REPORT ON PERSONAL PROTECTIVE EQUIPMENT (PPE) FOR … · In addition to standard PPE kits as...

Personal Protective Equipment (PPE) for Train Examination Staff

IRCAMTECH/GWL/20-21/M/PPE/1.0 September- 2020

केवल कायार्लय उपयोग हेत ु

(For Official Use Only)

भारत सरकार - GOVERNMENT OF INDIA

रेल मंत्रालय - MINISTRY OF RAILWAYS

REPORT ON PERSONAL PROTECTIVE EQUIPMENT

(PPE) FOR TRAIN EXAMINATION STAFF

No. IRCAMTECH/GWL/2020-21/M/PPE September - 2020

Maharajpur, Gwalior – (M.P.) – 474005 - INDIA

Draft- Copy



DISCLAIMER It is clarified that the information given in this handbook does not supersede any

existing provisions laid down in Railway Board and RDSO publications. This

document is not statuary and instructions given are for the purpose of guidance only.

If at any point contradiction is observed, then CAMTECH/Railway Board/RDSO/OEM

guidelines may be referred or prevalent Zonal Railways instructions may be followed.



Report on Personal Protective Equipment (PPE) for

Train Examination Staff

No. IRCAMTECH/GWL/2020-21/M/PPE September – 2020



ISSUE OF CORRECTION SLIPS The correction slips to be issued in future for this report will be numbered as follows: IRCAMTECH/GWL/20-21/M/PPE/1.0 – August - 2020 Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. of

Correction Slip Date of issue Page no. and Item No.

modified Remarks



FOREWORD

Personal Protective Equipment (PPE) for Train Examination staff are presently being procured as a general store item. Technical specification for these items have evolved based upon individual Railways past experience. There have been lot of development in the manufacturing technology of PPE in India as well as globally. Further some of the PPE used by IR may also not be fully compliant to current and relevant BIS/EN/ANSI standards. In such cases these may not be providing full protection to the staff. Since PPE items presently being procured individually, 100% availability of all PPE items all the time is not possible due to inherent limitations of the procurement system. Railway Board’s decision to review and revises the system of providing PPE will help in providing PPE of appropriate standard and improved availability of all PPE items is appropriate step towards upgrading the PPE quality and improving safety at workplace. Due to COVID-19 Pandemic travel restrictions, field visits could not be organized. Collection of information and interaction with Zonal Railways was done through series of online Webinar and conferences. Leading PPE manufacturers in the country have also been consulted to suggest changes in technical specifications and PPE kits for train examination staff to as per BIS/EN/ANSI standards. This report has been prepared to address above issues. It is recommended to upgrade the technical specifications of PPE and procure PPE as a kit to ensure 100% availability of all PPE items for Train Examination staff of Indian Railways. Since new technologies are continuously being introduced on Indian Railways, there may be additional requirement for some product or process specific to provide safe work environment to Train Examination staff. Details for such PPE may to be obtained by concerned Zonal Railway directly from OEM. In addition to standard PPE kits as recommended in this report, details of various types of PPE currently available, their important features, technical specification have been included. A PPE selection guide has also been provided in this report so that Zonal Railways can select and procure any additional PPE and provide the same to maintenance staff as per local field conditions and provide adequate protection to staff against any hazard at workplace. RDSO, Lucknow (Jitendra Singh) Date: 30.09.2020 Principal Executive Director



PREFACE

Railway Board vide letter No.2019/M(N)/951/28dated11.03.2020 advised IRCAMTECH to review the system of Personal Protective Equipment (PPE) procurement for Train Examination Staff of Indian Railways and submit recommendations for PPE procurement in complete set of kit and also suggest specifications of each item which is in line with relevant BIS specification. In cases where BIS specification is not available, specifications be prescribed out of relevant EN/ANSI standard. Accordingly, IRCAMTECH surveyed the existing scenario of PPE manufacturing in the country with leading manufactures and suggested procurement of PPE kits for Train Examination Staff.

1 Train Examination Supervisor 2 Train Examination Fitting Staff 3 Train Examination Welders 4 Train Examination Helpers

Technical Specifications have been suggested in line with suitable BIS/EN/ANSI Standard. It may be noted that BIS specifications for all PPEs used by Indian Railways are not available and Indian PPE manufacturers are having BIS as well as EN/ANSI or internationally accepted standards since they are also exporting which mandates EN/ANSI or similar Global Standard certification. They also get their products certified from independent accredited expert agencies. I am sincerely thankful to, respective OEMs and all zonal railway who helped us in preparing this document. This document will be useful for Zonal Railways to procure PPEs in Kits with upgraded specifications to provide better availability of PPEs to the train examination staff and provide them full protection from work place hazards. Technological up-gradation, systems improvement and learning are a continuous process. Please feel free to write us for any addition/ modification in this document.

CAMTECH, Gwalior (Manoj Kumar) Date: 30.09.2020 Director /Mechanical



OUR OBJECTIVES

To upgrade Maintenance Technologies and Methodologies and achieve improvement in Productivity and Performance of all Railway assets and manpower which inter-alia would cover Reliability, Availability and Utilisation.

QUALITY POLICY “We at IRCAMTECH, Gwalior are committed to maintain and update

transparent standards of services to develop safe, modern and cost effective railway technology complying with statutory and regulatory requirements, through excellence in research, designs and standards by setting quality objectives, commitment to satisfy applicable requirements and continual improvements of the quality management system to cater to growing needs, demand and expectations of passenger and freight traffic on the railways through periodic review of quality management systems to achieve continual improvement and customer appreciation. It is communicated and applied within the organization and making it available to all the relevant interested parties”.



Abbreviations

Abbreviation Description CAMTECH Centre for Advanced Maintenance Technology

NIOSH National Institute of Occupational Safety & Health

OSHA Occupational Safety & Health Administration

PEL Permissible Exposure Limit

OEL Occupational Exposure Limit

NIOSH P100 99.97% Efficiency @ 0.3 micron particle

HEPA High Efficiency Particulate Absorbing

BIS Bureau of Indian Standard

ANSI American National Standard Institution

EN European Norms

OEM Original Equipment Manufacturer

PPE Personal Protective Equipment

PU Polyethene

FDDI Footwear Design & Development Institute

HDPE High Density Polyethylene

CE Marked Conformitè Europëenne (CE) Mark

ISO International Organization for standardization

GSM Gram per square meter

CLRI Central Leather Research Institute

NABL National Accreditation Board for Testing and

Calibration Laboratories

RITES Rail India Technical and Economic Service

APAC Asia Pacific Accreditation Cooperation

MSEs Micro & Small Enterprises

MSME Micro, Small & Medium Enterprises

ILAC International Laboratory Accreditation Cooperation



Table of Contents

DISCLAIMER........................................................................................................................ 2

ISSUE OF CORRECTION SLIPS ..................................................................................... 4

CORRECTION SLIPS ISSUED ...................................................................................................... 4

FOREWORD ........................................................................................................................ 5

PREFACE ............................................................................................................................. 6

OUR OBJECTIVES ............................................................................................................. 7

QUALITY POLICY ............................................................................................................... 7

Abbreviations ........................................................................................................................ 8

Table of Contents .............................................................................................................................. 9

1. Introduction ........................................................................................................... 10

1.1. Terms of Reference ............................................................................................. 11

1.2. Methodology Adopted ......................................................................................... 11

2. Scenario of PPE manufacturing in India and recommendations .................. 12

2.1. Selection of PPE for train examination staff -Hazard analysis ...................... 12

2.2. Recommended Kit of PPE for train examination staff .................................... 14

2.3. Technical specifications of PPE ........................................................................ 14

2.4. Mode of procurement of PPE ............................................................................ 16

2.5. Stocking of PPE kits under unified PL numbers ............................................. 17

3. SUMMARY OF RECOMMENDATIONS .......................................................... 17

3.1. PPE kits in six groups (K1-K6) ........................................................................... 17

3.2. Railways to adopt updated technical specifications ....................................... 17

3.3. Unified PL Group for PPE Kits ........................................................................... 18

4. Road Ahead .......................................................................................................... 18

4.1. Role of management and Workers responsibility to ensure safety .............. 18

4.2. Integrated Quality certification ISO 9001,14001, and OHSAS 18001 ......... 18

Annexure - I ........................................................................................................................ 20

RECOMMENDED PPE KIT & SPEC. FOR TRAIN EXAMINATION STAFF ............ 20

Annexure - XVI ................................................................................................................... 37

TOOL BOX SAFETY TALK .............................................................................................. 37

AUTHORITY ....................................................................................................................... 38

About CAMTECH ............................................................................................................... 40



1. Introduction

Indian Railways are committed to provide a safe and healthy workplace for their employees. In this direction it has been decided by Railway Board to review the system of PPE procurement for train examination staff. Personal protective equipment, commonly referred to as “PPE”, is equipment worn to minimize exposure to a variety of hazards. Examples of PPE include items such as gloves, foot and eye protection, protective hearing devices (earplugs, muffs) hard hats, respirators and full body suits. Eliminating hazards through engineering or administrative control measures is the best way to protect people at workplace. The strategy used for the selection of controls is called the “hierarchy of controls” which prioritizes the types of controls that are most effective in eliminating or reducing the risk of exposure to the hazard.

Engineering methods could include design change, substitution, ventilation, mechanical handling, automation, etc. In situations where it is not possible to introduce any effective engineering methods for controlling hazards, the staff shall use appropriate types of PPE. For example, in under gear examination there is possibility of hitting the head with under gear equipment. Wearing a safety helmet will provide protection from such hazards PPE is the least effective method for controlling or preventing exposure to a hazard. PPE provides a barrier to protect the worker from potential exposure to hazards, however due to the reliance on the worker to select, wear and maintain PPE, the likelihood of exposure to the hazard with PPE alone increases. Use of PPE is an important and necessary consideration in the development of a safety programme. It is essential to select the right type of PPE and the management should ensure that the workman not only uses it as recommended but maintains it correctly.



This report has been prepared to select appropriate PPE, its specifications and improvement to the system of PPE procurement for train examination staff. 1.1. Terms of Reference

Railway Board vide letter No. 2019/M(N)/951/28dated11.03.2020 advised CAMTECH to review the system of procurement of Personal Protective Equipment (PPE) for train examination staff of Indian Railways considering latest development in PPE manufacturing scenario in the country in association with leading PPE manufacturers and submit recommendations for PPE procurement in complete set of kit and also suggest specifications of each item which are in line with relevant BIS specification. In cases where BIS specification is not available, specifications be prescribed out of relevant EN/ANSI standard. Therefore, this report has been finalized on following three specific issues.

a) Interact with Zonal Railways and PPE Manufacturers within country to identify appropriate PPE items

b) Suggest changes in technical specifications of PPE in line with relevant BIS/EN/ANSI Standard.

c) Recommend PPE kit for procurement in sets for train examination staff

1.2. Methodology Adopted

The following methodology was adopted for collection of information and relevant data was relied upon.

a) Information and Data was collected by online means of communication and Webinars from Zonal Railways, Production Units and OEMs/PPE manufacturers as field visits to maintenance depot and PPE manufacturers could not be undertaken due to COVID-19 pandemic and travel restrictions imposed countrywide.

b) Interactive feedback obtained from Zonal Railways through Webinars organized by CAMTECH in association with leading PPE manufacturers - M/s. Udyogi Plastics Pvt. Ltd., Kolkata, M/s. Mallcom India, Kolkata, M/s. 3M India Ltd., Bangalore.

c) Technical presentations on the latest scenario of PPE manufacturing in India

were organized by CAMTCH and these were attended by representatives from all Zonal Railways.

d) Information and suggestions received from 07 different Railways viz., SR,

ECR, WR, NR, CR, and NER& ER have been considered and suitably incorporated in finalising this report.



e) Data on PPE furnished by 14 coaching depots has been analysed and considered.

2. Scenario of PPE manufacturing in India and recommendations

Leading PPE manufacturers delivered online presentation on the development and current scenario of PPE manufacturing in the country. They were also consulted for selecting appropriate type of PPE and suggest changes in technical specification of PPE presently adopted by Indian Railways. 2.1. Selection of PPE for train examination staff -Hazard analysis

In order to identify appropriate PPE for a specific application, Hazard Analysis was conducted in association with PPE manufacturers. Applicability and selection of PPE for different Body parts and areas of protection have been done based on following selection criteria and PPE have been identified.

Body part Area of Protection Type of PPE Head Protections For protection of the head from injury due

to falling or moving objects, impact on stationary objects and from impact due to falls.

Safety Helmets, caps, turbans

Eye, ear and Face protection

To protect eyes from damage due to impact, penetration, burns, splashes and flying particles and ultra violet radiation.

Safety goggles, safety spectacles, Face shield, Ear plug or ear muff

Hand Protection To protect the hand from injuries such as cuts, grazes, burns, ingress of chemicals & electric shock

Hand Gloves, Hand -Gloves Leather, Arms Sleeves

Respiratory Protection.

To protect the user from breathing in contaminants in the air

Respiratory Face mask

Foot protection To protect the feet from risks ranging from crush and impact injuries to slips, cuts, penetration wounds, electric shock and splashes with liquids and molten metal

Leg Guard, Safety Shoe, Gum Boot

Body protection To protect the body from injuries such as cuts, grazes, burns and the effects of exposure to heat, cold and ultra violet Radiation & collision from moving machines

Protecting suit, Apron, Welder Suit

Table 1

Presently six types of PPE are being used by train examination staffas under.



a) Head Protection. b) Safety Footwear. c) Eye and Face protection. d) Respiratory Protection Equipment. e) Arm and Hand Protection. f) Protective Clothing and Coverall.

Zonal Railways are presently using following items of PPE for train examination.

SN PPE items Stock Non-Stock 1. Safety Shoe SR NER, ER, WR 2. Safety Helmet ECR SR, WR, NER, ER 3. Safety Hand Gloves WR, NR - 4. Gum Boot WR, NR NER, ER 5. Safety Goggle WR, NR, NER ER 6. Hand Gloves Leather NER - 7. Face Shield with carrier ER NER 8. Leg Guard - ECR 9. Rain Coat with Retro

Reflective strips - WR

Table 2

The workplace of train examination staff is also visited by Officers, trainees, OEM/Industry representatives. Hence, these persons are also required to be protected by providing bare minimum level of PPE at workplace and the same has also been taken into account during finalisation of recommendations. In addition, Zonal Railways during the deliberations in Webinars, have recommended to add following additional items as a part of PPE kit for train examination staff. SN PPE Type Recommended

by Railways Justification

1. Welder Suit WR, SR, ECR, NCR, WCR

Welder Suit and Arm Sleeve are required for protection of Welder during welding from UV radiations, Spatter and exposure to Heat.

2. Arm Sleeve WR, SR, ECR, NCR, WCR

3. Respiratory Mask NR, ER, WR, WCR

Respiratory Mask is required for protection on Welder from breathing contaminants in the air.

4. Protective Clothing SR, WCR, WR, ECR

Protective Clothing is required protect worker’s body from injuries such as cuts, grazes, burns and the effects of exposure to heat, cold, ultra violet Radiation & collision from moving machines.

5. Reflective Jacket WR Retro Reflective Jacket provide high



(High Visibility Warning Cloth)

visibility on train examination staff and protects them from accident during train examination.

6. Rain Coat with Retro Reflective strips

WR, SR Rain Coat with Retro Reflective strips will provide high visibility and protection to train examination staff during rains.

Table 3

It is recommended to provide above additional PPE items to protect train examination staff against hazard. 2.2. Recommended Kit of PPE for train examination staff

Based on the feedback received from Zonal Railways and conducting the survey with PPE manufacturers and according to the nature of work, PPE kits have been identified into six groups for train examination activities in following table.

PPE Kit Code -> K1 K2 K3 K4 K5 K6 S. N.

Item Name Su

perv

isor

Wel

der

Fitte

r

Hel

per

Offi

cers

Visi

tor

1 Safety Shoe ✔ ✔ ✔ ✔ ✔ × 2 Safety Helmet ✔ ✔ ✔ ✔ ✔ ✔ 3 Safety Hand Gloves ✔ × ✔ ✔ ✔ ×

4 Protective Clothing ✔ × ✔ ✔ × × 5 Gum Boot ✔ × ✔ ✔ ✔ × 6 Particulate Respirator Face mask × ✔ × ✔ × × 7 Welder Suit × ✔ × × × × 8 Hand -Gloves Leather × ✔ × × × × 9 Safety Goggle × ✔ × × × ×

10 Face Shield with carrier × ✔ × × × × 11 Leg Guard × ✔ × × × × 12 Arms Sleeves × ✔ × × × × 13 Retro Reflective Jacket ✔ × ✔ ✔ × × 14 Rain Coat with Retro Reflective strips ✔ × ✔ ✔ × ×

Table 4 2.3. Technical specifications of PPE



Technical Specifications adopted by Zonal Railways have evolved based upon individual Railway’s experience and therefore vary from Railway to Railway. Technical specifications of PPE presently being followed by Railways have been analysed in consultation with PPE manufacturers. Since there is no system of periodic review of these specifications, current specifications in use over Zonal Railways for many items are not based on latest specifications and relevant standards.

The comparison of PPE specifications presently being used by Railways and latest specification for these items are tabulated below. Items where revision of technical specifications is required is indicated in last column of the following table.

S. N.

PPE type Specification in use by Zonal

Railways

Recommended Specification

Remarks

1. Safety Shoe IS: 15298 part 2, 2002, design 'A'

IS:15298 (PT.2) 2016, (Second Revision)

Need revision

2. Safety Helmet IS: 2295:1984/EN 397

IS: 2925, 1984 or CE-EN-397 or ANSI – Z89.1-2003

Need revision

3. Safety Hand Gloves EN 388 EN 388 No change

4. Particulate Respirator Face mask

- NIOSH 42 CFR 84 –NIOSH

Need revision

5. Protective Clothing - Annexure -VI New item 6. Gum Boot IS: 12254:1993 IS: 12254:1993 No

change 7. Welder Suit - EN ISO 11612: 2008 Class

(A1+A2, B1, C1, E3, F1) New item

8. Hand Gloves Leather

IS:2573/86 (2nd Rev) Type-1

IS: 2573/86 (2nd Rev) Type-1

No change

9. Safety Goggle IS: 1179:1967 IS: 5983:1980 Need revision

10. Face Shield with carrier

ISI Mark ANSI Z87.1, EN 166 Need revision

11. Leg Guard - IS: 6153:1971 New item 12. Arm Sleeves IS: 6153:1971 IS: 6153:1971 No

change 13. Reflective Jacket

(High Visibility Warning Cloth)

- IS: 15809/2017 New item

14. Rain Coat with Retro Reflective strips

- Annexure - XV New item

Table 5



From the above, it may be seen that Railways are procuring some PPE to outdated specification. It is recommended to revise technical specifications of PPE in line with that currently being used by PPE manufacturers and industry as shown above. Annexure-I provides complete list of recommended PPE applicable to each group, relevant standards and detailed technical specifications for each PPE. PPE manufacturers were also consulted to suggest changes to detailed technical specification of each PPE item required for train examination staff. Detailed revised technical specifications of each PPE item are enclosed at Annexure - II to XV. 2.4. Mode of procurement of PPE

Procurement of PPE for train examination staff is presently being done in piecemeal manner like General Store item. Bulk items eg Safety Hamlets, Welding Gloves etc are stock items and procured through Stores department in most of the Zonal Railways. However, mode of procurement varies from Railway to Railway for the same item. Some PPE items being procured as stock item by one Railway are being procured as Non-Stock item in other Railway as can be seen from following table. Description of

PPE Railway Specification Stock Non-

Stock Safety Shoe WR Spec. No. IS:15298 (PT.2) 2016,

(Second Revision) - ✔

NER IS: 15298 (Part-II): 2011/ISO 20345:2004

- ✔

ER IS: 15298 (Pt. I & II):2011 - ✔ SR IS: 15298 part 2, 2002, design 'A' ✔

Safety Helmet ECR IS:2925/1984 ✔ - WR IS: 2925 - ✔ NER ISI Mark - ✔ ER IS 2295:1984/EN 397 or latest - ✔ SR IS 2925 - ✔

Safety Hand Gloves

WR, NR - ✔ -

Particulate Respirator Face mask

ER IS 9473 - ✔ NR --- ✔ -

Gum Boot ER IS: 12254/1993, - ✔ WR IS:15298(PART-2):2011(First

Revision) ✔ -

NR IS:5557/92 ✔ - Hand Gloves Leather

NER IS: 2573/1986 ✔ - ECR DLW SPEC NO.

MP/SAFETY/SPEC./PPE/1(ED-7) - -

WR BS 1651 - -



Description of PPE

Railway Specification Stock Non-Stock

Safety Goggle ER IS: 2573/1986 - ✔ Face Shield with carrier

NER ISI Mark - ✔ ER IS: 1179/1967 ✔ -

Leg Guard ECR - - ✔ Arm Sleeve ECR IS: 6153: 1971 ✔ Rain Coat with Retro Reflective strips

WR - - ✔

Table 6

Procuring PPE as individual items results into multiple efforts of procurement. There are chances that some PPE items are either not available or their supply gets delayed thus resulting into non availability of some of the PPE items at workplace. Thus, piecemeal procurement of PPE does not ensure 100% availability of all PPE items for train examination staff and prevention from hazards. It is recommended to procure PPE in kit form for train examination staff. Procuring PPE in kit form will ensure better availability of all PPE items and thus will provide full protection against hazards and fulfil safety needs of workmen at workplace. 2.5. Stocking of PPE kits under unified PL numbers

It is recommended to allot unified PL Nos for PPE kits which will bring uniformity and standardization on procurement of PPE for train examination staff. This will also reduce manpower and efforts presently deployed in procurement process. Improved availability of PPE will provide full protection to train examination from hazards and better work environment. 3. SUMMARY OF RECOMMENDATIONS

The following recommendations will help to improve the system of procurement, better availability of PPE for train examination staff on IR. 3.1. PPE kits in six groups (K1-K6)

PPE kits in six groups(K1-K6) are recommended for procurement as mentioned in para 2.2 and Table 4. PPE in kit form will provide better availability of all PPE items and full protection to train examination staff. This also includes additional items recommended by Zonal Railways to provide protection to train examination staff. 3.2. Railways to adopt updated technical specifications

Technical specifications for PPE may be adopted by Zonal Railways as mentioned in



Para 2.3. This will also bring IR specifications in line with current and updated specifications being used by PPE manufacturers and Industry. Detailed technical specifications of each PPE are given at Annexure - II to XV. 3.3. Unified PL Group for PPE Kits

It is recommended to allot unified PL Nos. for PPE kits which will bring uniformity standardization on procurement of PPE for train examination staff. 4. Road Ahead

In order to achieve continuous improvement in ensuring safety for train examination staff, as a long-term measure, following measures are suggested. 4.1. Role of management and Workers responsibility to ensure safety

Employers are responsible for providing a safe and healthy workplace for their employees. Employees are responsible for proper use and care of PPE to protect them from work hazards. Providing training on safety, proper use of PPE, and encouraging continual improvement in workplace safety and health is continuous process and need to be followed up on regular basis on following points.

i) Select appropriate PPE and ensure that PPE is used properly ii) Establish inspection, maintenance and replacement procedures to

make sure damaged PPE is not used iii) Train employees in proper use, limitations, care and maintenance of

PPE iv) Document assessment, selection, and training

The above objectives can be achieved by starting a system of involving staff to educate, motivate and guide on proper use on PPE such as “Tool Box Safety Talk”. A sample of Tool Box Safety Talk and list of related videos available on internet is enclosed at Annexure- XV”. 4.2. Integrated Quality certification ISO 9001,14001, and OHSAS 18001

During study it is learnt that Production Units (PU) of IR have much better system of PPE procurement which provides a sound and comprehensive system of periodic review of Personal Safety Management and continuous improvement system ensuring safety at workplace and protection to workers from occupational hazards. This system has evolved by implementing the Occupational Health and Safety requirements built into Integrated Quality Management system consisting of following three ISO certifications. • ISO 9001:2015QUALITY MANAGEMENT SYSTEM • ISO 14001:2004ENVIRONMENTAL MANAGEMENT SYSTEM



• OHSAS 18001:2007 OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM

OHSAS 18001 is an internationally accepted standard that defines the requirements for establishing, implementing and operating an Occupational, Health & Safety (OHS) Management System OHS framework allows an organization to consistently control its hazards, reduce the risk of accidents, injuries, down time and continually improve its processes and operations. Integrated ISO Quality certification provides frame work for systematic and continuous improvement in the entire working of the system thus providing improved working and safe work environment along with personal protection to workers. As some of the maintenance depots have already obtained ISO9001:2015 QUALITY MANAGEMENT SYSTEM, it is therefore suggested that train examination Depots may be advised to get Integrated ISO certification for ISO 9001:2015, 14001:2004 and OHSAS 18001:2007which will provide systematic improvement in safety and performance during Train Examination.

****



Annexure - I

RECOMMENDED PPE KIT & SPEC. FOR TRAIN EXAMINATION STAFF

PPE Kit Code -> K

1

K2

K3

K4

K5

K6 Standards

BIS/EN/ANSI Detail

Technical Specification as per Annexure

S. N.

Item Name

Supe

rvis

or

Wel

der

Fi

tter

Hel

per

Offi

cers

Visi

tor

1 Safety Shoe

✔ ✔ ✔ ✔ ✔ × IS:15298 (PT.2) 2016, (Second Revision)

Annex.-II

2 Safety Helmet

✔ ✔ ✔ ✔ ✔ ✔ IS: 2925, 1984 or CE-EN-397 or ANSI – Z89.1-2003

Annex. - III

3 Safety Hand Gloves

✔ × ✔ ✔ ✔ × EN 388 Annex. - IV

4 Particulate Respirator Face mask

× ✔ × ✔ × × NIOSH 42 CFR 84 - NIOSH

Annex. - V

5 Protective Clothing

✔ × ✔ ✔ × × Annexure-VI Annex.– VI

6 Gum Boot ✔ × ✔ ✔ ✔ × IS:12254:1993 Annex. - VII 7 Welder Suit × ✔ × × × × EN ISO 11612: 2008

Class (A1+ A2, B1, C1, E3, F1)

Annex. - VIII

8 Hand -Gloves Leather

× ✔ × × × × IS: 2573/86 (2nd Rev) Type-1

Annex. - IX

9 Safety Goggle

× ✔ × × × × IS: 5983:1980 Annex. – X

10 Face Shield with carrier

× ✔ × × × × CE EN166, EN170, ANSI Z87+

Annex.– XI

11 Leg Guard × ✔ × × × × IS: 6153:1971 Annex. - XII 12 Arms

Sleeves × ✔ × × × × IS: 6153:1971 Annex. - XIII

13 Reflective Jacket (High Visibility Warning Cloth)

✔ × ✔ ✔ × × IS: 15809/2017

Annex. - XIV

14 Rain Coat with Retro Reflective strips

✔ × ✔ ✔ × × Annexure-XV Annex. - XV



Annexure -II Technical Specification of Safety Shoe

(Industrial Safety Shoes IS: 15298: Part-2:2016)

CATEGORY Design – A

UPPER PU Micro-fiber with reflector at counter back portion thickness of 1.8 -2mm (Water Repellent)

COLOR Black INNER LINING Synthetic with foam padded (Silver) - 200 gsm VAMP LINING Highly abrasion resistant fabric IN SOCKS Moulded High Density PU Foam with Arch support

SOLE Sole made up of PU Single Density with moulded process, high density and resistant to oil, chemicals, mild acids, petrol, slip & heat resistance upto 120 deg.cel for 01 minute

Cleated Outsole with wider cleats for higher grip & self-cleaning effect TOE CAP Steel Toe cap with impact resistance of 200 J as per EN-12568 & as per

IS:15298: Part-2 INSOLE Non-woven with thickness of 2mm LACES Round Double color Nylon / Polyester for easy grip and aesthetics EYELETS Round Steel 200 nos.100% rust proof THREADS 3/6 ply nylon FOAM PADDING

High Density Foam 20mm

SIZES As per requirement WEIGHT OF SHOE

0.845gms. with tolerance of +/- 5% (Size-8)

FEATURES Light Weight &Slip resistant PU Sole Single Density Sole Resistant to Oils, Mild Chemicals, Mild Acids, Petrol and Resistant to

Hot Contact up to 120°C for 1 minute APPROVAL ISI marked of IS:15298:Part-2:2016 PACKING Each Pair of shoes must be wrapped in paper then separately in card board

packing box. MAKE Only ISI mark Brands are acceptable.

Documentary proof that the product quoted is an ISI certified product with special application for all the required sizes to be enclosed.

MARKING Firm’s name or registered trade mark, size and month & year of manufacturing must be marked clearly on the outsole of each shoe.

OUTSOLE WILL BE RESISTANT TO

Oil, Alkali, Acid, Abrasion & Water as per IS: 15298 Pt. 2: 2016. It shall have Antistatic feature.

OUTSOLE WILL BE RESISTANT TO INSPECTION

It shall have anti-skid properties. Firm to submit test certificate from foot wear design and development Institute (FDDI) for the same Inspection to be done as per user requirement.



Annexure –III

Technical Specification of Safety Helmet

(Standard - IS: 2925, 1984 or CE-EN-397 or ANSI – Z89.1-2003)

Specification for Head Protection Item Description Industrial Safety Helmet Material ABS Plastic Size Medium (540-590 mm) Weight Mass of the helmet shall not exceed 400 gms. Surface finish Glazed Harness The helmet shall be provided with harness including Head bank. Sweat

band, cradle, Nape strap, Chin Strap, ventilated holes & peaks. The material for harness shall be sweat resistant and non-irritant. The head band shall be securely fixed to shell & crown straps and readily adjustable. Sweat absorption pad to be provided at the front of head band inside.

Ventilated / non ventilated type

Ventilated type. Helmet should be provided with 3 or 4 rect./square holes build up in the mould on either side.

Ratchet arrangement

8 point adjustable ratchet type. Tightening of head band to be possible thru high quality, non slip ratchet arrangement at the back of head.

Nape strap The material shall be sweat resistant and non – irritant. It may be either integral or an arrangement to head band & adjustable.

Chin strap The material shall be sweat resistant and non irritant. It shall have an adjustment device to maintain tension.

Conforming Standards

IS : 2925, 1984 or CE-EN-397 or ANSI – Z89.1-2003 Bidder to submit along with offer, authenticated photo copy of latest test certificate for product conformity to relevant from standards as above from OEM/NABL approved Lab. Bidder to furnish tender specific authorization letter along with offer from Principals/OEMs.

Required Colours

White, Red & Yellow (Bidders offering helmets in all the three colors shall only be considered)

Markings Indian Railway Monogram shall be screen printed on the front side of the helmet. The size of the Logo (2.5 – 3.0 mm). Helmet shall emboss with relevant conforming IS/EN/ANSI stan-dards/marks. Helmet shall embossed Batch No., month and year of manufacturing.

Inspection Inspection to be done as per user requirement. Sample One sample to be submitted along with offer for verification of the

offered product at the time of technical scrutiny. Offers received without sample shall not be considered & ignored.

Guarantee certificate

Guarantee certificate to be given for any manufacturing defect along with its consignment for free replacement within three months from the date of receipt of material.

Packing The helmet shall be supplied, packed individually for protection from dust & damage.



Annexure –IV Technical Specification of Safety Hand Gloves

(Standard: EN 388 (4121))

Seamless Nylon shell with Nitrile Coated Hand Gloves

SN MODEL DESCRIPTION Nylon knitted gloves with Nitrile rubber coating

on palm and all around the fingers 1. THREAD Nulong Thread 2. SHELL Nylon Shell 3. SHELL THICKNESS 13 Gauge 4. SHELL COLOUR White 5. COATING Smooth Nitrile Coating 6. COATING COLOUR Grey Colour 7. WEIGHT OF GLOVES 35+5 grms. Per pair 8. LENGTH 10 inches 9. SIZE 7,8,9,10,11 10. RIB TYPE Knitt Wrist 11. ABRASION Level – 4 12. CUT Level 1 13. TEAR Level 2 14. PUNCTURE Level 1 15. STANDARD EN 388 (4121) 16. INSPECTION Inspection to be done as per user requirement.



Annexure -V

Technical Specification of Particulate Respirator Face mask

(NIOSH approved N95)

1 DESCRIPTION Particular Respirator face mask N95

2 DESIGN a) NIOSH approved N95 rating b) Adjustable M-nose clip c) Braided headbands d) Dual point stapled headband attachment e) Cool FlowTM Exhalation Valve f) Filter media should be easy to talk through without

removing the respiratory. g) The weight of respirator shall not be more than 18gms +-

10 %. h) The respirator should be able to filter particle dust up to

0.3 microns with 95% efficiency. 3 MATERIAL a) Straps: Braided Polyisoprene

b) Staples – Steel c) Nose Clip – Aluminium d) Filter – Polypropylene e) Shell – Polyester f) Valve – Polypropylene & Polyisopren

6 APPROVAL AND STANDARD

a) NIOSH approved N95 particulate respirator. b) Meets NIOSH 42 CFR 84 N95 requirements for a

minimum 95% filtration efficiency against solid and liquid aerosols that do not contain oil.

8 SHELF LIFE 5 Years from the date of manufacture. 9 COLOUR White

10 INSPECTION Inspection to be done as per user requirement.



Annexure -VI

Technical Specification of Protective Clothing

Protective Clothing (Jacket and Trousers)

FABRIC 100% Cotton Drill Cloth APRON Half Sleeve/Full Sleeve

Turn Down Collar Two chest pockets with flaps (Left side

& Right side, Size: 5”X6”) Two tools pockets at the lower half front

(Left side & Right side, Size: 5”X7”) Front closing with Zipper with Flap with

Punch buttons

COLOUR AVAILABLE

Navy Blue/Orange

SIZE As per user requirement Trouser • The trousers shall be provided with two side pockets • Metal Zipper

100% Cotton Overall with full sleeves (Coat and Pant Combined)

FABRIC 100% Cotton WEIGHT 210 GSM COLOUR Navy Blue/Orange DESIGN PATTERN

1-way zipper closure in front, front flap closure with Velcro. 2 breast pockets in front with flap closure, 2 pockets on both shoulders, buttoned closure on sleeves (for full sleeve)

SIZE As per user requirement



Annexure -VII

Technical Specification of Gum Boot

PVC Gum Boot with Steel Toe Cap conforming to IS: 12254:1993

UPPER MATERIAL

Direct injected, fully moulded single piece PVC.

TOE CAP With steel toe SOLE Complete body reinforcement with heavy duty cotton lining DESIGN Type Wellington design PVC gumboot SIZE 5 to 11 COLOUR Black INSPECTION Inspection to be done as per user requirement.



Annexure -VIII

Technical Specification of Welder Suit

(Standard: EN ISO 11612: 2008. Class A1+ A2, B1, C1, E3, F1)

Flame Retardant 100% Cotton Fabric Jacket and Trousers a) The fabric should be 100% cotton FR fabric b) The garment should be made of 350 gsm fabric c) The fabric should pass ENISO11612:2008 A1+A2, B1, C1, E3, F1(E3 for

molten Iron metal splash protection)

MATERIAL Fabric - 100% cotton FR fabric. PRODUCT RANGE

Jacket and Trousers

WEIGHT 350 GSM fabrics available. COLOR Navy Blue./Orange CLOSURE A heavy-duty brass metal zipper. Zipper will extend from

below to top of the collar. BUTTON Metal. ADJUSTEMENT Snap Button WASH 80 wash guaranty on PROBAN treatment. STITCH All stitches shall be lock-stitched & F.R. thread. SIZE S/M/L/XL/XXL (Should require the size conformation at the

time of Purchase Order). STANDARD ENISO11612:2008 A1+A2, B1, C1, E3, F1(E3 for molten

Iron metal splash protection) INSPECTION Inspection to be done as per user requirement.



Annexure -IX

Technical Specification of Hand Gloves (Leather)

(Standard: IS: 5914-1970)

1 APPLICATION The leather hand gloves shall be use in the welding and material handling activity

2 DESCRIPTION 2.1 The length of hand gloves should not be less than 15 inches.

2.2 The hand width size shall be 5.5 inches (min.) and calf width size7 inches (min.)

2.3 The gloves shall be made of split leather. 2.4 The gloves shall be dyed in dark rust/blue/black colour. 2.5 Thickness of leather shall be 1.2 mm minimum. 2.6 Thickness of leather should be hard wearing and heat

resistance Cowhide/Buffalo hide. 2.7 The gloves shall be so flexible that user must not feel

stiffness while doing continues welding. 2.8 The gloves shall have thinsulate insulation lining as

intermediate and cotton cloth shall be used for hand inner lining and fire resistance cloth for calf portion lining.

2.9 KEVLAR threads for stitching purpose. It should be1720-v-6 cord and single thread breaking load shall not be less than21 Newton.

2.10 The dumb of gloves shall be reinforced with a leather strip and stitched with two rows of Kevlar stitched.

3 TESTING PARAMETERS

3.1 Double Hole Stitch Tear Strength=50kg. /sq.cm. Minimum (Method of Test LC:8 of IS: 5914-1970).

3.2 Shrinkage Temperature=90°C minimum (Method of test LC10 of IS5914-1970)

3.3 Fat Content of Leather=7% to10% 3.4 Double Hole Stitch Tear Strength=50kg/sq. cm. minimum

(Method of test LC:8 of IS:5914-1970). 3.5 Shrinkage Temperature=90°C minimum (Method of test

LC10 of IS:5914-1970) 3.6 Fat content of Leather=7% to10% 3.7 Chromium content of Leather=3% minimum. 3.8 PH value aqueous Extract=not below 3.5(Method of test

LC:18 of IS:5582-1970) 3.9 Tear Resistance=25 Newton. 3.10 Contact Heat Resistance=100°C

4 TEST CERTIFICATE

4.1 All of the above tests shall be done from the Government lab like CLRI/ Engineering Institute/accredited lab of NABL.

4.2 All of above test certificates are required to submit along with at the time of bulk supply.

5 INSPECTION Inspection to be done as per user requirement.



Annexure –X

Technical Specification of Safety Goggle

(Standard: IS: 5983:1980)

Polycarbonate Safety Goggles

LENS Polycarbonate lens with soft PVC frame & body. Fully adjustable Headband attached to fits most users. Incredibly light, resilient, durable & over the glass protective

eyewear for all day wear. Soft goggle body conforms to facial contours for a very

comfortable fit to ensure for long time wearing. 4-point venting system that circulates air yet prevents dust,

splashes. Optical class I Lens filters out 99% of harmful UV light. Lens provides medium velocity impact & splash protection around

the eyes. Universal fit soft nose bridge conforms to facial contours to

ensure a comfortable fit. Fits over the spectacle.

INSPECTION Inspection to be done as per user requirement.



Annexure -XI

Technical Specification of Face Shield with Carrier

(Standard: CE EN166, EN170, ANSI Z87+) PRODUCT CHARACTERISTICS

Clear Polycarbonate Face Shield with Carrier for attachment of any helmet

TECHNICAL SPECIFICATION

FACE SHIELD CARRIER MATERIAL High Impact resistance ABS Polymer COLOUR Orange TYPE Flip-up and ratchet type adjustment AREA Large cover area for user’s forehead, providing full protection STANDARD Complied with CE EN 166, ANSI Z87+, CSA A94.3 FACE SHIELD VISOR MATERIAL Clear PVC THICKNESS 1.0 mm UV PROTECTION 99.9 % UV protection SIZE 8” X 15 ½” PROTECTION Protection against high-speed i.e. B level (120 m/s) at extreme

temperature, penetration, splash of liquid and heat QUALITY Protective films on both sides (prevent damages and scratches

during transportation) Edge fitted with aluminum beading for easy adjustment to face contour

INSPECTION Inspection to be done as per user requirement.



Annexure -XII

Technical Specification of Leg Guard

(Standard: IS: 6153-1971)

1. DESCRIPTION Leather Leg Guard 2. DESIGN 1)The leather leg guard would be full skirt type.

2) The leather leg guard shall be in two pieces. Two pieces should be horizontally stitched with double sewing. The joint should be reinforced with 1 inch wide leather strip of 3/4 inch overlap with two rows of sewing on both side covering the joint

3. MATERIAL Vegetable tanned leather or Chrome tanned leather conforming to IS:6153/1971 1) The leather shall be soft pliable free from pin holes and

other visible defect or loose fibers which could adversely affect its serviceability and strength

2) The leather shall not be treated as to obscure defects or be stained with compound of iron which would make it wrought under humid condition.

3) The leather shall not crack when folded grain side outward around a mandrel of minimum1.5mm diameter through an angle of 180°.

4) Thickness of leather shall be1.00mm to1.2mm. 4. STITCHING 1) Stitching thread shall be inherently fire resistant or be so

treated that should not smolder back along the seam when ignited.

2) Leather leg guard shall be machine stitched& minimum no of stitches shall be 4 per cm.

5. DIMENSION OF LEATHER LEG GUARD

As per drawing no. PL/M/MISC/09/261, as shown in Figure 1

6. MARKING Each leather leg guard shall be clearly marked permanently with the following information. 1) Manufacture Name/Trademark. 2) Year of Manufacture

7. SAMPLE FOR APPROVAL

The sample for feel and appearance must be supplied with the offer for approval.

8. TEST CERTIFICATE

A test certificate from Govt. Test House approved by Govt. agency certifying that material used for the manufacture of leather leg guard conform to IS:6153-1971.

9. PACKING Each leather leg guard shall be packed in a polythene bag. 10 INSPECTION Inspection to be done as per user requirement.



Figure – 1



Annexure -XIII

Technical Specification of Arms Sleeves

(Standard: IS: 6153/1971)

1. DESCRIPTION Leather Arm Sleeve 2. DESIGN The leather arm sleeve shall be made from one piece

without joint leather(Ref. fig.2, Page-8 of IS-6153/1971,supported by strip of quick release type& positive in action

3. MATERIAL Vegetable Tanned full grained leather conforming to clause 3.1.5.2of IS: 6153/1971 1) The leather shall be soft pliable free from pin holes and

other visible defect or loose fibers which could adversely affect its serviceability and strength

2) The leather shall not be treated as to obscure defects or be stained with compound of iron which would make it wrought under humid condition.

3) The leather shall not crack when folded grain side outward around a mandrel of minimum1.5mm diameter through an angle of 180°.

4) Thickness of leather shall be1mm to 2mm 4. STITCHING I. Stitching thread shall be inherently fire resistant or be so

treated that should not smolder back along the seam when ignited.

II. Leather Arm sleeve shall be machine stitched& minimum no of stitches shall be 4 per cm.

5. DIMENSION OF THE ARM SLEEVE

Overall length of Arm sleeve should be minimum 500mm.

6. MARKINGS Each leather leg guard shall be clearly marked permanently with the following information. 1) Manufacture Name/Trademark. 2) Year of Manufacture

7. SAMPLE FOR APPROVAL

The sample for feel and appearance must be supplied with the offer for approval

8. TEST CERTIFICATE

A test certificate from Govt. Test House approved by Govt. agency certifying that material used for the manufacture of leather leg guard conform to IS:6153/1971

9. PACKING Each Arm sleeve shall be packed in a polythene bag. 10 INSPECTION Inspection to be done as per user requirement.



Annexure –XIV

Technical Specification of Reflective Jacket (High Visibility Warning Cloth)

(Standard: IS: 15809/2017)

1. DESCRIPTION Reflective Jacket (High Visibility Warning Cloth)

2. DESIGN Three Side Opening Reflective Vest 3. MATERIAL 100% mesh Polyester

4. COLOUR Orange

5. REFLECTIVE

TAPE

High gloss Reflective Tape 3M Scotchine Tape 2925 Series

6. TAPE WIDTH 2 inches

7. STYLE 3 side opening

8. DESIGN One horizontal and two vertical reflective tape



Annexure –XV

Technical Specification of Rain Coat with Retro Reflective strips

S.No. Particulars Specification 1 Identification of Fibre Warp – 100% Polyamide

Weft – 100% Polyamide 2 Seams All seems to be sealed by Hot

Transparent Tape. 3 Mass of proofed fabric (GSM) 205 grams 4 Thickness of fabric 0.18 mm(Minimum) 5 Tensile strength of proofed

fabric Cut Strip (5 X 20 cms) Warp – 60 kgs. Weft – 48 kgs.

6 Tear Strength – Double tongue Warp – 3.00 kgs. Weft – 3.00 kgs.

7 Water Proofness By Pressure Head Test at 90 cm water column for 30 minutes i) Amount of water collected ii) Wetting of outer surface

Nil No Wetting

8 Hook & Loop Fastener Good quality corrosion/water resistant 9 Zipper Good quality corrosion/ water resistant 10 Nature of coated material on

fabric 100% Polyamide fabric coated with Polyvinylchloride

11 Shade Orange 12 Design detail As per drawing Figure 2. 13 Marking Railway Logo on left side of Chest 14 Warranty 2 Year 15 Inspection Inspection to be done as per user

requirement.

Size Standard Garment

Size Chest of Jacket Length of Jacket Length of Pant Medium 46 inch 27 inch 40 inch Large 48 inch 29 inch 41 inch Extra Large 50 inch 31 inch 42 inch Double Extra Large

54 inch 33 inch 43 inch



Figure - 2 Drawing of Rain Protection Suit



Annexure - XVI

TOOL BOX SAFETY TALK

Employees who wear PPE need to be trained on how it protects them from hazards, what its limitations are, how to wear and care for it and when it needs to be replaced. Use the Toolbox Talk below to walk employees through six guidelines that will help them stay safe on the job.Follow these six PPE guidelines to stay safer on the job:

PPE SHOULD BE THE LAST LINE OF DEFENSE

The first two lines of defense against safety hazards should be engineering and administrative controls. Only after deploying both of these should PPE be used to guard against safety hazards.

PPE MUST FIT AND BE WORN PROPERLY

PPE that is too large or too small may not properly protect you from hazards and could create additional hazards. Wearing improper PPE could subject you to harm.

REUSABLE PPE MUST BE KEPT CLEAN AND WELL-MAINTAINED

Reusable PPE should be cleaned after each use and inspected before every use to ensure that it is still in good working order.

PPE DOESN’T LAST FOREVER

Worn out PPE may not provide the proper protection and can become a hazard. Replace PPE when it shows visible signs of wear or when test data shows that it is no longer serviceable.

PPE ONLY PROTECTS YOU WHEN YOU’RE WEARING IT

Even the most expensive, highest quality PPE won’t protect you if it’s not on your body and properly applied.

STAY CAUTIOUS WHILE WEARING PPE

No piece of PPE will protect you against every workplace hazard. That’s why there are so many types and styles. Each one protects you from different types of hazards. No matter what PPE you wear, it is still essential to follow the safety procedures that have been established by your employer.

Note to Workers: It is your job, to make sure that it is worn properly and fits well. Tool Box Safety talk videos on PPE https://www.youtube.com/watch?v=XVNMj0ZxZsI https://www.youtube.com/watch?v=QEB7wE-YFXg https://www.youtube.com/watch?v=q2yAHDkC6Nw https://www.youtube.com/watch?v=HkKBnoUp_8E https://www.youtube.com/watch?v=9PMEVHKh_Ws

https://www.youtube.com/watch?v=XVNMj0ZxZsI

https://www.youtube.com/watch?v=QEB7wE-YFXg

https://www.youtube.com/watch?v=q2yAHDkC6Nw

https://www.youtube.com/watch?v=HkKBnoUp_8E

https://www.youtube.com/watch?v=9PMEVHKh_Ws



AUTHORITY



NOTES



About CAMTECH

CAMTECH is continuing its efforts in the documentation and up gradation of information on maintenance practices of mechanical assets. Over the years a large number of publications on electrical assets have been prepared in the form of handbooks, pockets books, pamphlets & video films etc. These publications have been uploaded on the internet as well as rail net.

If you have any suggestion & any specific comments, please write to us:

1. On internet visit : www.rdso.indianrailways.gov.in Go to Directorates

CAMTECH Publications for downloadMechanical Engineering 2. On Rail net visit RDSO website at 10.100.2.19 Go to Directorates

CAMTECH Publications for download Mechanical Engineering

A limited number of publications in hard copy are also available in CAMTECH library which can be got issued by deputing staff with official letter from controlling officer. The letter should be addressed to Director (Mechanical), CAMTECH, Gwalior.

For any further information regarding publications please contact:

Contact Person : Director / Mechanical Landline : 0751 - 2470890 CUG : 9752447040 Email : [email protected] Fax : 0751- 2470841

For any further information regarding publications please contact:

Director (Mechanical) Indian Railways Centre for Advanced Maintenance Technology (IRCAMTECH),

In front of Hotel Adityaz, Airport Road, Maharajpur, Gwalior- M.P- (INDIA)

Pin Code – 474 005

REPORT ON PERSONAL PROTECTIVE EQUIPMENT (PPE) FOR … · In addition to standard PPE kits as...

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