Thursday, December 31, 2020

December 31, 2020

Flare Maintenance Job Safety Analysis

Activities, Potential Hazards and Control Measures

1. Set up the crane for assembly of the crane used for flare tip removal. 

Potential Hazard

  • Drop of Crane’s heavy & Long legs on the person during crane setting up.
  • damaging of nearby machinery or components while crane set up due to drop of Crane’s heavy & Long legs.
  • Accidently loss of hydraulic pressure mechanism would cause uncontrolled dropping of the parts being lifted crushing co-worker or damaging other components of adjacent property or machinery.
  • The default type of pin or one missing a retainer could become the root cause of the crane to collapse under lifting stress.
  • Un-Standardized and bad welding work or insufficient alterations could cause the crane to collapse under lifting stress.
  • Crane wheels may sink in the soft ground causing the crane to tip over while lifting component.

Control/Mitigation Measures

  • Set up a crane in an open area away from other machines, components or other workers
  • Move crane slowly and carefully avoiding speed, quick cornering and rough floors which could cause latch pins to come off legs causing legs to fall free of the crane.
  • Tighten, repair or replace leaking component.
  • Replace pins with only Original Equipment Manufacturer (OEM) pins and retainers, never use ordinary bolts.
  • Crane may have to be re-examined and approved by Manufacturers Representative (MR) before use.
  • Portable Engine Cranes (PEC) are best to be used on smooth concrete floors.
  • Never use a crane on a slope ground level.

2. Removal of Nut & Bolts 

Potential Hazard

  • Unknown conditions of the bolts & gaskets.
  • Failure of bolts during removal operation on the adjacent bolt
  • Improper tools.
  • Falling material or tools.
  • Gas/fluid/vapour leak
  • Control/Mitigation Measures
  • Check the bolt nut condition before operation.
  • Experienced person allowed for the task.
  • Proper tools should be used.
  • secure and toe the materials from falling.
  • Keep the portable gas monitors & toxic clip.
  • The area should be barricaded and warning signs should be displayed before starting the work.

3. Manual Spading 

Potential Hazard

  • Isolation valve passing
  • Spark generation/fire
  • Exposure to toxic vapour
  • Splash of hazardous fluid
  • Leak/spill
  • Improper tools
  • Fall, stripping or caught in-between (in case of spading in height)
  • Miss communication
  • Falling men /material
  • Muscles collapse

Control/Mitigation Measures

  • Confirm Isolation Valve Integrity (IVI) by opening lightly the nearest vent/drain point.
  • Isolation must be done as per QP isolation procedure.
  • Isolations done by authorized person only Confirm the equipment before isolation
  • Ensure that all lines are drained and de-pressured before disconnections/opening is performed.
  • Always use personal gas monitors while performing spading activity.
  • Use non-spark tools & brass hammer in a hazardous location
  • Check the work area is free from the toxic vapour.
  • Marginally open one bolt/stud to confirm no pressure. Use airline unit if needed. Splash of Hazardous Fluid/substance.
  • Use safety goggles.
  • Loosen the bolts/studs slowly to ensure Leak / Spill
  • Use the correct type of tools to open & hold the flange.
  • Install the spade properly.
  • Ensure the flanges are tightened securely.
  • Ensure the erection of certified scaffolding done by certified inspectors.
  • Use approved safety harness/lanyard.
  • Supervision to be at the work front at all times by performing party to ensure that the workforce has a good understanding of the task and communication should be good and working to the approved JHA and Permit Requirements.
  • Secure all loose materials or remove any loose materials from the top of the scaffolding platform.
  • Use manual lifting procedure to avoid muscle collapse.

4. Erection & modification of scaffolding for flare tip 

Potential Hazard

  • Critical damage to onsite detectors /switches/transmitters etc. mechanism.
  • Fall of objects / Tools.
  • Accidental Fall of Person.
  • Unstable Scaffold.
  • Weak Scaffold.
  • Damaged Scaffold
  • Modified Scaffold
  • Improperly Supported Scaffold.
  • Incomplete Scaffold

Control/Mitigation Measures

  • Take great care during erection and override it if required. 
  • Provision of guardrail & toe board installations to stop falling of tools /objects.
  • Don’t keep the unwanted materials/objects/substances on the scaffold platform.
  • Hand tools must be tied and secured with a permanent structure or person.
  • The Scaffolders must use Safety Harness to prevent accidental fall.
  • The scaffold must be observed, inspected, certified & tagged by the authorized and competent person confirming its suitability and stability.
  • The purpose of the scaffold tag is to indicate the maximum load capacity that it can bear.
  • Inspection of the scaffolding shall be done by a qualified scaffolding inspector.
  • The scaffolding inspection is to be conducted at least weekly for any destruction/damage due to extreme weather condition for example heavy rain, high wind etc. or other unsafe conditions.
  • No one else is allowed to make any alteration in the scaffolding without the approval of scaffolding inspector/or any other responsible person.
  • In case of any additional alterations in the scaffold, it has to be re-inspected, observed & certified.
  • Make sure that the Scaffold is securely supported on a rigid ground and not on any unsafe ground conditions such as process piping/vessel or equipment.
  • Do not use the scaffold if green Tag is missing or outdated.
  • Do not use if the scaffold structure if the red tag is available.

5. Removal & Re-fixing of Flare tip using man basket

Potential Hazard

  • Work at height on man baskets
  • Uncertified man basket
  • Collisions/failure of equipment
  • High Wind
  • Fall of Objects/ Swinging
  • Overloading
  • Load failure
  • Manual handling
  • The collapse of the Crane & Load
  • Injury to Workers
  • Damage to the Load

Control/Mitigation Measures

  • use the approved and certified full body harness if the man working at height
  • Use tag lines to control the unwanted movement of the man basket.
  • use approved and certified Man basket.
  • A safe distance from overhead facilities (Power Cables/Pipe) and fixtures on both sides
  • Lifting plan to be completed and work according to the lifting plan
  • Confirm the signals between crane Operator & Banks man. Only trained Banks man to give the signal.
  • Do not carry out lifting activity during high wind conditions (25 knots above)
  • Good communication between rigger and crane operator. (Visual Contact/Radio communication). 
  • Follow QP lifting procedures.
  • Secured and fixed to the hook. 
  • The clip on the hook for safety purpose must be correctly and accurately closed.
  • Ensure Lift within SWL
  • Use tag lines to control the lifting load
  • Perform the activity according to the critical lifting plan
  • Supports to which lifting gears are attached shall be strong enough to withstand the lifting load.
  • Do not leave the load suspended
  • Ensure the load safety before lifting and never overload more than the capacity of the crane, pallet, container, slings /chain/ropes or tackles etc.
  • Outriggers of the crane shall be on firm and level surface, supported on spread weight and ground conditions to be suitable for lifting load
  • Use good manual lifting technique
  • Confirm & communicate manual lifting if to or more people are involved in   manual lifting
  • The competent crane operator and riggers approved in QP.
  • Use only certified lifting tackles for lifting approved in QP 
  • Inspect all lifting tackles before the start.
  • Confirm the stability of the crane at the worksite.
  • Conduct a safety check of the crane before start lifting.
  • Conduct the load test in case the crane is assembled at the workplace.
  • Inspect third party certificates of all personnel before the job.
  • Banks man to guide all crane movement in the plant area.
  • Never stand/walk on/under lifting load
  • Barricade the lifting area/ swing radius and place safety caution, boards
  • Verify the workforce is properly well trained for heavy lifting operations and non-essential person leave the area before lifting operations starts.
  • Double-check the suitability of lifting tackles & crane for the loads to be handled.
  • Check the Lifting Tools; Tackles & Crane have fitness validity, certificate and colour coding as per QP.
  • Ensure the area is free from obstacles for crane operations and the ground is properly compacted.
  • Always make sure that the load is secured properly for safe lifting.
  • Double-check and inspect the various components such as the slings, chain, ropes, eye bolt, pallet, container are not damaged and in a safe condition for lifting the load.
  • Lift the load slowly & check the slings/ropes/chains are not twisted keeping the load in a central position.
  • Utilize the rope for guiding the load if needed.
  • Utilize the rubber pads to check the abrasion from slings.

6. Sweep Blasting for inspection 

Potential Hazard

  • Severe exposure of Dust, Noise & Injury to Workforce.
  • Lack of Communication
  • Fire & Explosion
  • Continuous flow
  • Damage hose
  • Improper connection
  • Control/Mitigation Measures
  • Ensure workers involved in sweep blasting are wearing required PPE.
  • Short-term entry into the exclusion zone is acceptable if necessary respiratory protection and hearing protection is worn
  • Act as a safety observer for the blasting operator and to assist in an emergency.
  • Good communication between workers
  • Enclose the grit blasting the area with tarpaulin and post warning notice.
  • Keep a fire extinguisher 
  • Make sure that the blast gun is fitted with Emergency Release Handle and it is fully functional.
  • Ensure a continuous supply of breathing air to the blast hood.
  • Never leave the grit blast equipment un-attended with air supply on.
  • The blasting operator shall have direct control of the flow of abrasive material/substances through the nozzle. A positive, fast-acting emergency cut-off device (dead man control) shall be adjusted at the nozzle end of the abrasive blasting hose to automatically cut off the flow of abrasive material/substances from the blast pot if the person operating the nozzle becomes unable to control the flow of abrasive material/substances through the nozzle.
  • The startup, maintain and shut down the supply of compressed air or blasting media to the blasting operator as required.
  • Where respiratory protection is needed, a dedicated supply of breathing air shall be provided for the operator/workforce.
  • Flow control using a manually operated ball valve is not acceptable as an emergency cut-off device

7. Inspection of the flare tip

Potential Hazard

  • Fall, slip, trip
  • Improper barricade
  • Exposure to chemicals/gases
  • Poor visibility
  • Dust

Control/Mitigation Measures

  • Ensure that area is free from materials to avoid slip, trip or fall
  • Barricade the area properly and post warning signage.
  • Check the work area is free from the toxic vapour
  • use 24volt lighting for poor visibility
  • Proper cartridge mask should be used 

8. In the event of emergency alarm

Potential Hazard

  • Panic 
  • Unfamiliar with an emergency alarm
  • Slips trips and falls.
  • Lack of knowledge of the emergency procedure.
  • Control/Mitigation Measures
  • In the event of plant alarm or gas detector alarming following actions are to be taken
  • Immediate STOP/suspend all activities.
  • Do not run-in case of emergency to avoid to trip, slip, fall
  • Familiarized of emergency evacuation procedures.
  • Drivers stop vehicles and switch off the engine and other equipment also should be switched off
  • All personnel should proceed to the nearest muster point
  • Wait at the muster point for further instruction

9. Housekeeping

Potential Hazard

  • Slips trips and falls 
  • Scattered materials

Control/Mitigation Measures

  • Regular housekeeping at the site shall be performed. 
  • Ensure proper wind-up & housekeeping at the worksite.
  • Adequate and correct stacking of materials.
  • Regular inspection and immediate corrective action. Keep always clear of obstruction.
  • Regular clearing of worksite shall be implemented.
  • Access & Walking ways or Working Places Always Clear.

10. Manual handling

Potential Hazard

  • Hand injury
  • Back injury

Control/Mitigation Measures

  • Use proper PPE
  • Follow the ergonomics and ensure good supervision by the responsible person.
Download File

Tuesday, December 29, 2020

December 29, 2020

Pneumatic Test-Job Hazard Analysis

Activities, Potential Hazards and Control Measures

1. Mobilization of Materials & Tools

Potential Hazard

  • Slips and tripping hazard
  • Material Falling
  • Hand Injury
  • Strike against any equipment
  • Manual handling

Control/Mitigation Measures

  • Correct Sign Board should be posted.
  • Proper arrangement of all materials proper barricading to avoid any trips & slips
  • Secured All materials before transporting from one point to another
  • Removed all sharp objects
  • Use proper PPE to carry any kind of all potential obstacle/trip hazards.
  • Provide train banks man while the vehicle is moving
  • As per QP procedure transport should follow the speed limit
  • Supervised the workers and follow ergonomics while doing manual handling.
  • Proper communication while lifting the objects.

2. Site Preparation for the Work Activities

(Using Air compressor, Hydro-jetting machine, Vacuum Tanker, Diesel Generator, Trailer, Self-Loader, Crane, Pneumatic pump, Fork Lift) (If Requires)

Potential Hazard

  • The entry of equipment without a valid gate pass.
  • Poor communication between work parties.
  • Lack of safety awareness/Knowledge & inexperience
  • Injury from improper manual lifting
  • Improper tools

Control/Mitigation Measures

  • Must require valid gate passes for all equipment.
  • Supervision to be at the work front at all times by performing party to ensure that the workforce has a good understanding of the task and working to the approved JHA and Permit Requirements.
  • Good coordination and communication between team members.
  • All workers shall be instructed in safe lifting techniques/procedures.
  • If loads are awkward, gawky, too heavy, difficult to grasp, high traffic areas, two (2) men are required for carrying loads.
  • Proper tools should be used.

3. Pneumatic Test

Potential Hazard

  • Exceeding Maximum Allowable Pressure
  • injury to Workers
  • Damage to Equipment / System
  • Un-attended Pressurized Tool /Equipment
  • Changing the Duration of the pneumatic test
  • Unsafe Depressurization of pneumatic test
  • Fatal physical Injuries from Pipe fracture/damage / Or High-Pressure Water Blast
  • No Distance Barricades
  • No Preliminary Walkthrough
  • improper Disposal 

Control/Mitigation Measures

  • Ensure the pressure-relieving device such as Pressure Relief Valve (PRV) is set at maximum permissible pressure for the weakest part of the segment to be hydro-tested.
  • Always keep away from the pressurized portion of the system being pneumatic tested.
  • Appropriately monitor and observe the pressure gauge from a safe distance away from the possible potential source of high-pressure jetting (Such as Flange Joint, Spade, and Coupling etc.)
  • Ensure the workers are wearing required PPE
  • Never increase the pneumatic test pressure more than the maximum allowable pressure for the weakest portion in the segment or pressure rating of the hose & coupling
  • Never leave the pressurized hose or pump unattended when the pneumatic test is being in progress.
  • Make the isolation of equipment from all source of energy (electricity, water, lubrication/gas) when not in use.
  • Do not exceed or decrease the planned or pre-set duration of hydro-test without permission from Inspection Engineer/supervisor or other technical personal.
  • Hazardous and highly flammable or suffocated types of gases or vapours must be ventilated appropriately and essentially and clear of any area where personnel are working or where there is any possible source of ignition.
  • Valves of the energy sources must isolate any ancillary device or equipment not under test.
  • Mere calibrated test gauges shall be utilized and they shall be kept in the upright position. 
  • Pump discharge gauges must be visible to the pump operator during the duration of the pneumatic test.
  • The equipment/vessel shall have appropriate and essential vacuum relief capacity to avoid any severe destruction or collapse draining the test liquid.
  • The tested line shall be supported and secured.
  • Water supply Lines shall be drained and dried mechanically when the test liquid is corrosive or otherwise extremely hazardous.
  • A system under test shall be depressurized (except pressure due to a compressed airhead) before any work is done to stop leaks or repair weakness, including the tightening of bolts.
  • A block valve is needed on the line from the test pump to the equipment and or device under test.
  • Air shall not be used to displace test air from underwater equipment unless it has been determined that the equipment will not float.
  • All Piping, vessels, supports and foundations designed for gas service shall not be overloaded by the additional weight of the test liquid. Temporary supports and braces may be needed.
  • An accessible bleed valve shall be provided for the protection and prevention of the piping system in case an immediate depressurizing is required.
  • Pressure shall be increased slowly and steadily with 10 minutes hold at each step, no swift change in energy source pressure
  • Proper barricade and sign should be posted
  • Do not walkthrough while the test is performing
  • secure the area and do not block the area by materials
  • Disposal of waste should be properly stored
  • Any spill or leaks of waste should be cleaned immediately 

4. In the Event of Emergency Alarm

Potential Hazard

  • Panic 
  • Unfamiliar with an emergency alarm
  • Slips trips and falls.
  • Lack of knowledge of the emergency procedure.

Control/Mitigation Measures

  • In the event of plant alarm or gas detector alarming following actions are to be taken
  • Immediate STOP/suspend all activities.
  • Do not run-in case of emergency to avoid to trip, slip, fall
  • Familiarized of emergency evacuation procedures.
  • Drivers stop vehicles and switch off the engine and other equipment also should be switched off
  • All personnel should proceed to the nearest muster point
  • Wait at the muster point for further instruction
  • Make sure the Supervisors level attended the HSE induction and the information to be transferred to all workers)

5. Housekeeping

Potential Hazard

  • Slips trips and falls. 
  • Scattered materials

Control/Mitigation Measures

  • Regular housekeeping at the site shall be performed. 
  • Ensure proper wind-up & housekeeping at the worksite.
  • Adequate and correct stacking of materials.
  • Regular inspection and immediate corrective action. Keep always clear of obstruction.
  • Regular clearing of worksite shall be implemented.
  • Access & Walking ways or Working Places Always Clear.

6. Manual Handling

Potential Hazard

  • Hand injury
  • Back injury

Control/Mitigation Measures

  • Use proper PPE
  • Follow the ergonomics and ensure good supervision by a responsible person.

Download File
December 29, 2020

Angle Grinder Hazard Awareness Training Presentation


The objective behind Angle Grinder Safety awareness PPT is to appropriately and essentially communicate the hazards related to angle grinders and the controls that should be in place for all workers who involved using this Angle Grinder. 

Grinding & Cutting Hazards


  1. Proper PPE {glasses, full face shield, hearing protection); 
  2. Proper clothing -100% cotton or FR;
  3. All PPE and clothing must be in good order and free of oil and grease;
  4. Areas must be free of combustibles;
  5. Control spark direction by being aware of your surroundings;
  6. Use proper barriers like guarding of the work area, fire blanket, welding curtain; 
  7. Burning permit as required.


  1. Identify required respiratory protection for work being performed {P-100 cartridge);
  2. If grinding on potential lead-based paint, refer to OH-OEMP-SPL-05 for required controls; 
  3. Proper ventilation of work area (i.e., or mover, or smoke eater);
  4. Free area of secondary dust that may be present in the work area or on equipment being worked on (i.e., vacuum area, wash down area, or sweep area);
  5. Remove excess dust on clothing after performing work (i.e., Damp cloth or vacuum); 
  6. Be aware of possible combustible dust material.


  • Be aware of workpiece finish which will create fumes {paints, oils, grease, solvents, galvanized); 
  • Proper ventilation;
  • Identify required respiratory protection for work being performed {stainless steel, aluminum, metal oxides, silica);
  • Plan work to properly remove hazardous surfaces before grinding {lead paint etc.).


  1. Identify the required level of hearing protection (e.g., Single or double protection); 
  2. Inform people who may be affected by your work;
  3. Participate in the hearing testing program.


  1. If grinding for extending periods, the use of vibration gloves recommended; 
  2. Inspect disks to prevent excessive vibration and replace as required;
  3. Secure work to prevent vibration;
  4. Inspect grinder for worn bearings or abnormal vibration.

Projectile Material

  1. Secure workpiece; Housekeeping in the work area;
  2. Be aware of the direction of grinding sparks and material. Other barriers/shields may be required;
  3. Be aware the process of grinding can dislodge material from the workpiece and become an airborne

Projectile Disk

  1. The guard on grinder must be properly secured and in the proper position to protect the user from projectiles from the disk;
  2. Never use excessive force to the grinder disk;
  3. Do not use a cutting disk to perform grinding work;
  4. Never bump the rotating grinder disk onto the workpiece;
  5. Keep the grinding disk at a 15 to 30-degree angle to the workpiece; 
  6. Wear all required PPE {glasses, face shield and gloves);
  7. Check that the disk speed marked on the disk is equal to or greater than the maximum speed of the grinder;
  8. Do not twist or bend a cutting disk in operation;
  9. Do not overtighten the knurled nut that secures the disk;
  10. Ensure that you are using the proper type of grinding or cutting disk for the workpiece.

Fractured Disk

  1. Check the condition of the disk before using the grinder;
  2. If any defects or fractures found, remove and discard disk;
  3. Use proper disk for application to prevent "glazing" thus resulting in disk overheating causing failure; 
  4. Do not abuse the disk.
  5. Grinding wrong material
  6. Make sure to use the proper disk for the material being cut or ground {plugged or glazed disk causes overheating resulting in failure or the premature wear of the disk.).

Kick Back

  1. Always use and never remove provided safety attachments {handle & guard); 
  2. Firm grip on the grinder and handle;
  3. Never let the grinder go until the disk has stopped; 
  4. Do not apply excessive force to the disk;
  5. Good work practices not overreach, do not use the grinder without both hands on the tool {handle & grinder), do not use the grinder in a cramped area when you do not have full control of the grinder.

Work Environment (wet conditions, fire hazards)

  1. Conduct a workplace inspection before starting work {are there any hazard that could put you at risk while grinding or what hazards are in the area when you grind);
  2. Hot work permit;
  3. Proper housekeeping practices;
  4. Proper barricade/barrier in place for the work being performed.

Heat Generation from Grinding

  1. The workpiece will be hot due to grinding {use proper PPE or tools when handling hot workpieces); 
  2. Sparks coming in contact with combustibles.

Changing Disks

  1. Disconnect power to grinder;
  2. Use proper tools for the removal of the retaining nut {if provided); 
  3. Follow manufactures instructions;
  4. Do not strike grinder disk to loosen;
  5. Use a locking device to an in the removal of the disk; 
  6. Use Proper PPE.

Freewheeling {letting of grinder before disk stops)

  1. Never put a grinder down while the disk is still rotating;
  2. Do not force shut down of disk with force, allow the disk to stop on its own.

Download File

 Angle Grinder Hazard Awareness Training Presentation

Angle Grinder Hazards

December 29, 2020

Abrasive Wheel (Gurinder, Cutters & Saws)


To provide appropriate and essential awareness and knowledge to workforce on the use and care of portable hand-held grinders at the Workplace. 


To ensure technicians and or operators gave full command, competent and skilled in the inspection, use and care of portable hand-held grinders.

The Rules

  • Side handle must be fitted.
  • Quality material Kevlar sleeves must be worn.
  • Deadman’s handle (No lock-on option)                   
  • Unplug it before you change discs.
  • Put it down - Before repositioning yourself,
  • wait until the disc has stopped, then place the grinder in a safe position.
  • All guards fitted and adjusted.


  1. Coming into contact with dangerously moving parts of the machinery & equipment (including abrasive materials).
  2. Wheel/Disc bursting and material being ejected.
  3. During the grinder operation, abrasive and small particles coming into contact with eyes.
  4. Noise from equipment.
  5. Vibration from equipment.
  6. Kickback where the grinder is thrust away from the workpiece. 
  7. Inhalation of fumes and dust from materials being worked on.
  8. Entanglement with loose items drawing grinder to the personal.
  9. Electrocution (PAT TESTING)

Download File

Abrasive Wheel (Gurinder, Cutters & Saws)

Monday, December 28, 2020

December 28, 2020

Machine Guarding-PowerPoint Training

 Possible machinery-related injuries include:

  • Crushed fingers or hands
  • Amputations
  • Burns
  • Blindness

A good rule to remember is: 

While working in any manufacturing, construction or maintenance work activities, any machine part, function, or process which may cause fatal and severe human physical injury must be safeguarded properly and essentially.

Objectives Of the Training:

  1. Identify the main causes of machinery accidents.
  2. Familiar with basic machinery parts that expose the workforce to hazards.
  3. Familiar workplace situations involving machinery that requires guarding.
  4. Identify the requirements for machinery’s safeguards.
  5. Identify various types of machine guards including types of devices used to safeguard machines.

How machine accidents can occur:

  • Reaching-in to “clear” equipment.
  • Not using Lockout/Tagout.
  • Unauthorized workers or personals doing maintenance for machines or using the machines.
  •  Missing or loose machine guards.
For the complete “Machine Guarding” PowerPoint training file free download, click the following link:
Download File

Sunday, December 27, 2020

December 27, 2020

Training PowerPoint for Construction Hazards

The Most leading top ten risks and hazards from working on construction workplaces are as following:

  1. Working at height.
  2. Moving objects.
  3. Slips, trips, and falls.
  4. Noise.
  5. Hand-arm vibration syndrome.
  6. Material and manual handling.
  7. Collapsing trenches.
  8. Asbestos.
  9. Electricity.
  10. Airborne fibers and materials.

After training of this topic “CONSTRUCTION HAZARDS”, the trainees will able to know:

  1. Identify the four major hazards of construction work and how to avoid them.
  2. Describe methodologies/ways to protect themselves from hazards.
  3. Learn how to select and use Personal Protective Equipment (PPE) appropriately.
  4. Apply safety procedures when working in or around the most critical locations e.g., Trenches, Electrical equipment, Scaffolds and Power Tools
Download File

Saturday, December 26, 2020

December 26, 2020

Incident & Accident Report Form

The attached editable Incident & Accident Report Form and will help you to any workplace incident or accident reporting with great ease. 

For more health and safety-related free documents such as the method of statements, risk assessments, JSA’s. JHA’s, facility management, civil, electrical reports and forms, food safety documents, toolbox talks, HSE training, orientations in PowerPoint, and along with all these free downloads, you can also request for any document you required for your project. When you request for any document via our website at, we try to search for that document in our HSE Document library, if not found in the library, we request our professionals to prepare the requested document and upload as soon as possible on our website. Just subscribe our website to get every document’s uploading notification.

Use this simple Incident & Accident Report Form report template to standardize your worksite project team’s issue reporting process.

Download File

Incident & Accident Report Form

Thursday, December 24, 2020

December 24, 2020

QMS and EMS Manual (ISO-EMS-14001- 2004 & 2015)

ISO 14001:2015 Environmental Management System (standards) is regarding environmental management that helps organizations (a) to minimize and how their operations, processes, and business activities etc. negatively affect the environment and cause adverse changes:

  1. Air, Water, or Land
  2. ISO 14001:2015 Environmental Management System Comply with applicable laws, regulations, and other environmentally oriented requirements 
  3. Continually improve in the above. 

Benefits of ISO 14001:2015 EMS

  1. Result in reducing their environmental impacts. 
  2. Improvements in performance, 
  3. Achievement of several economic benefits including higher conformance with legislative 
  4. Regulatory requirements by adopting the ISO standard. 
  5. By minimizing the risk of regulatory and environmental liability fines and improving an organization’s efficiency,
  6. Reduction in waste, consumption of resources, and operating costs

Structure of ISO 14001:2015

The structure of ISO 14001 includes:

A. Development of an environmental policy

B. Identification of environmental aspects and evaluation of the associated environmental impact

C. Establishment of relevant legal and regulatory requirements

D. Development and maintenance of environmental objectives and targets

E. Implementation of a documented system, including elements of training, operational controls and dealing with emergencies

F. Monitoring and measurement of operational activities

G. Environmental internal auditing

H. Management reviews of the system to ensure its continuing effectiveness and suitability

Download File

QMS and EMS  Manual (ISO-EMS-14001-2015)

QMS and EMS  Manual (ISO-EMS-14001-2004)

Wednesday, December 23, 2020

December 23, 2020

Method Statement for Installation of Sleeves and Puddle Flanges

1. Scope of Work

This method statement is applicable for Installation of Sleeves & Puddle Flange for [Project/Facility Name] in accordance with the specified standards and regulations in project specifications.

The Scope of activity includes the delivery to Worksite, installation, pre-commissioning, testing, commissioning and guarantee of the system as described in the specification/contract documents and drawings.

2. References

  • Approved Shop drawing
  • Specification (V: xyz)
  • Approved inspection of material delivered on site. 

3. Responsibility

The Project engineer shall be overall accountable for arranging the materials/substances as per worksite stipulation.

Site supervisor shall ensure workmanship and will also make sure that all the work is done by the skilled workforce.

QA/QC engineer shall ensure that all work is done as per approved drawings and material used is approved and coordinate with [Organization MEP] Coordinator for internal checking prior to final inspection to consultant.

4. Equipments / Tools

Following equipment/devices and or tools shall be organized before starting the activity.

  1. Tool box 
  2. Welding machine
  3. Welding cable
  4. Welding helmet
  5. Chipping hammer
  6. Welding holder & earthing holder
  7. Spanner
  8. Portable grinder
  9. Gloves
  10. Goggles

5. Work Sequence/Procedure

5.1 Installation of Puddle Flange

  • As per approved shop drawings and Invert Level, mark the centre and invert level of Sleeve on reinforcement /steel bars for water walls.
  • Steel fixing contractor to bend and clear the exact area for installing Sleeve.
  • Once the location is clear, position the Sleeve in the steel area.
  • Once the Sleeve is in proper location recheck the level and alignment.
  • Tie the sleeves with suitable wires with steel to avoid any misalignment while concreting.
  • Clearance for civil contractor to close the shutter with exact holes matching with Sleeve to proceed with concrete pouring.
  • All the work to be inspected at all stages by consultant engineer.

5.2 Installation of Puddle Flange

  • As per approved shop drawings and Invert Level, mark the centre and invert level of Puddle flange on reinforcement /steel bars for water walls.
  • Steel fixing contractor to bend and clear the exact area for installing puddle flange.
  • Once the location is clear, position the puddle flange in the steel area.
  • Once the puddle flange is in proper location recheck the level and alignment.
  • Clearance for civil contractor to close the shutter with exact holes matching with puddle flange to proceed with concrete pouring.

5.3 Welding Process for Weld Neck Flanges on Puddle Flange

  • Preparing face and edge of pipe piece of puddle flange (outer side application area pump room) with proper finishing tools (finishing grinder and other tools).
  • After the edges are prepared and cleaned, final checking for alignment and position.
  • Clearing the selected area in front (if required on height scaffolding tower to be prepared in accordance with safety requirements).
  • Get the permits for Electric arc welding at basement area with all safety requirements.
  • As per consultant’s approval using the weld neck “socket end “flange with inside and outside welding.
  • In case of galvanized pipe first galvanize coating to be removed by grinding or suitable procedure to reduce the smoke generation.
  • All the work to be inspected at all stages by consultant engineer.

6. Inspection & Testing Plan

  1. All the Sleeves & Puddle Flange Installation works shall be inspected as per the inspection & testing plan and inspection checklists. Results of inspection & testing shall be document on the inspection checklist forms.
  2. Refer to inspection & Testing Plan No: ABC

7. Inspection Checklist.

  • Inspection Checklist 
  • Work Inspection Requests

8. Attachments

  • Risk Assessment
  • Inspection Checklist 

Download File 

Method Statement for Installation of Sleeves and Puddle Flanges.

December 23, 2020

Risk Opportunity

Risk Opportunity Assessment (RA), Disaster Management Plan (DMP) and Emergency Response Plan(ERP)

The following attached downloadable sample document elucidates the Risk Assessment (RA), Disaster Management Plan (DMP) and Emergency Response Plan (ERP) for the proposed project. You can make changes as per your company's requirements.

For more health and safety documents, visit our blog at, where you will find all about HSE content ready to download for free.

Download File

Risk Opportunity-DMP-ERP

Tuesday, December 22, 2020

December 22, 2020

Risk Assessment-Integrated Management System

The following are some important key points to conduct an Integrated Management System Risk Assessment:


  1. Falling materials objects
  2. Occupational health
  3. Manual Handling
  4. Tools & Equipment.
  5. Noise
  6. Solids Waste

Control Measures

  • Barricade sensitive areas,
  • Ensure falling protection.
  • Use warning signboards in those areas.
  • Use Head protection strictly.
  • Provide catch on the chuck to collect foreign particle when drilling upward.
  • Wear necessary PPE’s i.e., goggles, hand gloves, dust mask, earplugs etc.
  • No worker should be asked to carry loads above his physical lifting capacity and in any case, no-load shall exceed 30 kilograms per employee.
  • Avoid manual handling where reasonably practical. e.g., use mechanical equipment.
  • Before lifting any object/weight, always assess the weight of the item to be carried.
  • Take help if the load is large/very heavy.
  • Check the line of travel. Don’t allow the load to obstruct the view.
  • The area should be clean, tidy well house kept and free from fall, slip and trip hazards.
  • Training personnel in the kinetics of manual lifting.
  • Use personnel protective equipment as provided.  (Safety shoes, helmets, coveralls, hand gloves etc.)
  • Defective tools should not be issued or used to perform a task.
  • All portable power tools should be equipped with adequate fuse protection either in the tool body or in its electrical plug.
  • The weight, size and type of tool item, object or weight should be selected to suit the job being conducted.
  • Only those persons who have been adequately trained and experienced in the use of the tool should be allowed to use the same.
  • Tools should be maintained in good working condition and tested at regular intervals.
  • All tools & machines should be neatly and correctly stored when not in use.
  • The work area should be maintained in good condition, should be kept clear of loose materials and prevented from becoming slippery.
  • Appropriate approved personal protective equipment.
  • Noise measurements should be carried out where noise is produced and at other workplaces where operatives may be subject to a higher level than their work generates.
  • Use of alternative, less noisy tools and equipment or methods.
  • Appropriate ear protectors must be worn.
  • The waste material should be kept in one dedicated place.
  • All wastes should be removed from the site after the work daily.
  • Dispose off in specific waste bins/yards as per the requirements of [Organization/Govt. Bodies & main or sub-Contractors)].

Download File

Risk Assessment-Integrated Management System

Thursday, December 17, 2020

December 17, 2020

Checklist for ARC Welding Machine

Following are main and basic essential points while you are working with ARC metal welding machine. you can download good quality Checklist for ARC Welding Machine in word format just by clicking the link given at the end of these points for free:

  1. Are only competent, authorized, a trained and skilled technician is permitted to use such welding machine/equipment?
  2. Have all combustible materials/substances and flammable liquids and gases been removed from welding areas?
  3. Are welding and cutting cables completely insulated, good condition and free from any damage?
  4. Are fuel gas and oxygen hoses easily imperceptible, in good condition and free from any damage
  5. Is appropriate mechanical ventilation system provided at welding, cutting or heating locations when essential?
  6. Is proper and essential Eye Protective Equipment provided and used where required?
  7. Are painting service, activities, and the application of adhesives remote from welding and cutting operations? 
  8. Is fire watcher is appointed during the welding operation?
  9. Are arc welding and cutting operations protected by noncombustible or flameproof shields to protect employees from direct arc rays’ hazardous effects?
  10. Are only competent, authorized, a trained and skilled technician is permitted to use such welding machine/equipment?
  11. ON / OFF lever/button is provided (Inspect for damage and uninsulated lever).
  12. Controlling device (regulator with indicator) is provided.
  13. Arc welding cables connected to the welding machine with lugs at the joints.
  14. No destruction/critical damage in the insulation of welding cables/wires.
  15. Electrode rod holder and earthing holder are without any critical damage.
  16. No internal live electrical components of the welding machine are exposed.
  17. Trolley without damaged (wheels, pulling handles, etc.)
  18. Fire protection mechanism (Fire extinguisher and fire bucket with sand) are availability.
Download File

December 17, 2020

Fire-Fighting Equipment Checklist

To carryout site firefighting equipment such as fire extinguishers, sprinkler system,  fire hose reel, fire hydrant etc., prepare your own checklist as per the requirement. you have also option to download our quality checklist document in the word format. just click on the downloading link given at the end of the post:

  1. Are portable fire extinguishers provided in enough recommended quantity and type?
  2. Is inspection for fire extinguishers conducted monthly for general condition and operability with inspection note on the inspection tag?
  3. Are fire extinguishers recharged regularly and appropriately and essentially noted on the inspection tag?
  4. Are fire extinguishers mounted in easily accessible locations as per required NEFPA standards?
  5. Are FLS Technicians, facility employees routinely instructed, inducted and trained in the use of fire extinguishers and fire protection procedures (PASS)?
  6. Are all external private fire hydrants flushed since the previous year with a regular maintenance schedule?
  7. Are all facility fire doors being fire-rated and shutters in stable operating condition?
  8. Are fire doors being free from any obstruction?
  9. Are fusible links being essentially available?
  10. Is the internal fire department familiarized with the plant, location and specific hazards?
  11. Is a control system such as valves, air and water pressures, inspected weekly?
  12. Are control valves locked open?
  13. Is maintenance of the firefighting equipment system assigned to an accountable person?
  14. Are sprinkler system’s heads protected by metal guards were exposed to possible mechanical destructions?
  15. Is an essential minimum required clearance maintained around sprinkler heads?
  16. is FACP system tested as per required standards at least annually?
Download File

Tuesday, December 15, 2020

December 15, 2020

Bites and Stings

Millions of the pests and insect’s species are find in earth, but not all bites or stings by these species are the same. When we are beaten and or stung by any of the insects or pests, then we will need various first aid treatment and intensive medical care depending on what type of insect/pest and or animal has bitten or stung us. Some species can cause more destruction than others. Some people also have allergies/infections that raise the serious HSE risk of a serious reaction.

Here’s how to perceive and treat the symptoms of bites and stings from insects, spiders, and snakes.

If we look in wide scenario, nearly everyone has been bitten or stung by an insect at one time or another and unaccountable human daily get stung or bitten. Whether we’ve been stung by a mosquito, fly, bee, wasp, ant, or other bug, insect bites and stings generally cause a mild reaction. Our body reacts to venom/poisons or other proteins that insects inject into you or transfer to your body through their saliva. This can result in symptoms at the workplace of the insects/pests’ bite or sting, such as:

  1. Redness
  2. Swelling
  3. Pain
  4. Itching

The severity of our symptoms can different, depending on the type of insect/pest that bites or stings us. Some of us also establish a severe allergic reaction to insect stings or bites. Bee and wasp allergies are particularly very general. A severe allergic reaction can cause us as:

  • Hives
  • Abdominal Cramps
  • Nausea and Vomiting
  • Swelling of our Face, Lips, or Throat
  • Breathing Problems
  • Shock

If we or someone from us know begin to experience these symptoms shortly after being bitten or stung by an insect, call [EMERGENCY HELPLINE] or local First Aid Emergency Authority. A serious allergic reaction that affects multiple parts of OUR body is called anaphylaxis. It can be life-threatening and even death if not treated immediately.

If we, our workers at the workplace, our family at the home or any personnel near us ever had a severe reaction to an insect bite or sting, we should ask our ask doctor about allergy testing. If we been diagnosed with a serious allergy reaction, then our doctor should prescribe medication for such bites and sting named epinephrine. We can utilize a preloaded epinephrine auto-injector such as EpiPen to inject the medication in our outer thigh muscle. It acts very swiftly to raise your blood pressure level, trigger our heart, and reduce swelling of our airways. We should carry such type of medicine (EpiPen) with us at all times, particularly when we are far from any medical facility, or such areas where we might face such type of various venous insects.

Download File

Bites and Stings.pptx

December 15, 2020

Pump Overhaul in Confined Space

 Client Responsibilities:

Confirm that the following are in place to avoid latency and consequential extra costs:

  1. Confirm your workplace contact numbers will be available on agreed date/time of works.
  2. Mandatory - Supply a copy of the work site asbestos register.
  3.  confirm that all [Organization/Company-Facility] work areas can be considered as safe and free from Asbestos Maintains Materials (ACM’s). 
  4. Confirm availability of workplace First Aid Trained personnel to assist [Organization/Company-Facility] in an emergency.
  5. Provision of 110V or 240v power supply adjacent or within 10 meters of the working area.
  6. Provide appropriate parking at least for two vehicles.
  7. Provide all access/keys that are required.
  8. Provide all essential Permits to Work (PTW) including Confined space. 
  9. Provide any such induction as is required and details of site-specific health & safety, access & egress, emergency etc. rules/equipment, fire exits and or assembly points and location of first aid facilities.
  10. Allocation of proper and essential work-site welfare facilities. 
  11. Isolation of electrical supply to pump and establish “dead” status if not already isolated. 
  12. Provide guidance and escort for the duration of works to required works locations.

Important Emergency Contact Numbers for use in the event of an emergency on the worksite at any time outside of normal duty hours.

Medical Emergency Helpline:


Project Site Manager:


Project Engineer/Supervisor:


Health and Safety Engineer/Representative:


Appropriate PPE Summary 

Minimum Personal Protective Equipment (PPE) requirements will consist of Construction Safety Equipment (CSE) e.g., Safety Footwear (boots or shoes), high visibility vest or jacket with the addition of:

PPE Checklist


Gloves to EN:388

Whilst handling tools and working within the sump 


Whilst working within the sump

Safety goggles or glasses

Whilst working within the sump and drilling 

Safety headgear

Whilst inside the sump 

CSE Equipment

At all times when entering the sump

All site personnel are responsible for their PPE with adherence to the Health and

Safety at work act 1974.

Scope of work:

To overhaul the pump.


Workplace location is the effluent sump.

Materials and or substances to be kept at the workplace for the duration of works will be safely stored as directed by organization’s Technical Facilities Management personnel, ensuring no access/egress or other route is obstructed.

Sequence of Work

  • Report to Another Limited representative and obtain all necessary work permit Systems.
  • Develop workplace induction if new to worksite & get/obtain details of particular and related to access/egress, emergency etc. rules with emphasis to fire exits and assembly points areas.         
  • Create suitable and appropriate signage as required around workplace location.
  • Transport tools, equipment & materials in the work area and commence use of PPE per Risk Assessment including all Confined Space Equipment.
  • Make proceedings as per Confined Space procedures ensuring top man situated outside of sump, the second and third man attached to the winch with second man handling tools, equipment, third man entry into the sump pit.
  • Make proper organization for lifting equipment including a block and tackle to remove pumps.
  • Operate pump manually to drop level in the sump.
  • Lift the faulty pump using a block and tackle and remove for maintenance.
  • Observe and monitor 4x floats as the fault is on the level control and replace the floats if faulty.
  • Remove the block and tackle to a safe area to prevent an obstruction when the third man entering the pit.
  • The third man to enter pit via the attached access ladder (an additional ladder may be required if the electrics cannot be reached.
  • Replace the terminal box if faulty.
  • Second man to pass tools to the third man as and when required to then.
  • Make Service for the pump that runs and leave running in auto if possible.
  • The third man to climb back to a ground-level ensuring CSE equipment is still in use.   
  • Second man to remove from the winch.
  • Remove tools, redundant/surplus equipment & materials from the site and leave in a clean & tidy condition.  
  • Report to Limited representative upon accomplishment and leave the workplace.

PPE/Tools / Equipment / Materials

  1. The minimum Personal Protective Equipment (PPE) requirement for all work will be Occupational Safety Footwear hard shoes, high visibility vest or jacket with additional Personal Protective Equipment (PPE) consist or in compliance with Gloves to EN388 Abrasion, Blade Cut, Tear and Puncture, Overalls Safety headgear for example hard helmet or bump cap) Safety goggles or glasses to BS EN 166 1B349 CE2 (particulate) and CSE Equipment.
  2. Tools will be standard engineering hand tools 110V corded power drills or DC powered cordless tools with transformer, leads, associated plugs and sockets.
  3. All portable electrical equipment, devices o machinery will be under 12 months’ appropriate test.
  4. Equipment will consist of “A” Frame Lifting Gantry 1000 Kilograms capacity, block and tackle, Aluminium access ladder

Training / Competence

  • Confined Space Entry Procedure
  • First Aid – Nominated Personal
  • Electrical Engineering level 2
  •  (ACM’s) Asbestos Awareness
  • Manual Handling
  • Slips, Trips and Falls

Emergency Procedures

  • Company personnel will familiarize with site emergency procedures upon reporting
  • First Aid equipment will be carried by the company at all times. 
  • Any accident or incident and or near-miss will be notified immediately to the Main Contractor’s representative  
  • The company worksite Supervisor will be accountable for the Health and Safety of all company staff whilst they are executing these works
Download File