning activities
are still ongoing in the remaining plant. This period is called ‘semi-operation’ period.
Consequently, it is essential to follow all safety regulations during construction, commissioning
and semi operation as well.
4.2 Transfer from construction to commissioning When the test & commissioning of the plant commence, construction work will still be on-going
in other parts of the plant. Gradually, after finishing the pre-tests, the various systems will be
energised/pressurised (the power station gradually becomes live). In this period when the site
slowly and gradually changes from a construction site to a test and operation site, particular
attention shall be given to safety aspects from the site management as well as from everybody
working on the site. Especially the construction personnel shall keep very alert in this period,
as their working place and the equipment that they have been working on for a long period
with free access now becomes “LIVE” with an increased potential danger, and consequential
limitation of access.
Construction
Commissioning
Operation
Operations
Commissioning
Construction
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: General Safety Requirements
15
4.3 Transfer from commissioning to operations When commissioning is completed the responsibility for the operation is transferred to the final
operator and no work shall be carried out without the permission and knowledge of the
operator.
It is the responsibility of the Commissioning Manager in co-operation with the Site Manager to
keep all personnel working on the site well informed about which parts of the plant have been
taken over by the final operator.
4.4 Alcoholic beverage and drugs
Alcoholic beverages, cannabis or any kind of narcotic drugs are prohibited on the site.
Any person found to be under influence of alcohol, cannabis or narcotics are subject to
immediate dismissal from the site.
Personnel who need to use medicine which can influence their physical or mental ability to
safely perform their work duties shall report this to their superior such that a risk assessment
can be performed. Based on this risk assessment a decision will then be made as to whether
the person need to take time off or if it is acceptable to perform restricted work until the use of
the medication stops.
4.5 Language difficulties
BWSC construction sites are often a multi-cultural, multi-language environment. While all
BWSC supervisors have a good working knowledge of English, the same may not be the case
for contractors and operatives on the site. In cases where English is not widely spoken, it may
be necessary that safety related issues are communicated in other languages. The same will
be the case if foreign, non-English speaking nationals are employed on site, either by BWSC or
contractors. As a minimum, it shall be ensured that the Site Rules and any safety instructions,
signage etc. are translated to the relevant language(s). Likewise, the Site Safety Induction
shall be given in the relevant language(s), if necessary with the assistance of an interpreter.
Safety
First! ¡Seguridad
primero!
Πρωτιά
στην
Sikkerhed
først!
السالمة
أوال!
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Site Layout
16
5 Site Layout
5.1 Purpose and contents
The construction site layout is an important tool throughout the project for the coordination
and communication of safety related matters.
At the outset of the project BWSC design office will issue a layout drawing indicating known
installations and utilities as well as new structures and installations. This drawing will form the
basis for the Site Safety Layout drawing, which will be updated and re-issued by the Site
Manager as the project progresses.
The following list contains information which will be relevant to include on the site Safety
Layout:
5.1.2 Existing installations and site conditions
Overall demarcation of the site boundaries, indicating where BWSC is responsible for safety
and security. This may include areas which are not physically part of the main site, such as
off-site lay-down or work areas.
Existing services, underground and above ground (electrical, telecommunication, fuel, gas,
water, sewage etc.).
Existing building structures and installations, whether planned for demolition or to be
retained.
Areas with known or potential contaminated soil.
5.1.3 BWSC temporary site installations
Main access gate and security guard location, if any.
Site offices.
Welfare facilities (mess, sanitary facilities).
Emergency Assembly Point(s) and evacuation routes.
Location of Main First Aid Station/Infirmary, distributed First Aid Equipment, Fire Fighting
Equipment.
Storage containers, lay-down areas.
Refuse and waste handling areas.
Temporary utilities installation.
5.1.4 Traffic plan information
Site access, entrance and exit.
Car parking and turning areas.
Roads with indication of driving directions.
Pedestrian walkways.
Location of tower cranes indicating work radius and similar information.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Site Layout
17
Depending on the phase of the project, it may be relevant to include working areas showing
major excavations, large cranes, subassemblies, mechanical workshops etc.
When preparing the site layout, please keep in mind that too much information in a drawing
can lead to confusion. Therefore, the usefulness of the information provided shall be weighed
against the desired level of detail.
Below is an example of a Site Layout.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety Induction and Site Rules
18
6 Safety Induction and Site Rules
6.1 Site safety induction All personnel working at or visiting the construction site shall be given a Site Safety Induction
before commencing any work / visiting activities. The Site Safety Induction is based on the
General Site Rules, which are handed out and explained.
During the induction session, special emphasis shall be given to significant risks which are
relevant to the current construction phase.
The Site Safety Officer is responsible that all personnel are given the Site Safety Induction. He
may delegate the task to BWSC supervisors, or in the case of major contractors, to the site
management of such contractor. Records of all site inductions shall be kept by BWSC Site
Safety Officer.
Attendees at site inductions are required to confirm by
signature that they have attended the induction. The signature
sheet shall contain the correct revision number of the General
Site Rules applicable.
Personnel having completed the Site Safety Induction are given a
name / ID card to confirm that the site induction has been
attended.
ID card format is included in appendix.
6.2 General Site Rules
A set of ‘General Site Rules’ is provided in the Appendix. They are based on experiences from
BWSC sites and updated as new knowledge becomes available. The General Site Rules may be
amended by each site to suit the site conditions and the phase of the works.
The site rules however cannot remove or lessen requirements stated in the Health and Safety
Manual unless a formal deviation is approved.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Safety Induction and Site Rules
19
Fifteen fundamental safety rules
6.2 Fifteen fundamental safety rules
The below ‘Fifteen Fundamental Safety Rules’ apply at all BWSC construction sites. Local
regulations and/or client’s requirements may necessitate this set of rules to be amended for
each project.
1 Do it safely – or not at all
2 There is always time to do it right
3 Always comply with legislation and regulations
4 Always comply with BWSC internal procedures and requirements for QHSE
5 Always plan and execute work carefully to minimize risk to people and to the
environment
6 Always ensure that a safe system of work is in place and is followed
7 Always stop work when at-risk behaviour or risky conditions are observed
8 Always ensure that personnel are competent and suitably trained for their work
9 All personnel shall be given a site induction before commencement of work
10 All incidents including near-miss shall be reported
11 Smoking is only allowed in designated areas
12 Familiarise yourself with emergency and evacuation procedures
13 Alcohol and drugs are not allowed on site
14 All personnel shall wear the appropriate PPE
15 Be aware that risks are constantly changing as the site is developing
6.3 Health Information
BWSC cannot require employees to disclose details of their physical or mental condition unless
the employee in question agrees to do so voluntarily.
Personnel using prescription medicine shall inform the Site Manager such that contingency
measures can be taken.
Should certain items of work require particular physical abilities these must be evaluated
individually and only with the explicit consent of the employee and in accordance with the laws
of the country.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/201418
Subject: Safety Meetings
20
7 Safety Meetings
7.1 BWSC Safety Meetings
BWSC convenes safety meetings on a regular basis with the contractors engaged on the site.
The meetings are held as a safety meeting (Safety Board) involving all contractors working on
site at any given time. These meetings are supplementary to the meetings held individually
with each contractor (weekly site progress meetings).
Safety Meeting Agenda (typical)
1. Minutes of last meeting; comments and acceptance.
2. Review of safety incidents since latest meeting.
3. Outline of planned work and related health and safety
requirements:
One month look-ahead co-ordination of work and
outstanding risk assessments and method statements.
4. Training including toolbox talks.
Induction training provided, toolbox talks provided,
training needs identified
5. Initiatives and improvements.
Based on site inspections and review of outstanding
identified matters.
6. Special requirements including resources for future
work.
7. AOB
The Site Safety Officer chairs the safety meetings.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/201418
Subject: Safety Meetings
21
7.2 Toolbox talks
Toolbox talks are short informal gatherings,
often at the workplace around the toolbox,
hence the name "Toolbox talks”. They can
also be performed in a meeting room but
still be presented in an informal way.
A toolbox talk is focused on one specific topic and shall be addressed in simple terms. It is the
opportunity for a supervisor to emphasize the importance of a particular issue or procedure,
and for the rank-and-file to ask questions or make serious comments. Normally, toolbox talks
should be held on a weekly or bi-weekly basis, or when specific circumstances arise. They
generally last no longer than 5 to 10 minutes.
For getting a clear structure in your toolbox talks, consider the following 5 points:
1. Toolbox Talks should be presented - not read.
This type of training takes its name from the notion of supervisors and employees
gathering around the toolbox informally to talk about an important issue. This means
the presenter should review topic materials before the meeting, and then present the
topic.
2. Toolbox Talks should be presented by a supervisor, foreman or similar type of person
with hands-on experience.
Do not delegate this important task. Toolbox talks presented by a credible supervisor
are far more likely to be taken seriously.
3. Toolbox talks should address the hazards at your workplace.
Present toolbox talks that are relevant to the type of work being performed at the given
time. Otherwise, you will quickly loose the attention of your workers.
4. Toolbox Talks should be quick and to the point.
You can likely address one specific hazard or issue and the relevant safe-guards in a 5-
10 minute time span. You want your audience to absorb and remember this safety
training and you will have more success if you keep the talk short and to the point
5. Toolbox Talks shall be documented.
Keep records of the toolbox talks. Each participant shall sign his attendance at the
toolbox talk.
For inspiration on toolbox talks see for example www.toolboxtopics.com
7.3 Other safety meetings
Depending on the situation, the client or his representative may convene regular safety
meetings. Frequency, agenda and other formalities will follow the client’s requirements.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Site Safety inspections
22
8 Site Safety Inspections
8.1 Daily safety monitoring
Daily “walk-around” informal monitoring of the site safety is the responsibility of anyone
having a supervisory role and shall be a natural part of his daily presence on site.
The Site Manager will on his daily site walks monitor the safety and discuss any observed
issues with the responsible supervisor or contractor.
Breach of safety regulations shall be corrected immediately.
8.2 Formalised safety inspection
Formal and documented safety inspections shall be carried out by the Site Manager at regular
intervals, normally on a weekly basis or more often. Joint inspections with participation by
BWSC, the client’s representative and the safety officer(s) from contractors may also be
performed.
The overall purpose of the safety inspections is to review the implementation of safe working
practices. The inspections and subsequent reporting may be structured around the following
topics:
Housekeeping
Use of personal protection equipment (PPE)
Plant and equipment
Electrical installations (construction site power)
Work at heights
Lifting operations
Excavations
Work with power tools and special tools
Hot work
Fire hazards, fire-fighting equipment, alarm system
Use of chemicals and hazardous substances
Work inside large machinery
Work in confined spaces
Safety signage and posters
Emergency equipment
Safety records (induction records, equipment checklists)
Temporary works
Contractors’ health and safety control (management of health and safety)
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 - General Safety program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Site Safety inspections
23
Additionally BWSC and contractors will perform formal health and safety audits in accordance
with their audit programs.
8.3 Work in shifts If work is being performed in evening or night shifts, it may be relevant to carry out the safety
inspections at different times, as conditions may differ on these shifts.
8.4 Reporting from safety inspections The observations made
during the Safety
Inspection shall be
recorded and a report
issued to concerned
parties. The report may
also include
recommendations to
improve the observed
practices. A practical way
of doing this is to take a
series of photos, which can
then be included in the
written report.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Incident Reporting
24
9 Incident Reporting
9.1 Reporting of incidents (injury, illness, dangerous occurrence)
9.1.1 Principles
In BWSC we believe that all incidents are preventable. We also believe that good planning and
careful preparation is essential to prevent incidents. Despite good planning and preparation
incidents may occur.
Incidents are unplanned and undesired events which may or may not cause loss or damage.
Incidents represent opportunities for improvement if they are properly reported and their
causes are determined. Action shall be taken to prevent future similar situations by
instigating preventative measures.
The Site Safety Officer is responsible for reporting of incidents. A standard report form is
included in the appendix. A detailed risk management procedure is included in the BWSC
QHSE Management System.
Incidents are divided in two groups:
Injuries and
Dangerous Occurrences.
The following definitions apply:
9.1.2 Injuries
An injury is an unplanned event that results in injury to personnel. It is commonly agreed that
injuries are sudden occurrences while illness normally develop over a longer period of time.
Illness which is a consequence of work impact shall be reported as ‘injuries’.
9.1.3 Dangerous occurrences
A Dangerous Occurrence in an unplanned or undesired situation. The Dangerous Occurrence
may or may not result in loss or damage such as lost production, damaged equipment,
pollution etc. A Dangerous Occurrence which did not incur any loss or harm is often referred
to as a ‘near-miss’ situation.
9.1.4 Potential severity
The actual severity of an incident is the result or consequence of the incident. By determining
the potential severity of an incident we evaluate what the consequences of an incident under
slightly changed circumstances might have been. The severity of an incident – actual and
potential - should be determined using the risk matrix – see section 9.6. The potential
severity represents the likely risk of an unplanned or undesired situation and will determine
the degree of follow-up. Higher risk requires more stringent follow-up.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Incident Reporting
25
It is important that situations
which caused injury to
personnel or damage to the
environment are always
reported.
Similarly does BWSC require
that all incidents which
caused loss or damage to
machinery, installations or
other assets are reported.
Dangerous occurrences which
did not result in physical loss
or damage should also be
reported as they may be
used to prevent similar
situations in the future.
These situations are often
called near-miss situations
and represent a valuable
source of information.
Dropped objects - objects
which are lost or fall from
height - may have severe
consequences if persons are
hit. Energy above 40 Joule
will most likely result in a
person being killed by the
dropped object. Dropped
objects therefore have a
separate field in the Incident
Report form.
9.2 Distribution of incident reports Incident reports shall be distributed as follows:
Original signed form to Site Safety File
Electronic copies to BWSC head office (Construction Manager, Project Manager, QHSE
Manager)
Electronic copy to the Client and/or the Resident Engineer
Electronic copy to the engaging contractor
Electronic copy to the responsible and/or relevant BWSC supervisors.
Incident Report Project Number: Project
name/site: Report
number:
Date of incident: Time of incident:
Place of work:
Type of work:
Category of
incident (tick one only):
Injury or illness: Dangerous
Occurrence:
Incident title (short subject):
Details of the incident;
attach separate, detailed investigation report if risk is high or medium:
Potential risk of
incident:
See risk matrix
(tick one only) LOW
MEDIUM
HIGH
If dropped object calculate energy:
Mass (in kilos):
Height (in meters):
Energy
(in Joule):
Causes of the incident:
1
2
3
Responsible Target date Action taken to prevent future incidents:
1
2
3
4
5
Reported to authorities:
Yes (date): No, not required (tick):
Supplementary comments:
Approval:
………………………………………. BWSC Site Manager’s signature
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Incident Reporting
26
9.3 Reporting to the local authorities Local Regulations may stipulate the requirement to report incidents to the supervisory
authorities.
The site manager ensures that legal requirements are adhered to.
9.4 Incident statistics /Lost Time Injury Frequency Incident Reports are input to the BWSC database for incidents.
In line with international standards BWSC use the following formula for calculating the risk of
injuries to personnel:
Lost Time Injury Frequency = number of injuries calculated per one million
manhours worked
9.5 incident Summary Sheet Example of the Incident Summary sheet with the LTIF calculated according to above formula:
Incident Summary Sheet BWSCReport date (yyyy.mm.dd): Project name: / number:
Report Date of Incident title
Contractor/
subcontractor Injury
Dangerous
Occurrence
Lost time
injury > 1
day
Lost time
injury > 7
days
Reported to
authorities
No. Incident
1 2013.04.01 Operative twisted his ankle BWSC 1 0 1 0 0
2 2013.05.07 Operative burned his hand BWSC 1 0 0 0 0
3 2013.05.13 Technician got electrical shock BWSC 1 0 1 0 1
4 2013.06.04 Scaffold erected without handrailsSubcontractor A 0 1 0 0 0
5 2013.06.15 Concrete poured without proper work platformSubcontractor B 0 1 0 0 0
6 2013.07.16 Precast manhole hit operative Subcontractor C 1 0 1 1 1
7 2013.07.22 Unprotected rebar Subcontractor A 0 1 0 0 0
8 2013.08.01 Excavation without barrier Subcontractor D 0 1 0 0 0
9 2013.08.09 Cables obstructing walkways BWSC 0 1 0 0 0
10 2013.09.11 Gas bottles not secured Subcontractor B 0 1 0 0 0
11 2013.09.21 Poor housekeeping Subcontractors A, B, C 0 1 0 0 0
12 2013.09.29 Dropped object Subcontractor A 0 1 0 0 0
13
14
15
Number of incidents and type / Number of Lost Time Injuries (LTI) (automatically calculated):4 8 3 1 2
Number of BWSC mandays worked to report date (to be filled in): 7.650
Number of contractor mandays worked to report date (to be filled in): 55.760
Total number of mandays worked to report date (automatically calculated) 63.410
Lost time injury frequency (LTIF) (automatically calculated): 4,7 1,6
1 = yes - 0 = no
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Incident Reporting
27
9.6 Risk Matrix
The BWSC risk matrix below is used to assess the potential severity of an incident
thereby estimating its potential risk and the degree of follow-up. Further explanation
concerning risk and incident follow-up is found in the BWSC procedures for incident
reporting.
9.7 Dropped objects Dropped objects are dangerous occurrences, which may lead to severe personal injuries.
Objects with energy above 40 Joule (J) should be considered potential fatalities – see red area
below. Calculation of energy: height (in m) x mass (in kg) x gravity (9.8 m/s2) = energy (J)
Severity –
general
description
Personal
injury
description
Environmental
damage/ m3
spill
Loss of
production/
damage (EUR)
Value Risk
Catastrophic
harm or
damage
Multiple
fatalities
Area suffers
catastrophic
damage /spill >
1000 m3
Value > 5
million
5 5 10 15 20 25
Major harm
or damage
Single fatality,
potentially
disabling
injury
Area suffers
significant
damage / spill
> 100 m3
Value > 1
million
4 4 8 12 16 20
Severe
harm or
damage
Major injury /
lost time
injury /
restricted
work case
Area is severely
damaged / spill
> 10 m3
Value >
500,000
3 3 6 9 12 15
Minor harm
or damage
Minor injury /
medical
treatment
case
Area is
somewhat
damaged / spill
> 1 m3
Value >
100,000
2 2 4 6 8 10
Small harm
First aid injury Area is slightly
damaged / spill
< 1 m3
Value > 1.000 1 1 2 3 4 5
Value 1 2 3 4 5
Frequency of operation or
estimated potential frequency of unwanted event/incident
> 5
years
< 5
years
< 1
year
< 6
months
< 14
days
High risk
area
Medium risk
Low risk
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
28
10 Emergency Procedures
10.1 Emergency response plan
The detailed emergency response plan will depend on project specific conditions, ie. whether
the construction site is situated within or near an existing power plant or industrial complex
with specific safety hazards. In such cases, the emergency response plan will need to take
into consideration such special risks and may require close cooperation with responsible parties
with respect to evacuation procedures.
The following can serve as a guideline when preparing the emergency response plan:
Type of incident
What to do
Work Accident
Stop the accident without exposing yourself to danger.
Supply first aid assistance to the victim.
Call local emergency centre if necessary.
Fire
Activate fire alarm.
Prevent the fire from spreading to surrounding areas
Try to extinguish the fire without exposing yourself or
others to danger.
Help injured persons.
Call local Fire Brigade if necessary
Environmental
Incident
Try to stop the environmental incident if possible,
without exposing yourself or others to danger.
Help injured persons.
Call local emergency centre if necessary
Assistance
In case of criminal incidents inform the Site Manager
immediately.
The Site Manager will notify the police and other parties
as required.
In all cases: Notify the Site Manager as soon as possible.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
29
10.2 Certified emergency responders (First Aiders)
BWSC Site Manager and supervisory
personnel shall have completed training
as certified emergency responders (First
Aiders) from a recognized training
institution. This includes training in CPR.
A poster with names, mobile phone
numbers and photos of first aiders shall
be maintained and posted on the safety
notice boards.
10.3 First aid equipment At the time of mobilizing the site, BWSC will have available a comprehensive set of first aid
equipment, including oxygen mask, cardiac pulmonary resuscitation (CPR or cardiac
defibrillator) equipment and a stretcher.
It is the responsibility of the site safety officer that the first aid equipment is checked regularly
and replenished as required.
The first aid equipment shall be available and easily accessible at all times. Signage on the
building shall indicate the location.
10.4 First aid response First aid with small accidents
In case of small accidents, ie. cuts, scratches etc., first aid can be
carried out on site by the site safety officer or any of the certified first
aiders.
In case of serious accidents more systematic efforts are required.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
30
Start first aid as required by the situation
Call the safety officer or someone from site management quickly.
Investigate the seriousness of the accident.
Call an ambulance if required and make sure that somebody guides the ambulance to the
accident area.
10.5 Electrical accidents Do not touch the person before electricity is cut off.
Start first aid, including cardiopulmonary resuscitation (also
called heart-lung massage or CPR) and mouth to nose ventilation
method if necessary. Use oxygen equipment according to given instructions. Call an ambulance.
Electrical burns are treated by cold water on the burnt area until the ambulance personnel
take over
10.6 Burns
Burned places on the body shall be continuously flushed with water. Burned arms and legs
shall be held submerged in water (e.g. in a bathtub filled with water or similar) until the
ambulance arrives.
10.7 Acid burns
Immediately pour water over the burned part of the body
Remove clothing
In case of acid burns in the eyes, rinse with water from an eye
wash bottle or any other source of clean water
All acid burns require immediate hospital treatment.
10.8 Poisoning
To secure proper treatment in poisoning cases the hospital shall be
contacted right away and informed about which materials the
poisoned person has worked with.
Always bring the material safety data sheet (MSDS) for the chemical in question to the hospital
– alternatively bring the label from the container from which the poisonous substance came.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
31
10.9 Accidents involving the back and the neck
A person who may have suffered injuries to his back or neck shall only be moved by
experienced persons or under a doctor’s advice. It is important that personnel suspected of
having injuries to their neck or back are stabilised – i.e. put on a neck collar or use other
means to stabilise the head - until professional assistance arrives.
10.10 Fire protection and prevention
In case of fire the following guidelines will apply:
A fire requires three elements: Heat, combustible material and oxygen.
The fire is prevented or extinguished by removing any one of the three
elements.
Fire is prevented through good housekeeping, proper maintenance and a
safe system of work when working with open flame or equipment which
produces sparks.
To ensure that personnel can be accounted for at all times every person
inside the site perimeter shall register when arriving on site and again
when leaving site
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
32
10.10.1 Fire evacuation plan
In case of fire:
1. Activate the fire alarm.
Klaxon horns or similar are located in the work site and at the
BWSC and contractor site offices. Alternatively use the temporary
alarm system installed.
a. Prevent the fire from spreading to surrounding areas.
b. Try to extinguish the fire.
c. Help injured persons.
2. Call the Fire Brigade
3. Evacuate the site
4. Assemble at the muster point
5. The fire wardens will make an account of the personnel
6. Await signal by the fire warden that work may be resumed
10.10.2 Selection of fire extinguisher
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 1 – General Safety Program Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Emergency Procedures
33
10.11 Oil spill contingency
10.11.1 Oil spill hazards
The most likely environmental hazard is the potential for oil spill, mainly diesel fuel, heavy fuel
or lubrication oil. The hazards may be present during bunkering operations, when receiving the
fuels or lubricants from tanker trucks or vessels or during testing and commissioning activities.
Similarly may small spills occur during fuelling of forklifts or other plant and equipment if care
is not taken.
10.11.2 Oil spill controls
Specific method statement and risk assessment shall be prepared before bunkering or fuelling
operations commence. The risk assessments will assess environmental hazards, fire hazards as
well as hazards related to personnel exposure to chemicals and fumes from chemicals.
Controls and emergency response shall be carefully planned to ensure that any spill does not
contaminate the ground or water at site. Mechanical connections shall be examined to ensure
they match, are in good condition and do not give rise to potential leaks. Double skinned
drums and tanks are preferred, alternatively the tanks and drums should be placed in a
bunded area.
Should a leak occur despite preventative measures taken a comprehensive oil spill
containment kit (absorbent sand, oil spill mats, spill trays etc.) shall beforehand be placed
close to the work involving chemical substances.
Specific local circumstances may require that more comprehensive oil spill kits are made
available, including barriers, booms, skimmers etc.
The Site Manager shall familiarize himself with the availability of specialized companies in the
area which can assist in case of larger spills.
10.11.3 Reporting
All spills shall be reported to the Site Manager.
10.11.4 Reporting to the environmental authorities
The local hazardous waste regulations will stipulate the requirements and procedure for
reporting spill incidents to the Environmental Agency. The Site Manager shall familiarize
himself with any applicable regulations and/or seek local advice. A standard reporting format
is included in the appendix.
34
Remember to do it safely – or not at all.
There is always time to do it right !
35
Burmeister & Wain Scandinavian Contractor A/S
Health and
Safety Manual Doc. 6000.QH.001.001
Part 2 –
Specific Safety Instructions
36
Health & Safety Manual
Part 1 General Safety Program
Chapter 01 How to use the Health and Safety Manual
Chapter 02 BWSC H&S Policy
Chapter 03 Safety Organization
Chapter 04 General Safety Requirements
Chapter 05 Site Layout
Chapter 06 Safety Induction and Site Rules
Chapter 07 Safety Meetings
Chapter 08 Site Safety Inspections
Chapter 09 Incident Reporting
Chapter 10 Emergency Procedures
Part 2 Specific Safety Instructions
Chapter 01 Common Activities
Chapter 02 Civil Works
Chapter 03 Mechanical Erection
Chapter 04 Electrical Erection
Chapter 05 Test & Commissioning
Chapter 06 Switching of LV, MV and HV switchgear
Chapter 07 Steam Systems
Appendices
Revision history:
Revision Date of issue Main changes to recent revision
2 18.02.2014 Manual used to be project specific – it is now applicable for BWSC. Updated from revision 1 in its entirety. Main changes to part 1: Mandatory use of safety glasses and gloves, revised list of ‘site safety rules’, new incident report form, risk matrix. Main changes to part 2: new chapter ‘yellow rules for switchgear’, new chapter on steam. Update of some illustrations. Part 3 (generic risk assessments) removed.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of Contents
37
Table of Contents 01 Common Activities ............................................................................................................................. 42
01.01 Housekeeping ......................................................................................................................... 42
01.01.02 Dedicated Housekeeping Team ................................................................................ 43
01.01.03 Waste Categories ...................................................................................................... 43
01.01.04 Control of Dust etc. ...................................................................................................... 44
01.02 Fire Prevention ....................................................................................................................... 44
01.02.01 The Fire Triangle ............................................................................................................ 44
01.02.02 Spontaneous Combustion ...................................................................................... 45
01.02.03 Fire Emergency Response .......................................................................................... 45
01.03 Working Clothes .................................................................................................................... 45
01.04 Personal protective equipment (PPE) .......................................................................... 46
01.05 Hand Tools and Power Tools ............................................................................................. 47
01.05.01 Electric Hand Tools – testing .................................................................................... 47
01.05.02 Grinding and Cutting Tools ........................................................................................ 48
01.05.03 Compressors and Pneumatic Tools ......................................................................... 48
01.05.05 Machine Tools ................................................................................................................. 49
01.06 Working at Height .................................................................................................................... 49
01.06.01 General precautions ..................................................................................................... 49
01.06.02 Fall Arrest and Work Restraint Systems ............................................................... 50
01.06.03 Ladders and Step Ladders ........................................................................................ 51
01.06.04 Scaffolding ...................................................................................................................... 52
01.06.05 Mobile Scaffold Towers ................................................................................................ 53
01.06.06 Mobile Elevated Work Platforms (MEWP) ........................................................... 53
01.07 Lifting Operations.................................................................................................................. 54
01.07.01 General Precautions ..................................................................................................... 54
01.07.02 Rigging and Slinging .................................................................................................... 54
01.07.03 Examination of slings and lifting gear .................................................................. 57
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of Contents
38
01.07.04 Hand signals for Lifting Operations ........................................................................ 59
01.07.05 Heavy Lift Operations .................................................................................................. 60
01.07.06 Forklifts and Telehandlers ........................................................................................ 60
01.08 Working with Substances Hazardous to Health ........................................................ 61
01.08.01 Material Safety Data Sheets (MSDS) ..................................................................... 62
01.08.02 Control of Substances Hazardous to Health ...................................................... 62
01.08.03 Asbestos and Man-made Mineral Fibres (MMMF) ............................................ 63
01.08.04 Working with Explosives............................................................................................ 63
01.08.05 Radiation / working with radio-active materials .............................................. 63
01.09 Working in Confined Spaces ............................................................................................. 64
01.09.01 Confined space definition and examples .............................................................. 64
01.09.02 Typical Hazards to consider in Confined Spaces .............................................. 64
01.09.03 Risk Assessment ........................................................................................................... 65
01.09.04 Work planning – avoid or reduce entry into confined spaces ...................... 65
01.09.05 Safe System of Work ................................................................................................... 65
01.09.06 Permit to Work ............................................................................................................... 66
01.10 Lightning Safety ....................................................................................................................... 66
01.10.01 Awareness ........................................................................................................................ 66
01.10.02 Warnings and precautions ......................................................................................... 66
01.10.03 Safe places ....................................................................................................................... 67
01.10.04 First aid if a person is struck by lightning ........................................................... 68
01.11 Safety and warning signs - examples .............................................................................. 69
01.11.01 Prohibition signs ............................................................................................................. 69
01.11.02 Warning signs ................................................................................................................. 69
01.11.03 Emergency signs ............................................................................................................ 70
01.11.04 Fire fighting signs .......................................................................................................... 71
01.11.05 Personal Protective Equipment signs ..................................................................... 71
02 Civil Works ....................................................................................................................................... 72
02.10 Excavation Work ...................................................................................................................... 72
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of Contents
39
02.01.01 Excavation Permit................................................................................................................. 72
02.01.02 General Precautions ..................................................................................................... 73
02.01.03 Underground Services ................................................................................................. 73
02.01.04 Use of Excavators and Heavy Equipment ............................................................ 74
02.02 Concreting Works .................................................................................................................. 74
02.02.01 Work with reinforced concrete ................................................................................. 74
02.02.02 Installing and stripping of formwork ...................................................................... 74
02.02.03 Mixing and placing concrete ...................................................................................... 75
02.02.04 PPE when working with concrete............................................................................. 75
02.03 Demolition Work .................................................................................................................... 75
02.04 Erection of Large Superstructures .................................................................................. 76
02.04.01 Structural and Secondary Steel Erection ............................................................. 76
02.04.02 Installation of Cladding Systems ............................................................................. 76
02.04.03 Erection of Overhead Travelling Cranes ............................................................... 77
02.04.04 Erection of Chimney Stacks....................................................................................... 77
02.04.05 Erection of Storage Tanks .......................................................................................... 77
03 Mechanical Erection ..................................................................................................................... 78
03.01 Unit Erection ........................................................................................................................... 78
03.02 Hot work ...................................................................................................................................... 79
03.03 Chemical Cleaning of Pipes ............................................................................................... 80
03.04 Work with Hydraulic Tightening Tools .......................................................................... 80
03.05 Pressure Testing ....................................................................................................................... 81
03.05.01 Pressure Testing Hazards ........................................................................................... 82
03.05.02 Precautions ...................................................................................................................... 82
03.05.03 Leak Testing .................................................................................................................... 82
03.06 Work Inside Large Machinery ........................................................................................... 82
03.06.01 General precautions ..................................................................................................... 82
03.06.02 Work in the Crankcase ................................................................................................ 83
03.06.03 Work in the Exhaust Receiver .................................................................................. 83
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of Contents
40
03.06.04 Work in the Scavenge Receiver ............................................................................... 83
03.06.05 Responsibility for Operating the Turning Gear .................................................. 84
03.07 Erection of Large Structures at Height ......................................................................... 84
04 Electrical Erection ......................................................................................................................... 86
04.01 Electrical Erection Work in General................................................................................... 86
04.02 Particular safety hazards related to electrical erection works ................................ 86
04.02 Acid filling of Batteries ........................................................................................................... 87
04.04 Temporary Electrical Installations ..................................................................................... 88
04.04.01 Site Construction Power ............................................................................................ 88
04.04.02 Mobile Generators ......................................................................................................... 89
04.04.03 Mobile Generator Installation ................................................................................... 89
04.04.04 Mobile Generator Operation and Maintenance ................................................... 90
04.04.05 Temporary cables in S-hooks ................................................................................... 90
05 Testing and Commissioning ...................................................................................................... 91
05.01 Initial Energizing ...................................................................................................................... 91
05.02 Permit to Work Procedure .................................................................................................... 91
05.02.01 Issuing the Permit to Work ........................................................................................ 92
05.02.02 Completion of the work - or cancelling the Permit to Work ......................... 92
05.02.03 Re-establishing the System (removing safety precautions) ....................... 93
05.03 Working on Energized Mechanical Systems .................................................................. 94
05.03.01 Typical Safety Hazards in Mechanical Systems ................................................. 95
05.03.02 General Safety Precautions ....................................................................................... 95
05.04 Work on Energized Electrical Systems ............................................................................ 96
05.04.01 Typical Safety Hazards in Electrical Systems ..................................................... 96
05.04.02 General Safety Precautions ....................................................................................... 96
05.04.02 Earthing Procedures ..................................................................................................... 97
05.04.03 Earthing and short-circuiting devices .................................................................... 97
05.04.04 Procedure for the use of Earthing Cables ............................................................ 97
05.04.05 Safety Distance to Live Parts .................................................................................... 98
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Table of Contents
41
05.04.06 Work on Alternators ................................................................................................... 100
05.04.07 Equipment Containing Sulphur Hexaflouride (SF6) ....................................... 100
05.04.08 Work in Substations with Exposed Live HV Conductors ............................... 100
05.04.09 Use of Cranes, Portable Ladders and Long Objects ....................................... 101
05.05 Switching Operations on Switchgear.............................................................................. 101
05.05.01 Persons Operating Circuit Breakers ..................................................................... 101
05.05.02 Switching ........................................................................................................................ 101
05.06 Yellow Safety Rules for switching of LV, MV and HV switchgear ........................ 103
06 Steam Systems ............................................................................................................................ 105
06.01 Steam system hazards ....................................................................................................... 105
06.01.03 High pressure steam or feed water pipe leakage ........................................... 105
06.02 Preventative measures ........................................................................................................ 105
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
42
01 Common Activities
01.01 Housekeeping A neat and tidy work place is a major contributor to the prevention of accidents and to
increased work efficiency.
The following precautions shall be observed on BWSC work sites:
All areas being worked in shall be kept clean.
Walkways and scaffolding decks shall be kept clear, free from rubbish, tools, electrical
cables, materials, protruding nails, splinters, loose boards etc.
Access ways shall be kept in good condition.
Floors shall be kept free from oil, grease and water.
Any spillage shall be wiped up as soon as possible after being spotted.
Rubbish and scrap shall be removed to a disposal or storage area as soon as possible.
Waste bins shall be used throughout the construction site.
This will prevent that operatives are injured by tripping, stepping on or bumping into tools and
other objects lying around or by objects falling from above.
Maintaining good housekeeping at all times is a task which requires constant management
involvement and monitoring. From the start of the project all parties will be required to
demonstrate discipline and respect for good housekeeping.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
43
01.01.02 Dedicated Housekeeping Team
When several contractors or teams are working in the same area, each team shall be
responsible for the housekeeping relating to their own work. In practice however there may be
good , this may lead discussions about who shall do what. In such cases, it may be better to
employ a separate and dedicated team with no other task than to maintain good
housekeeping.
The Site Manager and Supervisors shall ensure that arrangements are in place so that
materials and waste generated during construction will be removed from scaffolding and
footpaths/access routes on a daily basis.
As a general rule, every individual shall clean up after himself at the end of the day, including
placing tools and equipment in the designated tool stores. Once a week, time shall be set aside
to a more thorough general cleaning of the work areas.
01.01.03 Waste Categories
Local rules and regulations will determine
the requirements with respect to sorting
waste and refuse in various categories.
The Site Manager will familiarize himself
with such requirements.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
44
01.01.04 Control of Dust etc.
Under dry conditions and where dust
could otherwise be generated, roads and
debris shall be sprinkled with water to
minimize the resulting health and safety
hazards.
01.02 Fire Prevention
01.02.01 The Fire Triangle The fire Triangle is a simple model for understanding fire. It
illustrates a fire requires three elements: Heat, fuel and
oxygen. The fire is prevented or extinguished by removing
any one of them.
Looking at the work place, the factors listed below shall be
considered when reducing the risk of fire.
Good housekeeping reduces the risk for fire.
Electrical installations shall be kept clean and protected against accidental cutting,
hammering, etc.
Smoking is only permitted in designated places.
Flammable fluids shall be stored in their original packaging and in designated areas. All
use shall be subject to the relevant safety precautions.
Special safety instructions apply to hot work, ie. any type of welding, soldering and
flame cutting. Please refer to Section 3 under mechanical erection.
LED lamps shall be preferred to illuminate work areas – they consume less power and
consequently present a reduced fire hazard. If halogen lamps (flood lights) are to be
used they shall be securely fastened.
Gas cylinders, such as LPG, acetylene and oxygen shall be kept in proper trolleys or
baskets, fully secured with straps. When not in use, the valve fitted to the cylinder shall
be closed. Cylinders shall be capped when the regulator is removed.
Fire extinguishers shall always be in good working conditioning and easily accessible.
Extinguishers are subject to regular inspection and re-fill according to the date labels.
As a minimum, two different types of extinguishers, ie. CO2 and Foam Extinguishers
shall be available throughout the site.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
45
01.02.02 Spontaneous Combustion
Spontaneous combustion occurs when a fire starts by itself, without an external ignition
source. Substances with low ignition temperature exposed to oxidation or bacterial
fermentation may begin to release heat. If the heat cannot escape, the temperature may rise
above the ignition point and the material will self-ignite and burn.
Materials likely to be affected by spontaneous combustion, and which are commonly found in
the work place is clothing, rags or other fabrics that have been in contact with oil. Such
material shall immediately after use be removed from the work area and kept in a closed steel
drum.
In biomass plants, various types of fuel may be subject to self-ignition, such as wood chip
piles, haystacks, seeds containing oil or animal manure. Special guidelines are available and
shall be consulted in these circumstances.
01.02.03 Fire Emergency Response
More detailed instructions are given in this manual Part 1, Chapter 10.05.
01.03 Working Clothes Suitable work clothes in proper condition shall be worn at all times. Normally full-body work
clothes are required, however in hot conditions and where the risk of fire is small or negligible
T-shirts may be allowed at the discretion of the site manager.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
46
01.04 Personal protective equipment
(PPE) Personal protective equipment shall be selected and used
when workplace hazards cannot be eliminated or
controlled by other means.
Certain PPE shall always be worn on site – see symbols on
the right. Risk assessments shall be carried out and used
to determine the need for additional PPE.
PPE shall NOT be the primary or only means of controlling
hazards. Always try to eliminate or avoid the hazard in
the first place.
Hard hat, safety glasses, hi-vis
vest or jacket, gloves and safety
shoes or safety boots is
mandatory PPE on all BWSC work
sites
Mandatory personal protective equipment
on BWSC sites:
When grinding, chipping and cutting or when working adjacent to such work, safety goggles
and ear protection shall be worn. Respiratory protection, e.g. filter masks or disposable masks
may also be required in situations when dust is created.
During welding operations the welder shall wear gloves, eye/face protection mask. If the
natural ventilation is insufficient mechanical exhaust ventilation shall be installed and used.
Special rubber (nitrile) gloves, apron, boots and full face shield shall be used if the worker
works with acidic or caustic media.
Whenever diesel engines or other noise generating equipment is in operation, ear protection is
mandatory.
The responsible supervisors shall make available appropriate equipment to satisfy the above
requirements. PPE shall be CE marked or similar and maintained or replaced as appropriate.
The Site Manager may dispensate from the general requirement to wear safety glasses,
hard hat or gloves in cases where the PPE does not add safety, e.g. termination of cables could
be difficult while using gloves. Another example: The use of hard hat and safety glasses is
probably not required inside the control room.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
47
01.05 Hand Tools and Power Tools
01.05.01 Electric Hand Tools – testing
General precautions
Before using any electrical power tool always ensure that the electrical connections,
plugs, cable insulation and extension cords are intact and without damages.
All hand tools should be either earthed or double insulated.
All extension leads shall be fully extended to prevent overheating.
Always use a machine of type, size and capacity appropriate to the work.
Charging points for battery powered tools shall only be used in dry and safe areas of
permanent or temporary buildings.
Use proper drill size in accordance with the drilling machines capacity.
Adjust the pressure applied to the drilling machine to the actual working position and
material to be drilled.
Be prepared for an abrupt stoppage of the drill bit.
Never drill in loose material, always secure the material before drilling operation
commences.
Testing (PAT)
Electrical hand tools/power tools shall be
subject to regular testing.
In the UK: Portable Appliance Testing (PAT testing) as
follows:
Double insulated tools: Every 6 months
Other electric tools: Every 2 months
In other countries follow local rules and regulations.
The testing includes the following:
Check that cable and the insulation is intact
Check that the plug and cable relief arrangement is intact
Check that the appliance (housing etc.) is intact
Check that the appliance is in working order
Appliances that fail the test shall be marked “Do not use” and set aside for repair or disposal.
All repairs shall be performed by a skilled electrician.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
48
After successfully completing the test the
appliance shall be clearly marked with a
suitable label.
01.05.02 Grinding and Cutting Tools
Use the correct disks for the task (cutting or grinding) and the material.
Ensure that the grinder operates with the correct speed for the disc.
Attach the grinding disc properly, using the correct tools.
Guards shall be correctly positioned and properly adjusted.
Use the grinding-cutting machine correctly only applying correct pressure
Always remove loose hanging clothing before commencing operation.
Disc cutters shall only be used when standing on a firm, level base.
Wait until the disc stops spinning before laying down the machine.
Be careful not to place the machine so the disc can get wet.
Be aware of sparks being emitted. When grinding in an area where other people are
working or may pass by, make sure that sparks are contained. This can be done by
shielding the area by temporary, movable walls or curtains.
01.05.03 Compressors and Pneumatic Tools
Compressors/ tools are subject to planned maintenance and regular inspections.
Air receivers shall be fitted with pressure gauge, safety valve, drain point and access
for cleaning.
The safe working pressure shall be identified on all air receivers.
All guards and covers shall be fitted over moving parts of compressors, especially on v-
belts and pulleys.
Cutting tools provided are to be kept sharp and should be held securely in their fitment.
Ensure that hoses are the right size for the tool and that the length of the hose is kept
as short as possible.
Hoses shall be kept free from corrosive materials and protected from interference by
passing traffic.
Hoses shall be kept clean when disconnected.
All connections shall be properly clamped to prevent the hose whipping.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
49
01.05.05 Machine Tools
A common machine tool used during construction work is the pipe threading/cutting machine.
The following precautions shall be observed:
When piping is operated in the pipe threading/cutting machine and extending beyond
the machine, the operator shall make sure that the pipe is free to turn and properly
supported.
Fittings shall not be applied to the threaded pipe while in the machine.
Cutting of pipes in the machine shall only be performed if the machine is equipped with
a proper cutting tool. Never use a hack-saw while the pipe is spinning.
Threading and/or cutting of pipe where fittings already are mounted shall never be
performed in the machine.
Always make sure that the electrical cord to the machine is undamaged.
Do not allow cutting oil to spill onto the floor. It causes a slipping hazard
and damages the concrete. Use a suitable bucket to collect any overflow
and keep absorbent sand at hand.
01.06 Working at Height
01.06.01 General precautions
Work above 2 meters shall be carried out using scaffolding or mobile Elevated Work
Platforms (MEWP).
Safe means of access and egress shall be established and maintained.
Erect signs and barriers directly below works to warn of overhead operations.
Erect edge protection at all openings or edges ie. main guard rail at 1000 mm above the
floor level, a mid-rail 500 mm above floor level and a toe board at least 150 mm high.
Where edge protection is not practicable identify alternative means of fall prevention/fall
arrest or work restraining system. See below.
To protect third parties against debris falling, chutes, or full enclosures shall be installed.
All equipment used shall be checked to ensure it is in good working order, to correct
specification, and in date for inspection.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
50
01.06.02 Fall Arrest and Work Restraint Systems
Providing adequate platforms and edge protection may not
always be possible or reasonably practicable. If so, either
safety nets or harnesses will be required. They do not stop
people falling but can minimize the potential injuries after a
fall.
If nets are used, make sure they are properly installed by
competent riggers.
There are two types of harness protection that a person can
use:
Work Restraint System - this stops a person from falling in
the first place
Fall Arrest System - this stops the person after he has
fallen
If harnesses are used, make sure they are fully intact, including lanyard, shock absorbing
mechanism and/or retractable device. Check that the inspection date on the harness is valid.
They shall be securely attached to a strong anchoring point above the person using it. Using
harnesses require user discipline and active monitoring by management.
When using a fall arrest system, due consideration shall be given to the rescue of a person
suspended in the lanyard. A procedure and suitable equipment shall be in place before the
work commences.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
51
01.06.03 Ladders and Step Ladders
Ladders shall be of an approved type, constructed,
maintained and used so that their use will not endanger
the user or other workers.
Ladders shall only be used for work of short duration or
for access in cases where it is not possible to build proper
access stair.
Only one person shall be on the ladder at any given time
Stepladders shall not be used.
The ground base for the ladder shall be firm and level.
The correct angle of rest for a ladder is 75 degrees, or a base to height ratio 1:4.
Ladders shall be secured against slipping, by tying it to the scaffold or the wall.
Ladders may only be footed as a precaution against movement if less than 3m high.
Damaged ladders shall be immediately taken out of service and destroyed.
Ladders used for access to scaffold, platforms etc. shall extend minimum 1.3 m above
the step-off point.
Cable ladders shall not be used as working ladders.
Ladders shall not be placed in front of a door, unless the door is prevented from
opening.
Metal ladders shall not be used near live overhead electrical lines.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
52
01.06.04 Scaffolding
Only trained competent operatives may
erect, modify or dismantle scaffolding
towers.
Scaffold may only be erected or built from
approved materials.
Any modification of a scaffold requires that
the scaffold be re-inspected and its approval
renewed.
After moving of a scaffold – also if the
complete scaffold is lifted by a crane - the
scaffold shall be inspected again and
approval renewed.
Excavations adjacent to scaffold bases
should be avoided; where this is
impracticable the excavations shall be
monitored to ensure the stability of the
structure is not affected.
All scaffolding shall be inspected on erection and after alterations.
Scaffolding over 2m in height shall be inspected every seven days, and the results shall
be recorded.
Approval by scaff-tag or similar shall be clearly visible at the entrance to the scaffold.
All platforms shall be fully boarded and fitted with toe-boards and guardrails.
Unused ladder gaps shall have guardrails and toe-boards fitted.
Scaffold should not be used in the vicinity of live overhead power lines.
Full enclosure, debris guards, netting and fans shall be considered for high-rise
scaffolds and those close to public areas.
Ties shall be used in exposed or windy conditions.
Traffic movements shall be restricted around scaffold bases.
Materials or debris shall not be permitted to accumulate on the working platforms.
Maintain good housekeeping on the scaffold.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
53
01.06.05 Mobile Scaffold Towers
For Mobile Scaffold Towers, the following
precautions shall apply in addition to the items
listed under ‘scaffolding’ above:
Personnel and materials are to be removed
before the tower is moved.
The ladder access should be internal and on
the narrowest side.
Always apply the wheel brakes before using
the tower.
When applicable, the stabilizer arms shall be
extended and in firm contact with the ground.
01.06.06 Mobile Elevated Work Platforms (MEWP)
Platform capacity shall be checked to ensure
sufficient height and safe working load for the
work undertaken, including number of persons
and materials.
The area of the work is to be cordoned off.
Platforms shall not be operated outside limits
set by the manufacturer.
The operating area shall be firm and level.
Stabilisers shall be fully extended before the
platform is raised; platforms are not to be left
unattended in the raised position.
Persons inside the cage of cherry pickers shall
always wear a safety harness clipped to the
designated clip-on point.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
54
Platforms shall not be moved until they are clear of loose material.
Maintain good housekeeping on the working platform. Avoid loose tools and materials
lying around on the platform floor.
Platforms and similar equipment shall be regularly maintained. Records shall be kept.
01.07 Lifting Operations
01.07.01 General Precautions
The following precautions and responsibilities apply to all lifting operations:
1. All lifts require that a specific Risk Assessment and Method Statement be prepared.
2. The operator shall make sure he knows the weight of the load and his equipment’s Safe
Working Load (SWL).
3. The operator shall refuse to lift if the load exceeds the SWL or if the rigging on the load
or the hook is not done properly.
4. The operator shall never lift a load that is not placed freely and shall never pull
sideways on a load.
5. The operator shall be familiar with the lifting equipment and it’s manual.
6. Never leave a lifting device with load hanging in the hook or without the brake being
applied.
7. The operator shall immediately stop the lifting operation until defects are corrected.
8. Rigging of loads shall be done by workers with sufficient training and knowledge about
rigging work.
9. All rigging equipment such as wires, chains, etc. shall be approved for safe working
load. The rigging equipment shall periodically be examined for damage and shall be
immediately discarded if damaged.
10. Safety distances from live electrical equipment shall be maintained as defined in the
safety rules for electrical works.
01.07.02 Rigging and Slinging
Rigging
1. A rigger is a dedicated person who attaches or releases a load from a crane hook.
2. The rigger shall work closely with the crane operator and he shall be authorized by his
superior or a rigger after sufficient instructions.
3. The rigger shall reject any slings and other lifting gear, which is damaged.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
55
4. The rigger shall be informed about the weight of the load to be lifted.
5. The rigger shall be informed about special loads, which shall be rigged in a certain way.
Slinging
1. Slings and lifting gear shall be clearly marked with safe working load (SWL).
2. All slings and lifting gear shall have a SWL certificate.
3. Special lifting gear shall only be used for its intended purpose.
4. Slings and lifting gear shall be kept and stored properly.
5. Slings and lifting gear shall be kept clean, so that it is possible to read the safe working
load marking and inspect for damages.
6. Allowance should be made for increased loading on the eyebolt when angled slings are
used.
7. Use the longest sling practicable to reduce the angle between the legs of the sling.
8. The size of the sling should be adequate for the load being lifted.
9. Slings should be protected from sharp edges by suitable
packing.
10. Slings should not be knotted, and wire slings made up of wire
clamps are not allowed to be used for lifting operations.
11. When using slings on machine components, protect the part
with wood, cloth or use a special soft sling designed for this
purpose.
12. The tip of a hook is relatively weak and should not be used for lifting.
13. The load should be slung centrally to avoid eccentric loading on the hook.
14. A safety catch shall be used to prevent load displacement from the hook.
15. Never attach a sling to a finely machined surface such as the journal bearing of a shaft.
16. Make sure the slings are free from kinks.
17. Items may never be lifted in one point only unless a special lifting point on the lifting
device has been provided.
18. Items may never be lifted in a sling just passing unlocked over the hook, if it is
connected to 2 individual points.
19. As soon as the load is lifted off the supports check the wires before carrying out further
handling operations.
20. The BWSC supervisor shall ensure that all rigging for heavy lift operations is approved
by competent person before start of operations.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
56
Sling Angles
Lifting Beams
Lifting beams (also called spreader beams) are used in slinging/rigging to distribute the load or
keep slings in required positions.
Some lifting beams are custom made and supplied together with the equipment they are
designed to lift. As an example, the chimney sections are often supplied with the lifting beam
used for erection of the chimney sections. Another example is the lifting beams used for heavy
lift of diesel engines and generators.
Handling of roof or wall panels are often done by special lifting beams/attachments. Special
attention shall be given to handling these light objects in windy conditions.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
57
Examples of lifting beams:
Adjustable spreader beam Simple lifting beam Four point spreader
Lifting beams shall be marked with SWL and only used according to their intended purpose.
Eyebolts and Shackles
1. Certain eyebolts, particularly those without collars, or those with welded collars are
unsuitable for general lifting purposes. Use the correct eyebolt for the job and make
sure it is screwed firmly onto the joint faces and that its collar is properly seated.
2. Safety allowance should be made for increased loading on the eyebolt when angled
slings are used.
3. When using a shackle use the appropriate pin. Do not use a temporary pin.
4. The suspension or anchoring point to which any tackle is attached should be as strong
as the lifting tackle itself.
Eyebolt Shackle Collar
01.07.03 Examination of slings and lifting gear
Slings and lifting gear shall be thoroughly examined by a competent person at least once every
12 months. These inspections shall be recorded by the Site Safety Officer.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
58
Wire rope slings shall be rejected if:
They are attacked by rust or corroded.
A single strand in the wire is broken.
They have received a kink that cannot be straightened out.
They have been crushed.
Chains shall be rejected if:
A single chain link is visually damaged or worn.
A single chain link is deformed.
There are signs that a heavy corrosion/pitting corrosion have
taken place.
Synthetic fibre straps shall be rejected, if:
They bear sign of wear and tear.
SWL label or markings are missing.
Hooks shall be rejected if:
They have been straightened and/or damaged.
The safety hatch is slack or missing.
In case any of the above requirements are not complied with work shall be stopped and
reported to the supervisor in charge of the work and to the site manager.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
59
01.07.04 Hand signals for Lifting Operations
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
60
01.07.05 Heavy Lift Operations
The heavy lift procedures for transportation, unloading, sliding and positioning of engines and
generators are subject to individual analysis, Method Statement and Risk Assessment. The
operations will always be under direct supervision of authorized specialists from BWSC or a
BWSC appointed person.
01.07.06 Forklifts and Telehandlers
A forklift or telehandler (forklift with a telescopic boom) shall never be loaded above the limit
stated on the fork lift marking plate. It is the operator’s responsibility to know the weight and
the approximate centre of gravity of the load.
The driver shall always make sure that he has a clear view in the driving direction. If this is not
the case, or when working in congested areas, a banksman shall be used.
The driver of a forklift shall be trained in forklift operation and possess a valid certificate in
accordance with the local regulations.
Daily inspection/checks by the operator shall be made including brake testing. These checks
shall be recorded.
Safety Precautions:
Always drive with the forks in low position and the frame tilted back.
Do not drive with passengers.
Always watch clearance during lifting or lowering.
Be extremely careful with transport of long items.
Never drive if load is not safely loaded. Palletised loads shall be checked for safety
before lifting.
The load shall never be carried above other persons.
Pay attention to the stability of a fork lift truck which can be adversely affected by such
things as uneven, soft, slippery or sloping ground, rapid turning, breaking or
accelerating.
If the fork lift truck is operated inside a building, adequate ventilation will be provided
to disperse any fumes generated by the engine. Electrical trucks shall be preferred.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
61
Fork lift trucks shall be fitted with safety belt and this shall be used by the operator.
Roof windows shall be fitted with a protection grille or similar.
If a telehandler is equipped with a lifting attachment, the rules and precautions listed under
cranes shall apply.
01.08 Working with Substances Hazardous to Health
Many substances have the capacity to cause injury to personnel. The injury may be
immediately apparent, or it may take years to manifest itself.
Some substances used at work are obviously dangerous e.g. sulphuric acid. But many
substances used at work are not obviously hazardous and the injury or damage sometimes
appears unexpectedly after a period of time. Hazards may be biological, chemical or physical
and include fire and explosion.
Handling of chemicals shall be carefully considered and a risk assessment worked out.
United Nations Hazard Symbols (UN Globally Harmonized System of Classification and
Labelling of Chemicals (GHS):
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
62
01.08.01 Material Safety Data Sheets (MSDS)
A material safety data sheet (MSDS) shall be available on site for all substances with potential
harmful effects. The MSDS provide workers and emergency personnel with procedures for
handling or working with that substance in a safe manner and includes information such as
physical data (melting point, boiling point, flash point, etc.), toxicity, health effects, first aid,
reactivity, storage, disposal, personal protective equipment and spill-handling procedures.
It is important to use an MSDS specific to both country and supplier, as the same product (e.g.
paints sold under identical brand names by the same company) can have different formulas in
different countries.
The Site Safety Officer will maintain a file of MSDS as part of the safety files. In addition,
relevant MSDS may be posted in the actual work place, near to the place where the substance
is used and stored.
It is the responsibility of the Supervisor to familiarize himself with the MSDS for any
substances handled under his scope of work, and to ensure that necessary guidelines are
communicated to and followed by the personnel working with these substances.
01.08.02 Control of Substances Hazardous to Health
Based on the information obtained from the MSDS and other sources, an assessment can be
prepared with respect to the necessary controls (in UK regulations referred to as the COSHH
assessment - Control of Substances Hazardous to Health).
This will include an assessment of:
Potential hazards.
Frequency and duration of exposure.
Control Measures, including necessary PPE to be used, training of operatives, emergency
procedures, safety signage etc.
General Precautions
When chemicals arrive on the Site, check container labels and consignment notes, to
make sure that the goods are supplied as ordered.
Check that the containers are not damaged.
Ensure that handling and storage arrangements are in accordance with the suppliers
warning labels and instructions.
Ensure that different chemicals are kept apart, to ensure that if a leakage should occur,
incompatible chemicals would not come into contact.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
63
Display hazard warning signs at the entrance to the store if appropriate.
Never mix different chemicals, even in small quantities, without the manufacturer’s
recommendation or instructions. Mixing of different chemicals may produce a
dangerous reaction.
Operatives shall be provided with a suitable barrier lotion or appropriate gloves when
they undertake work, which may cause skin damage.
Use protective clothing and goggles/face shield as appropriate.
When required, appropriate ventilation apparatus shall be used.
If there is a danger of a contamination of the skin or eyes an emergency shower or
other means of washing facilities shall be provided close to the place of work.
Eyewash facilities shall be available, conveniently located and marked.
If there are signs of a person having been exposed to dangerous/poisonous materiel, i.e.
showing symptoms of headaches, dizziness, looking intoxicated or very tired, correct medical
treatment shall be provided right away. The doctor shall be informed of which substances the
injured person has been working with.
01.08.03 Asbestos and Man-made Mineral Fibres (MMMF)
Asbestos was earlier a very common material used in buildings as well as mechanical and
electrical equipment. BWSC will never use Asbestos in any new installations.
If asbestos is present in existing installations where BWSC shall undertake work, this shall be
subject to a job-specific Method Statement and Risk Assessment under the guidance of
asbestos specialist advisors.
01.08.04 Working with Explosives
Work with explosives shall follow local and general rules for storage, transport and use of
explosives. The work will be subject to job-specific Risk Assessment and Method Statement.
01.08.05 Radiation / working with radio-active materials
All radioactive material on site shall be properly marked and
stored in accordance with international law.
Use of radioactive source or x-ray for material control shall
take place when other workmen are not at the work site. If
this is not possible, proper marking and warning shall be
given by the operator before using the radiation source or
releasing it from its protective shelter.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
64
If a person has been exposed to a radioactive source, medical treatment shall be sought
right away and the Safety Officer shall be advised. It is also important to find out where the
affected person has been and for approximately how long, such that the doctor can be
correctly informed of the potential dose of exposure to radiation.
Always remember radiation is dangerous and that you cannot see, smell or hear it.
Always be extra careful and follow the x-ray operators’ advice.
01.09 Working in Confined Spaces
01.09.01 Confined space definition and examples
A confined space can be any space of an enclosed nature where there is a risk of death or
serious injury from asphyxiation, fire or explosion.
Examples of Confined Spaces
Specific examples of areas which, depending on the work being
undertaken may come under the definition of a confined space:
Storage/service/buffer/run-down tanks (fuel, lubricants, water)
Flues, chimney stacks
Exhaust gas silencers
Ductwork (air intake, exhaust, ventilation)
ID Fans
Diesel engines’ housing, generators
Vessels
Boilers
SCR Reactors
Silos (urea granulate)
Excavations, tunnels etc.
Data floors and similar places where egress may be difficult
01.09.02 Typical Hazards to consider in Confined Spaces
The most likely hazards that can occur in a confined space are:
Lack of oxygen
Poisonous gases, fumes or vapour
Liquids and solids which can suddenly fill the space
Fire and explosions
Residues left in tanks etc.
Dust in high concentrations
Hot conditions leading to dangerous rise in body temperature
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
65
Apart from these, all usual hazards which can be found outside the confined space may also be
present inside the confined space. This includes electricity or mechanical equipment. Where
these hazards are present in a confined space the precautions will almost always be more
extensive than where they appear outside the confined space simply because of the enclosed
nature of the space.
01.09.03 Risk Assessment
Any work in confined spaces requires a Risk Assessment to be carried out by a competent
person.
If the Risk Assessment identifies risks of serious injury from work in the confined space, the
following key duties will apply:
If at all possible, avoid entry into the confined space
If entry is unavoidable, follow a safe system of work
Put in place adequate emergency arrangements before the work starts
01.09.04 Work planning – avoid or reduce entry into confined spaces
Good work planning or a different approach can reduce the need to enter the confined space or
at least reduce the frequency of access to the confined space. Some work may be done from
the outside (pre-assemblies, extended tools etc).
01.09.05 Safe System of Work
The following checklist includes some essential elements:
01 Appoint a supervisor with the responsibility to ensure that the necessary preparations
are made and that suitable precautions are taken.
02 Appoint a person, who is placed outside the confined space at all times during the
works.
03 Deploy only persons suitable for the work (correctly trained, physical build, experience,
medical condition etc.).
04 Mechanical and electrical isolation of equipment which could inadvertently be operated.
Check that isolation is effective.
05 Clean before entry.
06 Check the size of the entry. Is it big enough for workers wearing all the necessary
equipment to climb in and out easily and provide safe access and egress in an
emergency?
07 Provision of ventilation. It may be necessary to increase the number of openings or
provide mechanically forced ventilation.
08 Testing the air may be necessary to see if it is free from toxic or flammable vapours
and fit to breathe. Suitable gas detectors shall be used by a competent person.
09 Provision of breathing apparatus may be necessary. Never try to “sweeten” the air in a
confined space with oxygen as this can greatly increase the risk of fire or explosion.
10 Provision of special tools and lighting may include non-spark tools and specially
protected lighting or use of low voltage equipment.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
66
11 Fire fighting equipment and a fire warden shall be in place before hot work starts.
12 Emergency arrangement shall be in place, and includes equipment, training and
practice drills.
13 Rescue harnesses shall have a lifeline running back to a point outside the confined
space.
14 Communications shall be adequate, reliable and tested between people inside and
outside the confined space.
01.09.06 Permit to Work
Confined space work requires a Permit to Work in which comprehensive controls are described
including the need for a contingency plan for rescue of the person(s) inside the confined space.
Remember that the confined space work also needs to take into account other work on site
which may result in a fire alarm or otherwise affect the confined space work.
01.10 Lightning Safety In locations prone to thunderstorms, the Site Management shall implement this Lightning
Safety Policy. The policy covers the following safety issues:
Awareness
Warnings and precautions
Safe places
First Aid in case of lightning
01.10.01 Awareness
Everybody on site shall be aware of the hazards, dangers and precautions associated with
lightning. Consider to incorporate safety awareness of lightning in the site safety induction
program and in the site rules. Use tool box talks and site safety notices to ensure the
necessary guidelines are known to people.
01.10.02 Warnings and precautions
The weather forecast is the obvious source of information when planning the work activities
that are prone to risk of lightning. However, the forecasts may not be accurate, and
thunderstorms can occur at very short notice. Take notice of early signs of thunderstorms:
high winds, dark clouds, rain, distant thunder or lightning.
Activities which are particularly risky during lightning include crane work, erection work and
work on or near tall structures. Keep in mind that some work activities cannot easily be
abandoned with short notice.
If these conditions exist, do not start a task you cannot quickly stop. Examples of such
activities are heavy lift operations and pouring of monolithic concrete structures.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
67
Consider the measures necessary in case a job has to be aborted at short notice. Consult
specific Risk Assessments and Method Statements where applicable.
01.10.03 Safe places
Access to a safe place is not always readily available on a construction site, and therefore,
shall be planned in advance. Since there is no safe place outdoors, the only safe shelters will
be buildings and vehicles.
A safe building is one that is enclosed with a roof, walls and floor. A structural steel building
where the cladding roof and walls are not yet installed can also be considered safe, as the steel
structure will provide a Faraday’s cage. It is required however, that sufficient steel is in place
so as not to leave major open gaps in the structure. Once inside, stay away from plumbing and
pipework, electrical cables and electronic equipment unless these items are not yet connected
to any outside structure.
Unsafe buildings include work areas covered by a sun shade roof only, open garages, covered
patios, lunch/coffee break shelters or sheds.
A safe vehicle is any fully enclosed metal-topped vehicle.
Backhoes, bulldozers, loaders, graders, scrapers, mowers, and other heavy equipment that
employ an enclosed rollover systems canopy are safe in nearby electrical storms. The operator
should shut down the equipment, close the doors, and sit with hands in lap, waiting out the
storm. While inside a safe vehicle, do not use electronic devices and avoid touching any metal
parts. Under no circumstances during lightning should the operator attempt to step off the
vehicle in an attempt to find another shelter.
Unsafe vehicles include convertibles and open cab construction vehicles without any roll over
canopy. The rubber tires of a vehicle do not provide any safety against lightning.
Assess your lightning risk and take appropriate
action.
During thunderstorms no place outside is safe.
If you can hear thunder, lightning is close enough
to strike.
Stop what you are doing and seek safety in a
substantial building or a hard-topped metal vehicle.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
68
How far away is the lightning?
Count the number of seconds between a flash of lightning and the sound of the
resulting thunder.
Divide this number by 5 to get an estimate of the distance in miles to the lightning
strike.
Each second corresponds to a distance of one kilometre
Remember, if you are outdoors and can hear thunder, you are in danger of being struck by
lightning.
01.10.04 First aid if a person is struck by lightning
Lightning victims do not carry an electrical charge. They are safe to touch and need urgent,
medical attention. Cardiac arrest is the immediate cause of death for those who die.
Some deaths can be prevented if the victim receives the proper first aid immediately.
Call Emergency Ambulance and perform CPR if the person is unresponsive or not breathing.
Use an Automatic External Defibrillator if needed.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
69
01.11 Safety and warning signs - examples
The following signs are commonly used on BWSC construction sites.
01.11.01 Prohibition signs
No smoking No naked fire No pedestrians
No handling vehicles Not drinking water No unauthorized persons
01.11.02 Warning signs
Inflammable
substances or high temperature
Explosive
substances
Toxic substances Corrosive
substances
Radioactive
substances
Overhead loads Handling vehicles Electrocution
danger
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
70
Warning Laser rays Unlevelled fall Falling materials
Oxidizing
substances
Non ionizing
radiation
Strong magnetic
field
Harmful or
irritating substances
01.11.03 Emergency signs
Emergency way out Emergency way out Emergency way out
First aid kit Emergency way out Emergency shower
Defibrillator (AED)
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Common Activities
71
01.11.04 Fire fighting signs
Fire hose Fire extinguisher Emergency phone Emergency way out
01.11.05 Personal Protective Equipment signs
Use safety glasses Use protection helmet Use ear protector
Use chemistry mask Use protection boots Use protection gloves
Use face protection Pedestrian way Use protection harness
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
72
02 Civil Works
Civil Works are normally subcontracted partially or in whole to local subcontractors. It will be
part of the subcontractor’s responsibility to provide risk assessments for the activities under
his scope of work.
BWSC however maintain the overall responsibility for implementation of a management
system. For this purpose, the following guidelines are provided.
02.10 Excavation Work
All excavation work is to be planned in such a way that safety
hazards are minimized and controlled.
When working on construction sites within existing industrial
facilities, special precautions shall be taken with respect to any
underground and/or overhead services, as well as the potential
for contaminated soil.
02.01.01 Excavation Permit
In some cases where specific risks are
identified, such as underground obstacles or
special soil conditions, a “Permit to Excavate”
may be required. Where such system is in
place, no excavation may be carried out
without an Excavation Permit signed by the
person in charge.
A sample format is included in Appendix.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
73
02.01.02 General Precautions
Excavations shall be clearly marked all around. When required warning signs, including
electric warning lights shall be installed and maintained at all times.
Concrete barriers shall be placed where there is a risk of wheeled traffic coming close to
the edge of the excavation.
Materials shall be stock piled clear of the edge of the excavation.
Excavations should be back filled as soon as practicable.
All excavations that are to be accessed by persons and deeper than 1 m shall be
supported/shored or the sides battered, such that these are no steeper than 35 degrees
unless a qualified civil engineer determines otherwise.
Safe means of access to the excavation shall be established.
When designing the excavation support system, proper account shall be taken of the
loads from the surroundings, including traffic load and vibrations.
No change to the slope or shoring shall be made without prior approval.
Where flooding risk occurs, cofferdams/caissons to be installed with pumps of adequate
capacity.
02.01.03 Underground Services
Full details of underground services shall be obtained in advance from the owner, utility
or relevant authority.
Existing drawings to be utilised to trace buried services.
Accurate location of underground services by operatives trained in
the use of locating equipment such as cable scanners.
Trial holes may have to be dug by hand to confirm locations, taking
into account physical indicators such as junction boxes, manholes
and ground conditions.
The lines and depths of services to be marked, using paint, wooden
pegs, etc. before work begins.
Hand digging may be required in many cases.
CAT cable
scanner
All services are to be assumed to be live until proven otherwise - written confirmation
required.
Services crossing excavations to be supported.
Work to be supervised at all times.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
74
02.01.04 Use of Excavators and Heavy Equipment
Planned maintenance programme applies to excavators and other earth moving
equipment. Inspection register shall be completed.
Excavators and other plant to be operated by trained, certificated and authorised
operators
180 degree machines: When using the backhoe the bucket shall be lowered to the
ground.
360 degree machines: At least 600 mm clearance to be allowed for tail swing.
No persons are allowed to stand inside or work within the operating radius without the
operator’s specific permission.
Bucket/arms shall not be slewed over personnel, vehicles cabins or huts.
Travel and operations on a gradient shall be controlled to ensure machine stability.
On wheeled excavators it is essential that the tyres are regularly checked for condition
and correct tyre pressure.
Banksmen are to be used where the driver’s vision is impaired or he is operating under
congested conditions. Large excavators shall never be permitted to travel in a confined
area or near people without a banksman to guide the driver.
Machines shall not be refuelled whilst engine is running. Necessary precaution shall be
taken to prevent oil spill.
Trenching/deep excavation work shall be supervised to ensure the stability of the
machine and excavation.
Particular attention shall be paid to electrical lines overhead.
02.02 Concreting Works
02.02.01 Work with reinforced concrete
Working with reinforced concrete involves a great deal of manual work. When reinforcement is
cut and bent on site the contractor will establish a separate area for this work. An important
safety factor is properly organizing the area maintaining good housekeeping. The flow of
material – mainly steel bar- shall be planned and the cut-off collected in a suitable manner.
Cranes offloading steel bars, or loading sub-assemblies such as foundation baskets, should not
slew over the people operating the cut and bending machine.
Once the reinforcement bars are placed in situ, all protruding ends shall be capped with plastic
“mushrooms”.
02.02.02 Installing and stripping of formwork
The installation and subsequent stripping (removing) of formwork often involves the use of
cranes. Consequently, the precautions listed in this manual under “Lifting Operations” shall be
observed. Whether pre-fab panels are used, or the formwork is constructed in situ, manual
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
75
work will be necessary, involving stairs, scaffold and platforms. The relevant precautions for
such activities are described under “Working at height” – see chapter 01.06.
02.02.03 Mixing and placing concrete
When using ready-mix concrete, the potential safety hazards on site are
mainly related to risks of moving mixer trucks and use of concrete
pumps. Particularly, the hose from the concrete pump is a serious safety
hazard as it swings around over the area, and shall be carefully
controlled. In case the concrete is placed by using buckets lifted by
cranes, additional precautions shall be observed related to Lifting
Operations.
When using poke vibrators the operator is subject to vibrations through
his hands and body. The impact shall be minimized by use of good
equipment, work organization and PPE.
Where concrete is mixed on site, additional hazards shall be considered from the use of
hazardous substances and machines.
02.02.04 PPE when working with concrete
Skin contact with concrete may cause severe allergic reactions and shall therefore be
prevented. The use of protective skin cream / barrier cream is recommended. The use of
hard hats, safety goggles, safety boots and gloves shall be strictly enforced for all workers
engaged in concrete operations. Most likely the PPE needs to be supplemented with aprons
and full face shields if the operatives are in close contact with the concrete depending on the
risk assessment performed.
02.03 Demolition Work
This description refers to demolition of simple, internal walls, etc. and external single storey
outbuildings. Specific risk assessment shall be prepared in case of larger structures.
Ensure that all necessary permissions have been obtained.
Underground services to be located utilising site plans and location equipment.
Work area to be cordoned off utilising physical barriers.
Overhead power lines to be shrouded or disconnected.
Water, gas and electric services to be disconnected prior to work commencing.
Identify prior to work commencing whether the demolition area contains asbestos.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
76
Dust shall be controlled by dampening, housekeeping and local exhaust ventilation.
Associated noise known to be above the action level shall be controlled by work rotation
and barriers.
Work sequences to be planned and defined by site management.
Safe access and egress shall be maintained at all times
Suspicious substances or contamination to be investigated before work commences,
where contaminants are found during demolition process the area shall be evacuated
and tests carried out to ascertain the contents.
Monitoring shall be done continuously to ensure that all voids and open edges are
covered or fenced off.
Demolished material shall be disposed of at a controlled and approved tipping area.
In case asbestos or other contaminated building materials are found, all handling and disposal
shall follow local regulations and approved procedures. It will be necessary to prepare risk
assessments and involve specialist advisors.
02.04 Erection of Large Superstructures
The following structures are traditionally installed under the scope of BWSC Civil Works:
Structural and secondary steel erection for major buildings.
Installation of cladding systems on steel structure buildings.
Erection of Overhead Travelling cranes.
Erection chimney stack.
Site fabrication and erection of steel storage tanks.
Separate and specific Method Statements and Risk Assessments will be prepared for these
works.
02.04.01 Structural and Secondary Steel Erection
The hazards and necessary controls and precautions are mostly associated with lifting
operations and work at height. However, a safe system of work depends on erection
methodology, sequencing etc. which may vary from case to case, depending on availability of
cranes and other equipment. Consequently, a project specific Method Statement and Risk
Assessment will be required for these activities.
02.04.02 Installation of Cladding Systems
Basically, the same conditions will apply as mentioned above under steel erection. Again, the
cladding systems vary, from heavy concrete panels, over built-up systems to light sandwich
cassette systems. In case of light elements, the wind condition shall be monitored not to
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: Civil Works
77
exceed safe wind speeds. The erection methodology and types of equipment being used varies
accordingly, as do the safety hazards and controls.
02.04.03 Erection of Overhead Travelling Cranes
Basic hazards are associated with lifting operations and working at height. Additional hazards
shall be considered in connection with installation and commissioning of the electrical power
supply system. Overhead cranes are subject to regulatory testing. Legislation may demand an
independent 3rd party test with particular emphasis of static and dynamic load.
02.04.04 Erection of Chimney Stacks
Steel chimneys, whether lattice towers or steel casings, have the safety hazards associated
with lifting operations and working at heights. The heights involved are significantly more than
for other structures, usually 50 to more than 70 meters. Often two cranes will perform tandem
lifts, which further emphasises the importance of a well-planned work system and use of
proper equipment. Specific Method Statements and Risk Assessments shall be prepared.
In cases of concrete stacks, the hazards associated with concreting and slip forming/jump
forming will need consideration as well.
When welding inside the flues is required, the confined space rules will apply.
02.04.05 Erection of Storage Tanks
The fabrication and erection of steel storage tanks is subcontracted to specialised
subcontractors. However, it is the responsibility of BWSC Civil Works supervisor and Safety
Officer to ensure and monitor that a safe system of work is planned and implemented.
In case of smaller pre-fabricated tanks, the safety hazards are those associated with lifting
operations. In case of larger, on-site fabricated tanks, the hazards associated with work at
height, hot work and painting operations will also apply. Special hazards associated with use of
jacking systems may also be present.
The confined space requirements may be applicable for this type of work.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
78
03 Mechanical Erection
This chapter covers the Mechanical Erection activities up to the point of filling with media and
pressurising the systems. For all activities associated with mechanical systems or subsystems,
after they are pressurised, please refer to the Test & Commissioning in Chapter 5.
03.01 Unit Erection A large proportion of mechanical equipment is unitized and arrives to site as subassemblies in
various stages of completion. Piping is also to a large extent unitized in the form of complete
pipe racks, or sets of pre-fab pipe spools. Consequently, mechanical erection involves a large
extent of materials handling, lifting operations and work at height, which are covered by
Chapter 1, Common Activities. This chapter will, therefore, deal exclusively with those
activities which are specific to the mechanical erection work, before systems are pressurised.
Illustration from BWSC Erection Guidelines for fuel separator units.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
79
03.02 Hot work
Welding, soldering, flame cutting and metal grinding are types of ‘hot
work’.
The ignition sources - heat, open flame or sparks - that are produced by
the hot wok may ignite flammable material in the vicinity of the hot work
area.
The following precautions will apply:
Correct and appropriate PPE such as gloves, boots, overalls, aprons and welding
goggles/face shield shall be worn in accordance with the risk assessment.
A specific risk assessment shall be carried out and used to identify and evaluate the
presence of flammable or explosive substances.
A hot work permit may be required.
Fire sentries / fire wardens shall be placed as required e.g. if there is risk of fire or heat
being transferred to adjacent areas.
Mechanical extraction of fumes from the work place shall be used. Specific risk
assessment shall be prepared which may evaluate if natural ventilation can be used in
place of forced mechanical ventilation.
Operatives shall check equipment at the start of shift and disconnect when not in
attendance.
Personal jewellery shall be not be worn by operatives.
All necessary fire prevention equipment and fire extinguishers shall be checked and
shall be in place prior to commencement of work.
Always ensure that an escape route away from the work place is established and tested
before work starts.
Adjacent personnel shall be protected from arc welding glare by use of barriers such as
curtains or other means of screens.
When metal grinding, the emitted spark beam shall be caught and stopped in a box, net
or plate placed in front the beam.
Before welding or flame cutting on the external of tanks, check that the tank is either
completely empty and clean or filled with water. If the tank cannot be filled with water,
it shall be checked by measuring, that the tank does not contain flammable vapours
(gas-free), and that the tank is kept open, so no pressure can build up during the work.
Proper ventilation of the tank during the work shall be ensured.
When welding or flame cutting inside tanks the tank shall be clean with no oil or other
flammable liquid. Before entering the tank check by measuring that the tank does not
contain flammable vapour and that adequate ventilation is available. Light and other
equipment used in tanks shall be a type intended for work in tanks (safety voltage). All
personnel working in tanks shall before work commences receive detailed instructions
from the supervisor about the safe working procedure.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
80
Hot work inside tanks is also controlled under the confined space requirements. Please
refer to chapter 01.13 in this manual dealing with confined space work.
03.03 Chemical Cleaning of Pipes
Chemical cleaning of pipes (“pickling”) will normally be subcontracted to specialist companies.
In cases where chemical cleaning operations shall take place on site, this shall be subject to
specific risk assessments that are prepared beforehand (COSHH).
In general, the following precautions will apply when working with chemical cleaning of pipes:
All proper PPE shall be provided and worn.
Necessary emergency procedures and first aid measures, including safety showers,
shall be provided.
All required safety signage shall be in place.
All relevant environmental controls shall be in place.
Hazardous liquids shall be disposed according to local regulation and approved
procedures.
Never add water to acid, always add acid to water. Rule: ‘A’ to ‘W’.
03.04 Work with Hydraulic Tightening Tools
In general, working with Hydraulic tightening tools requires special attention to safety
procedures, and safety precautions shall be followed at all times to minimize the risk of
accidents in case of equipment failure or other failures during the works.
1. When using hydraulic tools appropriate PPE such as safety helmet, safety shoes, and
especially eye protection and gloves shall be used to prevent injury from spray of high
pressure hydraulic oil or in case of a hydraulic hose or pipe fracture.
2. Always inspect the tools for damage before using it on the works. Never use damaged
hydraulic tools, hoses, connectors or jacks. In case of doubt please contact the
supervisor or the Site Safety Officer.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
81
3. Always make sure that the hydraulic equipment is suited for the work. The maximum
safe working load or pressure on hydraulic jacks and hoses shall not be exceeded.
4. A safety zone shall at all times be kept clear around and above the hydraulic equipment
to prevent injury in case of equipment failure or fracture of the bolt being tightened.
5. Please note that crack propagation and fracture of bolts have been experienced due to
material defects, notch effect related, corrosion fatigue and other faults.
6. Always carefully follow manufacturers’ instructions.
7. Please see below photo showing an example of a safety zone, where you shall not, for
any reason, be inside or lean into, with any part of the body.
03.05 Pressure Testing
Normally pressurized tanks and receivers are supplied with a pressure certificate from the
supplier. These will therefore not require any further testing on site.
In cases where pressure test of tanks or receivers is carried out on site,
and when pressure testing pipe work, the relevant safety hazards and
precautions shall be evaluated.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
82
03.05.01 Pressure Testing Hazards
The main hazard when pressure testing is the unintentional release of stored energy. Pressure
testing using a liquid as the pressurizing medium (hydraulic testing) is by far the safer method
compared to pneumatic testing because the energy levels are significantly lower (typically 200
times lower).
Consequently pneumatic pressure testing shall NOT be used on BWSC work sites.
03.05.02 Precautions
The following precautions shall be observed:
1. The pressure test shall be carried out with water or diesel oil.
2. It is NOT allowed to pressure test systems or equipment by use of air or other gas.
3. The system being tested shall be totally filled with liquid and properly vented to exclude
air pockets.
4. A pressure pump shall be used to achieve the test pressure.
5. Test pressure is normally 1.5 x working (operating) pressure or 1.5 x the design
pressure depending on the code applicable for the system.
6. The duration of the pressure test (constant pressure) is normally one (1) hour.
7. The work areas shall be cordoned off and proper safety signage shall be in place.
8. The test personnel shall advise other personnel about the test being carried out.
9. All pipe connections from tanks or receivers shall be closed.
10. All instruments, except the test pressure gauge, shall be disconnected.
11. The safety valve (relief valve) shall be disconnected.
12. The pressure gauge used for the test shall have a valid calibration certificate.
03.05.03 Leak Testing
Note that pneumatic leak testing is not considered pressure testing in this context and may be
carried out at a pressure not exceeding 10% of the design pressure.
03.06 Work Inside Large Machinery
03.06.01 General precautions
The following precautions apply to work inside large machinery such as diesel engines
(including crank case, scavenge receiver, exhaust receiver, air cooler space) and generators.
Whenever entering inside the machinery a back-up person shall be left outside the
machine. The back-up person shall not leave the site until all personnel having entered
the machinery are back and accounted for.
Before entering the person in charge shall check that starting and turning of the engine
is positively prevented, ie. start air valves are closed and locked.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
83
The Turning Gear shall be engaged, and the person in control of the turning gear shall
keep constant contact with the person(s) inside the machinery.
Note that in most cases, the confined space requirements will apply to work inside large
machinery. Please refer to chapter 01.09.
03.06.02 Work in the Crankcase
When entering the crankcase, stepping boards shall be used, even for short durations
of work.
If stepping boards cannot be used for practical reasons, a safety harness shall be used.
The condition of the stepping boards shall be checked before use, and faulty boards
replaced.
03.06.03 Work in the Exhaust Receiver
Operatives shall use safety harness when placing the staging ladder to gain access from
the gallery to the exhaust receiver.
When climbing the ladder, the safety lanyard shall be properly secured to a point above
the person before he starts climbing.
03.06.04 Work in the Scavenge Receiver
Under no circumstances, during port inspection or for other reasons, may a hand be inserted
into the cylinder from the scavenge space.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
84
03.06.05 Responsibility for Operating the Turning Gear
The use of the turning Gear shall be under the
responsibility of a nominated Turning Gear Key
holder. The key holder(s) are responsible that all
applicable safety precautions and procedures are
followed.
The turning Gear key holder may grant
permission to nominated Turning Gear operators
to operate the turning gear under their
supervision.
A list of nominated Turning Gear key holders and
operators shall be prepared and signed off before
the work commences.
The Turning Gear Procedure format is included in
Appendix.
03.07 Erection of Large Structures at Height
The mechanical erection works include erection of a number of large structures at height, such
as:
Exhaust silencers and associated ducting.
Exhaust gas boilers and associated steam vessels, ductwork and dampers.
Abatement units in the exhaust gas stream.
Chimney stacks.
Radiator Coolers
Engine hall ventilation systems.
While the general hazards are covered under the chapters for work at height, ‘common’ lifting
operations, use of forklift etc. the risks related to installation of heavy equipment shall be
assessed specifically, based on the actual weights, dimensions and weather (wind, rain, snow,
visibility etc.) conditions, crane limitation etc. BWSC Construction Department will cooperate
with BWSC Engineering in the production of detailed method statements and risk assessments.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 03 Mechanical Erection
85
Illustration from BWSC Erection Guidelines
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 04 Electrical Erection
86
04 Electrical Erection
This chapter covers the Electrical Erection activities up to the point of energizing. For all
activities associated with electrical systems or subsystems, after they are energized, please
refer to the Test & Commissioning in Chapter 5.
04.01 Electrical Erection Work in General Electrical Erection includes installation of the following:
Cable runways, typically ladder racks, cable trays and conduits
Elevated floor systems, typically in the Control Room and the LV/MV rooms
Step-up and auxiliary transformers
LV, MV and HV panels and switchgear
Pulling and termination of power cables and control cables
Battery banks
Light & Small power installations
Fire detection and alarm systems
Telephone systems
Computer network cabling
CCTV and PA systems
04.02 Particular safety hazards related to electrical erection
works
The safety hazards associated with the above activities are first and
foremost those related to working at height, lifting operations and
use of power tools. Working at height from scaffolding or mobile
elevated work platforms takes place throughout the erection period.
As the safety hazards and precautions related to these activities are
covered in Chapter 1 under Common Activities, no further
descriptions will be given here.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 04 Electrical Erection
87
Cable pulling often involves working with heavy loads at places with restricted and difficult
access at considerable heights. Particular attention shall be given to the safe system of work
under these circumstances.
Typical cable ladder arrangement, suspended from ceiling. Illustration from BWSC Erection
Guidelines.
04.02 Acid filling of Batteries
In plants where acid filled batteries are
used for the battery system, a
considerable amount of acid is handled
during filling operations.
The filling shall take place in a well
ventilated room, and there shall be easy
access to Emergency Eye Wash station
and Emergency Shower.
Illustration from BWSC Erection Guidelines
During the acid filling of the batteries, a voltage will build up,
and the risk of electrical short circuiting or electric shock is a
potential hazard which shall be controlled. Only proper
insulated tools shall be used.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 04 Electrical Erection
88
When handling acid the following PPE is required:
Eye protection goggles type
Rubber gloves
Rubber boots
Rubber apron
Filling batteries is subject to separate Method Statement and Risk Assessment (COSHH
assessment).
04.04 Temporary Electrical Installations
04.04.01 Site Construction Power
Site construction power supply will be established during the initial site mobilization. Since the
BWSC Electrical Supervisor will not be on site at that point in time, the works shall be carried
out and supervised by external, fully qualified electricians. Often, this task will be included in
the Civil Contractor’s scope of work.
Applicable national safety rules for Electrical Work shall be observed.
The following precautions shall apply:
When BWSC’s Electrical Supervisor is mobilized, all temporary electrical installations
shall be subject to his approval.
Supply cabinets which form part of the system shall be locked.
Electrical hazard warning signs shall be displayed on supply units.
Only approved electrical plugs and extension cables shall be used.
Avoid routing extension cables through busy areas.
When possible, route the cables at height where it cannot be damaged or impose
tripping hazards or danger for persons working in the area.
Always make sure that proper earth and overvoltage protection is installed.
Temporary electrical installations shall be subject to frequent inspections. Cables with
damaged insulation shall be replaced or repaired; faulty plugs or sockets shall be
replaced.
The temporary installations shall be documented in a single line diagram, showing main point
of supply, switchboards, cabling and protection.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 04 Electrical Erection
89
04.04.02 Mobile Generators
Diesel or petrol driven mobile gensets are frequently used on our
construction sites, either as local supply of power tools in areas where
general construction power is not available, or as site wide source of
construction power. The size of gensets commonly used varies from
portable units giving a few kVA to skid-mounted or containerized units
providing several hundred kVA.
The illustration on the left shows an example of a 250 KVA genset
which typically forms part of a more permanent site construction
power installation.
Generators are frequently hired from plant-hire companies which
in turn are responsible for providing the hirer with information for
the safe installation and use of their equipment.
BWSC Electrical Supervisor or other competent person shall always be consulted and involved
in the installation of mobile generators.
While the small size, portable gensets require no particular considerations, the larger
installations require a range of precautions as detailed in the following.
04.04.03 Mobile Generator Installation
Earthing and protection devices shall be installed as required. This depends on the type
and mode of operation and shall be determined by the plant-hire company or BWSC
Electrical Supervisor.
As the generators require frequent re-fuelling, a safe fuel handling arrangement shall
be in place. Apart from the internal tank, usually found in the base frame of the genset,
often the gensets will be connected to an external fuel tank through hoses and change-
over valves. The arrangement shall be installed so that the risk of fuel spill is
minimized. All valves shall be provided with padlocks to prevent use by un-authorized
persons.
It is a requirement that the fuelling operation is supervised at all times.
Easy and safe access shall be provided for fuel trucks and bowsers.
Exhaust fumes shall be able to escape away from working areas.
Heat generated by the generator shall be able to escape freely.
Noise hazards should be minimized. If the generator is not provided with its own noise
enclosure, other means of noise control shall be in place.
Fire extinguisher of correct type (powder ABE or foam) shall be available close to the
generator and any external fuel tanks.
Cables shall be routed such that they are not subject to damages or posing a hazard to
people working in the area.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 04 Electrical Erection
90
Mechanical protection shall be installed on main supply cables.
If feasible, the generator installation shall be enclosed by suitable temporary fencing
with access through a lockable gate.
04.04.04 Mobile Generator Operation and Maintenance
An authorised person shall be appointed to be in charge of the gen-set installation, including
the daily start and stop and re-fuelling. Do not allow any other person to operate or maintain
the generator and associated installation.
Generators are subject to planned maintenance and regular inspections are required. Always
follow the instruction provided in the manufacturer’s Operation & Maintenance Manual.
04.04.05 Temporary cables in S-hooks
Temporary cables shall be placed so that they do not get damaged or obstruct walkways and
stairs. They shall be hung from glass fibre safety hooks – so-called S-hooks as shown below:
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
91
05 Testing and Commissioning Testing and commissioning includes the initial energizing of dead systems, as well as
subsequent work on systems previously energized.
The systems can be divided into mechanical systems and electrical systems, however due to
the nature of the work both mechanical and electrical safety hazards may be present at the
same time.
Test & Commissioning activities involve materials handling, lifting operations and work at
height, which are covered by Chapter 1, Common Activities. Reference is also made to
“Working in confined spaces” and “Work inside large machinery” covered in previous chapters.
This chapter will, therefore, deal exclusively with those activities which are specific to the test
and commissioning work activities and which are not covered elsewhere.
The chapter will give an introduction to the type of risks involved and appropriate controls to
avoid or mitigate those risks, including Permit to Work procedures. Specific Risk Assessments
shall be in place before undertaking work on energized systems.
05.01 Initial Energizing Before initial energizing of mechanical and electrical systems the T&C Manager will obtain
confirmation from the BWSC Erection Supervisors that installation of the equipment in question
has been fully completed. The confirmation will be reviewed with relevant P&I diagrams and
electrical diagrams and wiring lists.
Once the components and systems have been energised they will be clearly
marked with the appropriate warning signs.
When panels have been energized, the switchboard rooms will be considered
restricted areas where particular measures are enforced, doors are locked,
separate operator induction, signatures for authorization etc.
Doors are normally marked ‘Authorized and controlled access only’.
Work still require planning by means of the RAMS system.
05.02 Permit to Work Procedure
As a general rule, all work on equipment, which has already been energized, requires a Permit
to Work (PtW) to be issued by BWSC’s Authorised Person, typically the T&C Manager. This
includes the work of physically locking out the equipment. In cases where work ties into
installations of an existing power station or transmission system, such permit will be issued
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
92
jointly with the power station’s Authorised Person, typically the Shift Charge Engineer.
Likewise, cancellation of the Permit requires authorization from both parties.
The purpose of the formalised Permit to Work system is to describe the formal checks that
need to be undertaken such that all elements of a safe system of work are in place.
Specifically, the Permit to Work will ensure that the equipment upon which work is to be
performed has been clearly identified, de-energised, isolated and grounded as may be
necessary from any mechanical or electrical sources or inflow of energy or hazardous
substances, and that such sources have been locked out and tagged out.
At the time of handing-back, ie. re-instating and returning the equipment to service, the PtW
will ensure that all formal checks and procedures have been followed in the reverse sequence
before equipment is taken into use.
05.02.01 Issuing the Permit to Work
Please refer to the illustration page 92 (this section) showing the standard format for the
Permit to Work. The form is also included in Appendix.
The permit is issued by following these steps:
1. The Authorised Person (the permit issuer) will fill in Part 1 of the permit together with
the Person in Charge (the permit user). During this process, the equipment shall be
identified by specific references to P&I Diagrams, electrical diagrams or other relevant
documentation, the safety checklist shall be completed and any special instructions shall
be agreed, such as use of PPE.
2. Both the permit issuer and the user shall check and verify that the required mechanical
lock-out is in place and that the system is dead/non-pressurised. In case of electrical
systems, the checks shall include that proper earth is in place.
3. The Authorized Person will then sign Part 1 and the Person in Charge will sign Part 2.
05.02.02 Completion of the work - or cancelling the Permit to Work
After completion of the work or if the work has been suspended, the Person in Charge will sign
Part 3 of the permit. This will be acknowledged by the Authorised Person who signs Part 4.
The activities listed below shall be completed before the permit can be cancelled.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
93
05.02.03 Re-establishing the System (removing safety precautions)
Re-establishing a system which has been logged out under a Permit to Work can only be
performed after the work has been confirmed completed by the responsible supervisor.
The responsible supervisor confirms that
1. The work is completely finished
2. All tools are removed, including preliminary shielding and scaffolding
3. All respective covers and fences are closed and locked
4. All warning signs removed
5. Area is cleaned
Specifically for electric switchgear the following precautions shall apply:
Before switching, the responsible supervisor shall, together with the person responsible for the
switching, perform the following:
1. Check that all panels or cells are closed/locked and ready for energizing
2. Remove the “DO NOT OPERATE” signs
3. Unlock circuit breakers and earth switches (removal of padlocks)
4. Open earth switches (remove earth) and remove temporary earth cables
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
94
Parts 1 & 2
Starting the permit
Parts 3 & 4
Closing the permit
05.03 Working on Energized Mechanical Systems The mechanical systems are typically pressurized and/or operate at high temperatures, such
as the Fuel Oil system, Lubrication Oil system, Steam Systems, Cooling Water system and
Compressed Air systems.
Other mechanical systems where particular safety hazards shall be addressed are charge air
system, exhaust gas system, abatement system and firefighting system.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
95
05.03.01 Typical Safety Hazards in Mechanical Systems
Personal injuries can occur by:
HOT surface of mechanical equipment and pipes
HIGH PRESSURE in mechanical equipment or pipes
ROTATING or MOVING part of mechanical equipment
VOLTAGE on rotating/moving equipment
05.03.02 General Safety Precautions
The following safety precautions are general and will apply to all energized and pressurized
mechanical systems and components:
Always make sure that the equipment cannot be started automatically e.g. from the
control room or if triggered by start signals from other systems
Open the switch in the distribution switchboard: Lock and place signage
Open the local electrical safety switch
Read temperature and pressure on the equipment
The local control box shall be:
o Placed in “local” control mode
o Locked by personal and unique padlocks or other mechanical key locking device
o Equipped with BWSC “DO NOT OPERATE” signs
If physical locking is impossible the power supply cables shall be disconnected in the
supply end
Before opening a system make sure (positively confirm) that the system is de-
pressurized.
Operating of valves shall always be done slowly
Close valves before and after the equipment and drain the system. Pay attention to oil
and water waste, so that no risk of slipping occurs. The valves shall be locked with
chain and padlock
Appropriate PPE shall be issued and used
When removing or disassembling heavy parts, these shall be suspended in a crane or
chain block before the fixing screws are removed
Suspensions and hauling ropes shall be able to carry the weight of the components. The
direction of motion should be vertical if possible. If this is not practicable, the
component shall be secured by means of additional ropes to prevent it from swinging
and tilting
Do not work under suspended loads
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
96
05.04 Work on Energized Electrical Systems Electrical systems are typically referred to as LV, MV and HV systems. While the voltage level
associated with these terms varies according to the locality, the following general definitions
can be used as a guideline:
LV Low Voltage: Any voltage not exceeding 1000 volts
MV Medium Voltage: Voltage levels up to 36 kV
HV High Voltage: Any voltage exceeding 36 kV
Work on MV systems shall follow the same safety precautions as are applicable for HV system
work.
05.04.01 Typical Safety Hazards in Electrical Systems
The typical safety hazards in electrical systems are
Electric shock, electrocution
Electric burns
Fire
Explosion
05.04.02 General Safety Precautions
Before commencing testing and commissioning work on LV, MV or HV systems (busbars,
busducts, generators, switchgears, etc.) the following precautions shall be followed:
Anyone working on LV, MV or HV systems shall always personally ensure that the
system is de-energised and earthed by at least checking the following:
o Voltmeters
o CB-position and locking with padlock
o Earth switch position and locking with padlock
Ensure/witness that an authorised person, by means of test pins specified for the
voltage level, has checked that the equipment is de-energised
All necessary safety precautions are taken, including fencing off and shielding of
equipment
Required safety distance to live equipment or components is maintained
Work teams shall consist of at least two skilled workers
Work team members shall be able to speak the same language
Only tools and equipment suitable for the work shall be used. Electrical tools shall have
the insulation required for the voltage level
Appropriate PPE is issued to all team members - and is used.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
97
Lock-out Hasp
To be used when more than one person works in the same locked out
area or if multiple other entities want to secure the lock out area at same
time
05.04.02 Earthing Procedures
When HV plant and apparatus is to be discharged and earthed, it shall be done:
1. Where practicable by the use of a circuit breaker or specially provided earth switch.
When the circuit breaker is used, the trip feature shall be rendered inoperative before
closing unless this is impractical. After closing the circuit breaker or earth switch it shall
be locked in the earthed position.
2. Where above is not practicable, the HV plant or apparatus shall be tested to ensure that
it is switched off and will then be discharged and earthed by temporary earthing cables
applied by means of an insulated pole or other approved apparatus.
3. Earthing cables and associated clamps shall be of an approved type and of adequate
capacity and the minimum length for duty at the point of application. Minimum 70mm2
copper or 90 mm2 aluminium earth wire shall be used.
4. Earthing cables shall be properly maintained and always inspected just prior to use by
the Authorized Person.
05.04.03 Earthing and short-circuiting devices
05.04.04 Procedure for the use of Earthing Cables
1. Verify that the circuit is dead. Where practicable, test by means of a test-pin voltage
indicator of approved type. The indicator shall itself be tested immediately before and
after each use.
2. Earthing cables shall be connected to the earth system, which shall be solidly earthed
before being connected to the phases. They shall only be secured to the phases by
means of an insulated pole or other approved apparatus. Care shall be taken to ensure
that good contact is made, and that clamps are of adequate capacity for the potential
fault level.
Earthing and short-circuiting of electrical installation is a vital part of the
safety rules.
The figure shows an example of commonly used equipment for earthing
and short-circuiting
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
98
3. All phases shall be earthed and short circuited, even if work is to be carried out on one
phase only.
4. Earthing cables shall not be applied in any cell or compartment in which there is any
exposed live metal at High Voltage at all.
5. When earth cables are being removed, they shall be disconnected from the phases first
and the earth system last.
6. For the purpose of applying earth on spout contacts of metal clad switch-gear, only
approved appliances shall be used. Alternative, if no spout is installed, then make
earthing to the PE-Bar. The insertion of the hand or any tool into contact spouts for this
purpose is forbidden.
7. The spout will be checked by an approved test-pin, voltage indicator before the earth is
applied.
8. The indicator itself shall be tested before and after each application.
05.04.05 Safety Distance to Live Parts
The Safety Distance is defined as the necessary distance to avoid flash over from live parts.
Safety distance for non-authorized personnel is marked Distance Vicinity (DV)
Safety distance for authorized persons working on live parts is marked Distance Live
(DL)
Zone DL: Defined as the zone surrounding a live component, where the level of insulation
does not prevent accidental discharge.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
99
Zone DV: Defined as a safety zone, surrounding the DL zone. Any personnel in the DV zone
shall be AUS certified or working under instructions from certified personnel.
DV zone shall be clearly indicated by use of plastic chain, tape or barriers, and if deemed
necessary, the zone can be expanded, to ensure safety for all personnel.
The Safety Distances should always be determined in the following situations:
1. When inspecting non-embedded live high-voltage plant parts
2. When working close to non-embedded high-voltage plants, including establishment and
cancellation of safety precautions in connection with the work
3. When working on high-voltage components under voltage, special preparations, tools
and certified personnel are always to be used
Explanation of Danish abbreviation above: AUS = ‘Arbejde Under Spænding’ (work on live
equipment).
Further information on AUS can be obtained in section 5 of the Danish regulation
‘Stærkstrøms-bekendtgørelsen’, in the international standard EN 50110, or equivalent national
standard.
The Safety distance is defined as the minimum necessary distance from a live source to any
conductor, which ensures that no voltage is present in the latter. Under normal atmospheric
conditions, this distance is determined by the voltage level of the live source according to the
table below.
Nominal Voltage
AC or DC kV
Distance Live
(DL) in mm
Distance Vicinity
(DV) in mm
<1
3
6
10
15
20
30
50-60
132
150
220
400
0
220
250
350
380
400
560
830
1100
1200
1600
2500
500
1220
1250
1350
1380
1400
1560
1830
3100
3200
3600
4500
The distance shall be measured from any live part that is not completely contact safe.
For insulators, the safety distance shall be measured from metallic components in direct
contact with live parts.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
100
In addition to the above defined safety distances DL & DV for skilled and instructed personnel,
it is recommended to review the work area in regards to access for any other person, transport
of equipment or passage of vehicles.
In case of activities in the vicinity of the work area, it is required to implement an additional
Safety Zone, preferable barred and clearly marked.
05.04.06 Work on Alternators
In addition to the electrical safety rules given in this chapter, the following precautions shall
apply for work on alternators:
1. The prime mover, starting device and exciter shall be immobilized, starting gear shall
be engaged and the points of isolation locked
2. The HV circuit shall be isolated and locked. An earth lead shall be applied between the
point of isolation and the point of work
3. The HV supply to any independent excitation system shall be isolated
4. Work may take place on the rotary exciter, using the same Work Permit, if reference to
this is made by the Authorized Person, on the Work Permit
5. When the alternator windings are at high voltage, the general provisions of this section
shall apply
Refer to Chapter 03.06 regarding work inside large machinery. Please note that the confined
space requirements may apply to work inside alternators.
05.04.07 Equipment Containing Sulphur Hexaflouride (SF6)
The equipment shall be made safe as per the rules given in this chapter.
Additionally:
1. The gas contained within the apparatus shall be removed using approved methods, and
as specified by the manufacturer of the switchgear, and the apparatus subjected to
atmospheric pressure.
2. The interior shall then be cleared of any dust or breakdown products using disposable
tissues which are to be disposed of in an approved manner.
05.04.08 Work in Substations with Exposed Live HV Conductors
When work is to be carried out in a substation or switchyard in which live HV overhead
conductors are exposed, the minimum clearance from the nearest exposed live conductor shall
be as specified in rules for “Safety distance to live parts”, unless the whole equipment is
switched off.
If work is to be performed above ground level, the above minimum clearances shall be
obtained from the nearest exposed live HV conductor, to the closest point where the work is
carried out.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
101
05.04.09 Use of Cranes, Portable Ladders and Long Objects
Portable ladders shall be of an approved type and of no greater length than is required for the
work involved. Metal ladders shall not be used in the vicinity of exposed conductors.
Portable ladders and other long objects shall not be used without the permission of a Person in
Charge. The handling of ladders shall be carried out only in horizontal position and as near the
ground as practical.
When cranes, telehandlers, pre-assembled scaffolding or
similar equipment is taken into or out of a substation, the
route to be followed shall be agreed by the Authorized Person
and shown on the Permit to Work.
Cranes or other equipment shall be connected to the
substation earth system as soon as possible.
The limits of operation of such equipment shall be defined by
an Authorized Person and thereafter the equipment shall be
installed and moved only within these limits under the direct
supervision of the Person in charge.
05.05 Switching Operations on Switchgear
05.05.01 Persons Operating Circuit Breakers
Switching (opening/closing) of circuit breakers (CB) can only be authorised by BWSC’s T&C
Manager. Where work is performed within an existing power station, such authorisation will be
issued jointly with the power plant shift charge engineer.
Switching may only be performed by appointed personnel from BWSC test team or the existing
Power Plant.
05.05.02 Switching
Switching performed by BWSC test members shall always and only be performed in co-
operation of 2 (two) persons who speak the same language
When several switching operations have to be performed, a switching programme shall
be elaborated in writing and followed
CBs and earth switches ensuring that the de-energised area is prepared for work or
access shall be:
Placed in “local” control mode
Locked by padlocks or other mechanical key locking device
Equipped with BWSC “DO NOT OPERATE” signs
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Testing and Commissioning
102
If physical locking is impossible lines/busbars should be short-circuited/grounded by means of
flexible wires according to separate instructions and safety rules.
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Switching of LV, MV and HV switchgear
103
05.06 Yellow Safety Rules for switching of LV, MV and HV switchgear
This instruction is valid for:
- work close to energized equipment, and
- equipment which has been initially energized
1. Persons operating Circuit Breakers
Switching (opening/closing) of circuit breakers (CB) can only be performed with the consent of
the Power Plant Shift Charge Engineer and BWSC Commissioning Manager.
Switching shall only be performed by Power Plant responsible switching-operators or BWSC
test team members authorised for switching.
2. Switching
Switching performed by BWSC test team members shall always and only be performed by two
(2) persons together. When several switching operations have to be performed a switching
program shall be elaborated in writing.
Circuit breakers and earth switches ensuring that the de-energized equipment prepared for
work or access shall be:
a. Placed in local control mode
b. Locked by padlocks or other mechanical key locking device
c. Equipped with BWSC ‘DO NOT OPERATE’ sign
If physical locking is impossible lines/busbars should be short-circuited/grounded by means of
flexible wires according to separate instructions and safety rules.
3. Safety Precautions
Before commencing work on LV and/or MV and/or HV systems (busbars, busducts, generators,
switchgears, etc.) the following precautions shall be taken:
1. Confirmation by the BWSC Electrical Supervisor that the equipment in question has
been designated READY FOR WORK and has been properly de-energized and earthed
2. Confirmation by the BWSC Electrical Supervisor of the physical and geographical
location of the equipment in question.
3. Confirmation and understanding of the system configuration by single-line diagram to
be supplied by the BWSC Electrical Supervisor and/or the test team
4. Each and everybody, who is supposed to be in contact with LV and/or MV and/or HV
systems shall always personally ensure that the system is de-energized and earthed by
at least checking the following:
a. Voltmeters
b. CB-position and locking
c. Earth switch position and locking
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 05 Switching of LV, MV and HV switchgear
104
d. Ensure/witness that an authorised person by means of test pins specified for
the voltage level has checked that the equipment is de-energized
NOTE! ‘No voltage’ is a confirmation that the above mentioned safety precautions have been
activated – system is de-energized.
4. During Work on Equipment
1. No person shall commence work before the BWSC Electrical Supervisor on the actual
work location has given accurate instructions to all work team members about:
a. The extent of work
b. Limits of the working area
c. Any energized equipment nearby the work area
d. The execution of the work – safe system of work
e. Safety precautions taken (see item 3.3 above) including:
i. Warning signs
ii. Fencing
iii. Shielding of equipment
f. Safety distance to other energized equipment
2. It shall be ensured that the work team members speak the same language
3. Work teams shall at any time during the work consist of at least 2 (two) skilled workers
who are instructed according to item 4.1 above
4. The working area shall be properly marked during the whole working period
5. The BWSC Electrical Supervisor shall ensure that only tools and equipment suitable for
the work are being used.
5. Re-establishing the System (Removing Safety Precautions)
1. Re-establishing of a system being under safety precautions for work can only be
performed when the BWSC Electrical Supervisor has confirmed the following:
a. work is completely finished
b. All tools are removed, including preliminary shielding and scaffolding
c. All covers and fences are closed and locked
d. All warning signs removed
2. The BWSC Electrical Supervisor shall, together with the person responsible for the
switching (BWSC Commissioning Manager and/or Power Plant Shift Charge Engineer)
before switching, perform the following:
a. Check that all panels or cells are closed/locked and ready for energizing
b. Remove the “DO NOT OPERATE” signs
c. Unlock CB´s and earth switches (removal of padlocks)
d. Open earth switches (remove earthing)
3. The switching is to be performed in accordance with item 1 and 2
Burmeister & Wain Scandinavian Contractor A/S
Health and Safety Manual – part 2 - Specific Safety Instructions Responsible: HAJJ Approved by: JPE
Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014
Subject: 06 Steam Systems
105
06 Steam Systems
06.01 Steam system hazards Hazards in high pressure steam and water systems are mostly related to accidental escape of
steam or water due to failure of the pipe system, such as cracking, failure of gaskets/seals or
even pipe rupture.
Leaks in modern, high pressure piping are rare as both design and installation is thoroughly
controlled by international regulations.
06.01.03 High pressure steam or feed water pipe leakage
Feed water, boiler and turbine piping systems contain water or steam at very high pressures
and temperatures. In case of a leak of feed water it will evaporate almost instantaneously and
turn to superheated steam.
Note that superheated steam is invisible. Unless it cools down and forms a visible steam jet it
may only be detected by a hissing sound.
Smaller leaks of steam/water may cause fatal scalds, burns or cuts. Larger leaks may due to
the rapid expansion of steam suppress the air in the room and lead to suffocation.
If a leak is heard or detected personnel shall IMMEDIATELY locate the nearest exit, evacuate
the building and report the observation to the control room.
Repair is performed by specialist crews only.
06.02 Preventative measures Never perform work on or near a high pressure steam/water systems without proper working
permit and safeguarding of working environment.
Keep walkways, stairs and doors free of debris and equipment at all times to keep escape
routes free
Ensure escape routes are clearly marked and well illuminated.
Always familiarise yourself with the building and remember where your nearest exit is located.
106
Remember to do it safely – or not at all.
There is always time to do it right !