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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.


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



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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



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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


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

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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.



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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).



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2 BWSC quality, health, safety and environment (QHSE)

policy


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.



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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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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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.



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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.



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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.



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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014

Subject: General Safety Requirements

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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!


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.



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Subject: Site Layout

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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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014

Subject: Safety Induction and Site Rules

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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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014

Subject: Safety Induction and Site Rules

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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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/201418

Subject: Safety Meetings

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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.



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Subject: Safety Meetings

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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.

http://www.toolboxtopics.com/



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014

Subject: Site Safety inspections

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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)



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.



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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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


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.


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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



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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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.



Doc. no.: 6000.QH.001.001 Rev.: 2 Date: 18/02/2014


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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.



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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.

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http://images.google.dk/imgres?imgurl=http://www.afirig.dk/image/loftegrej/6.jpg&imgrefurl=http://www.afirig.dk/AFI RIG AARHUS loftegrej.html&usg=__zu-7SmGMvedDsrDPb7_UGRk6NPE=&h=152&w=170&sz=18&hl=da&start=26&tbnid=3R8nQmwqEe2GmM:&tbnh=89&tbnw=99&prev=/images?q%3Dsj%C3%A6kler%26gbv%3D2%26ndsp%3D21%26hl%3Dda%26sa%3DN%26start%3D21

http://images.google.dk/imgres?imgurl=http://www.altombord.dk/images/421880_03.jpg&imgrefurl=http://www.altombord.dk/d%C3%83%C2%A6ksudstyr-kovs-c-61_207.html&usg=__B4d8AWOaPnAQtC_dPz-TK8227sU=&h=400&w=400&sz=10&hl=da&start=2&tbnid=wwGprVSF74TQrM:&tbnh=124&tbnw=124&prev=/images?q%3Dkovs%26gbv%3D2%26hl%3Dda



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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.



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01.07.04 Hand signals for Lifting Operations



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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.



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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):



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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.



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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.



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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

http://www.google.dk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=2y9AcHBfGTTzNM&tbnid=t0WfgurTH7TcoM:&ved=0CAUQjRw&url=http://www.usmra.com/repository/PHOTOS/Confined_Space/index.html&ei=QwXqUrrzJueK4ASVhoCwDw&bvm=bv.60157871,bs.1,d.bGQ&psig=AFQjCNEcc0LIaUdgm4CtSP7iTSYjPyIgWw&ust=1391154134239254



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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.



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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.



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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.



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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.



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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



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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)

http://z.about.com/d/chemistry/1/0/G/h/magneticfieldsymbol.jpg



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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



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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.



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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.



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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



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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.



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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



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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.



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.



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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.



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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.



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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.



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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.



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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.



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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.



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Illustration from BWSC Erection Guidelines



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.



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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.



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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.



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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.



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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:



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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



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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.



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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



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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.



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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



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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.



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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



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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.



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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.



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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.



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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



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If physical locking is impossible lines/busbars should be short-circuited/grounded by means of

flexible wires according to separate instructions and safety rules.



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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



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



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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 !

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