WAVEBIT INFRATECH PRIVATE LIMITTED.
TATA STEEL KALINGA NAGAR
OPERATIONAL CONTROL PROCESS.
PROCEDURE FOR PIPE AND DUCT FABRICATION JOB.
DOC NO :- WIPL/TSK/OCP/01
General-
1- Discussion of work to be done in TBT.
2- Use of proper PPEs for the under taken work to be discussed in TBT.
3- Operational checking of tools and tackles before starting the job.
4- Improved safety hazards to be discussed in the TBT and to be followed
strictly.
Before start of work :-
1-procure the work permit.
2-check the workplace for housekeeping.
3-use proper PPEs knowing about the hazards involved in the work
concerned.
4-protect the site as per the procedures discussed above.
During work:-
A- Loading and unloading of materials by pick & carry mobile
crane.
A 1.-Crane must be positioned on flat surface & it's out rigger surface
must be placed on timber or suitable material for pads to Evenly distribute
the load to the ground.
A.2- Crane to be located within the radius for the loads being lifted & it
should be barricaded with warning signs. Ensured in crane movement
area. Safety implication of crane down and record maintained
A.3- Check slings for rips and tears and remove from service if faults are
found A.4- Do not march with load
on extended boom.
A.5- Ensure max travel speed 1.4 km/ hr and use first gear during
movement of crane with load.
A.6- Standardization of safe load indicator (SLI) which cannot be by
passed.
A-7- to maintain daily checklist.
A.8- prepare the lifting scheme for every lifting operation more than 1 mt .
A.9-Only Odisha government approved third party certifies Tools & tackles
should to be used. Makeshift Tackles shall be prohibited.
A.10- Selection of crane as per load & follow the load chart.
A.11- Proper assessment of load to be handled by crane & Lifting gear /
equipment inspected and tagged with appropriate monthly colour tag.
A.12-Using of tag line.
A.13-Operator should be trained & medically fit.
A.14-Always keeps the required safe distance between the crane and the
power lines using the distances as per Indian IE Rule.
B- Marking and cutting
B.1- Plate and other material should be shifted to the desired
location and arrange them accordingly.
B.2- Trolley should be placed on firm ground and ensure prevention of
toppling. B.3-
Oxygen/LPG cylinder is to be kept in upright position on trolley with proper
tie by chain.
B.4- 1. Cylinder must be placed on designated stand and secure by chain
only. B.5- 2. Gas
cylinder should be stored at isolated place.
B.6- Cylinders -shall be kept far enough away from the actual welding or
cutting operation so that sparks, hot slag, or flame will not reach them.
When this is impractical, fire-resistant shields shall be provided.
B.7- Cylinders shall be placed where they cannot become part of an
electrical circuit.
C-Bending of plates.
C.1- shift the desired plates to the feeder of bending machine.
C.2- check all the guards of moving parts and make sure that all the
guards are in place.
C.3- check all the RCB and starter are working properly.
C.4- only competent operator should be deployed in workplace.
C.5- loose clothing, ring, chain, long hair of person is not allowed
near bending machine area.
C.6- after bending the cell should be place in the designed location
and rollover protection should be placed in both sides of the cell.
D- Fit-up jobs:-
D.1- shifting of cells to the desired location by the rigger.
D.1-Competent person(fitter) should fit-up the cells into desired length
with his team.
D.1-During movement of pipe all control measures should be taken by
the gang.
D.1-Placing of rollover protection should be in place during the fit-up
time.
D.1-All mandatory work-related PPEs should be used during the work.
D.1-Maintain social distance during fit-up time.
E- Welding jobs :-
E.1- Ware guard should be use in case of welding in confined space, wet
area and at height.
E.2- Transformer type welding machine should not be used at site.
E.3- 7. Rubber Mats should be provided for accessing DB and welding
machine
E.4- Ensure proper routing of cable along with designated holders and
protects sharp edges with suitable padding.
E.5- cable shall not be kept or routing on passageways. ladders and stairs.
E.6- If required cable should be laid through cashing pipes for crossing the
access road. E.7- Gas hoses
and electrical cable shall not be allowed to touch each other and must
have a minimum distance of 250mm between them.
E.8- All welding M/S's to be earthed (body earth) with suitable earth pit.
E.9- All welding M/S's will be electrically connected through ELCB of 30mA
sensitivity.
Proper welding return path to be ensured within 3 meters
E.10- Nobody will allow executing welding work during rain.
E.11-. Proper PPE's (Safety shoe, Safety Helmet, Face shield, Hand Gloves etc.)
will be used. E.12- Take rest time to time and
wash eye with cold water.
E.13- Do not see-welding by naked eye.
E.14- Electrical cables should be properly covered with ceramic cloth. Use
ceramic cloth or GI sheets for arresting spatters.
E.15- Remove the nearby flammable material and welding cables.
E.16- Sufficient -number of fire extinguishers; & sand buckets will be kept at
site. E.17- All inflammable
materials will be removed from site.
E.18- Generated scrap (inflammable materials) removal will be done on
continuous basis and proper area housekeeping to be maintained at site.
E.19- Electrical cables should be properly covered with ceramic cloth.
F-Grinding job
F.1- Area should be barricaded.
F.2- Don't lift, drag or shift the grinding machine by its cord.
F.3-Wear leather gloves and inspect slowly.
F.4- Grinding/cutting wheels which are properly labelled & marked should be only
used. Instructions for use written on the wheel should be strictly followed.
F.5- All Grinding/cutting wheels will be checked for internal cracks before starting
the grinding works and ring test to be done.
F.5-. Wheel guard will be provided to all the grinding/cutting m/c.
F.6- Appropriate grinding wheels will be used based on the grinding m/c
suitability. F.7-Proper alignment of the
wheel to be ensured before starting the grinding M/C.
F.8- Before use each wheel must be run up to its maximum operating speed on
the machine under no load conditions for about 30 seconds.
F.9- All relevant PPEs along with transparent face shield should be used.
F.10- All grinding/cutting m/c will be connected through ELCB of 30mA resistivity.
F.11-No person will be allowed to carry out grinding/cuffing without plug top
F.12- Proper insulation of power cable joint (if any) should be ensured
F.13- Power cables to be routed property
F.14-Main power to the grinding m/c to be disconnected keeping out the plug top
from the switch board when it is not in use.
F.15- Switch board should be kept.
F.16-Double insulation to be ensured.
G- Loading and despatch
G.1- Crane must be positioned on flat surface & it's out rigger surface must be placed on timber or
suitable material for pads to Evenly distribute the load to the ground.
G.2- Crane to be located within the radius for the loads being lifted & it should be barricaded with
warning signs. Ensured in crane movement area. Safety implication of crane down and record
maintained
G.3- Check slings for rips and tears and remove from service if faults are found
G.4- Check chains, shackles, hooks and rings for cracks, corrosion, wear, cracks, mechanism faults,
etc and remove from service if faults are found.
G.5- Using of proper PPEs, only trained riggers should be allowed for the job.
G.6- Lifting gear /equipment inspected and tagged with a monthly colour tag.
G.7-Controlled movement of vehicle in the premises.
G.8-Vehicles movement within plant should be limited to 20 km /h and during safety timing speed
limit restricted to 15 Km/h.
G.9- Driver / Operator should have valid transport vehicle driving license and they should have eye
examination certificate.
G.10- Depute Forman and use of scotch block.
G.11- Check the condition of tyre before start of the vehicle.
G.12- Area should be levelled & barricaded and guidance of vehicle by foreman.
G.13- Proper tying / lashing of materials by chain/slings with the bed If required, weld the structure
with the trailer bed. Use ladder for climbing on the vehicle.
G.14- Install steel posts at the required.
H-Housekeeping.
H.1- at last check the area for housekeeping and maintain the records and Close the permit.