Professional Documents
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Safety Manual
Safety Manual
Safety Manual
E ELECTRICAL OPERATIONS
E 1. General Safety Precautions
E 2. Authorisation for doing work
E 3. Protective Equipment
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E 27. Testing of Electrical Equipment
ST 12 Discussion on usage of
safety tags in day to
day operations
C CONSTRUCTION
C 1 Scaffolds
C 2 Rigging and Hoisting
C 3 Welding, Burning &
Cutting(General)
C 4 Handling & Storing Compressed
Gases
C 5 Explosives: Storage &
Transportation
C 6 Handling & Use of Explosives
C 7 Excavations
C 8 Concreting & Cementing
T TRANSPORTATION
T 1 General Precautions
T 2 Driving
T 3 Parking
T 4 Operation of Trucks & Trailars
T 5 Procedure in Traffic Accidents
F First Aid
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SAFETY POLICY OF COMPANY
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3. FUNDAMENTALS OF SAFETY
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leaving objects where they are likely
to fall, improper packing, combining
chemicals to form a dangerous
mixture.
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(b) Defective Material or Equipment
such as mushroomed chisels, split
handles, poorly constructed
scaffolding, damaged tools,
electrical hand tools without proper
insulation.
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(a) Work to be done
(b) Hazards that may be encountered
(c) Proper procedure for doing the work safely.
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(2) Practical joking and horseplay or gossiping
while on the job is strictly prohibited.
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(3) After absence from work due to illness or
injury, an employee may be required to
pass a physical examination to determine
fitness for duty.
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Definitions :
Accident :
Work Injury :
Reportable Accident :
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liaison with the hospital and advise by way
of remarks on internal report form. The
second copy of the internal report form
should be sent to Safety Officer / Steward
and the third retained in Occupational
Health Centre / Dispensary / Office for the
records.
Role of Visitors
Role of Injured
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with Medical Officer / Retainer / Specialist in
treatment, hospitalisation, discharge and re-
instatement. The advice of Medical Officer /
Retainer / Specialist is binding on all
concerned personnel.
Statutory Reporting
Thermal – Trombay
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ESI scheme is applicable to Mumbai region
(including Kalyan and Ambernath) and Lonavla.
G-8 HOUSEKEEPING
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should be carefully stacked or
stored.
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(4) Rope tackle and slings, wherever required,
should be checked to ascertain that they
have sufficient strength to perform the work
in hand.
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Specifications of Manila, Polypropylene and Nylon
Ropes as per IS-1084, IS-5175 and IS-4572
Manila Ropes
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Polypropylene Ropes
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Nylon Ropes
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(8) Some of the dependable rope knots and hitches
are shown in the attached sketches indicating their
special purpose and advantages.
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G-11 LADDERS
(11) The use of ladders for other than their intended use
and the use of defective ladders is prohibited.
(17) Do not work higher than the second step from the
top of a stepladder or the third rung from the top of
a straight ladder.
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(26) Metal ladders are not to be used in locations where
they may come in contact with electrical conductors
except for special jobs performed in switchyard that
must be approved by the supervisor prior to
beginning the job.
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G-12 HAND TOOLS
GENERAL
GENERAL
A. GENERAL:
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C. GAS WELDING & CUTTING:
GENERAL:
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F. COMPRESSED AIR:
G. EXCAVATIONS:
GENERAL:
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4. No more than 8 meters of lateral travel in an
excavation 4 feet deep or more is allowed without
an adequate means of egress.
H. ABRASIVE BLASTING:
GENERAL:
I. LABORATORIES :
GENERAL:
J. COAL HANDLING :
GENERAL :
K. ASH HANDLING:
GENERAL:
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G-19 SAFEGUARDING THE PUBLIC
Protection for PPE to be PPE protecting from ------- PPE to be used during ------ / in
used -------
Body Cotton Uniform Exposure to Steam, Hot Oils, Constant use in designated places.
Chemicals, Alkalis.
Rubber Apron Splashes of Acids, Alkalis, Sampling, transferring, Filling,
Solvents. Drumming.
Head Helmet Falling objects and materials Constant use in designated places.
Eyes Safety goggles Flying objects, Splashes, Breaking of flanges, Chipping
Sprays concrete / metals, Gas Cutting,
Uncoupling of hoses, De-
pressurising, Venting, Sucking,
Sampling.
Welding Ultraviolet rays from welding Arc welding, Gas welding.
Goggles arc
Face 1. Face-shield Chemical Splashes Grinding, Furnace burner lighting,
Chemical handling, Metal shaving.
2. Blue Face- Hot rays, Ultraviolet rays, Arc welding, Gas welding.
shield Grinding sparks
Hands 1. Electrical Electric shock Working on high voltage electrical
Shock proof equipment / lines.
Gloves
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2. Leather Abrasion Pulling ropes / chains, Using tools
Gloves like spanners, Operating hard
valves, Welding.
3. Asbestos Hot burns Handling hot materials, Tightening
Gloves steam leak.
4. PVC Acids, Alkalis, Chemical handling
Gloves
5. Rubber Oils, Aromatic solvents, Chemical handling
Gloves Alcohols.
Foot 1. Safety Falling object, Striking against Constant use in designated areas
Shoes object
2. Gum Muddy Land, Water, Chemical Use under specific condition
Boots Spill,
Respiratory 1. Canister Toxic Gas, Vapours, Use for specific jobs.
System Mask
2. Self Toxic gas leaks, Smoke, Use for specific conditions.
Contained Emergencies.
Breathing
Apparatus
Set
3. Dust Air containing dust / solid Coal / Fly Ash handling, Grit
Mask particles blasting.
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Sweeping, Mopping up saw dust Dust Mask, Safety Goggles.
Concrete chipping, cold metal chipping Safety Goggles.
Painting Safety Goggles, Safety Harness Belt for the job
to be done at heights.
Acid / Caustic handling, filling toxic chemicals Rubber Apron.
Spading / de-spading, Connecting / disconnecting Safety Goggles / Face-shield.
hoses
Erecting scaffolding Safety Harness Belt, Leather Gloves.
Working on scaffolding Safety Harness Belt, Gloves (as per job).
HdPE pipe welding Safety Goggles, Leather Gloves.
Chlorine tonner connection / disconnection Canister mask
Lead Acid Battery maintenance jobs Safety Goggles / Face-shield.
Drawing samples Safety Goggles / Face-shield.
Transferring chemicals Safety Goggles / Face-shield.
Emptying / filling carboys / drums Safety Goggles / Face-shield.
Opening draining / de-pressurising valves Safety Goggles / Face-shield.
De-choking lines Safety Goggles / Face-shield.
Air blowing operations Safety Goggles / Face-shield.
Steaming operations Safety Goggles / Face-shield.
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(2) Flammable liquids shall be kept in approved safety
cans and identified by proper labels.
ELECTRICAL FIRES
Nature of Fire
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What is Fire
CLASSIFICATION OF FIRES
II. Smothering :
III. Cooling :
Fire Triangle
Fuel O2
Oxygen
Heat
Fuel Heat
FIRE PREVENTION
I) Good Housekeeping
II) No smoking (or separate preparation of smoking
zone)
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III) Use of fire resistant paint
IV) Electrical safety
V) Fire check doors
VI) Compartmentalisation
VII) Separate storage of Hazardous chemicals
VIII) Naked Flame safety
IX) Use of earth leakage and current balance relays
and thermostat, fireproof chokes.
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Carry out head counting before starting and after
closing the days work.
G-26-1
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1. Common Guide Lines for Various Systems
in Thermal Stations
G-26-2
G-26-3
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12. If skin contact occurs, flush areas with water and wash
with soap. Obtain medical attention if irritation
persists.
13. If control fluid is swallowed, give large amounts of salty
water to cause vomiting. If unsuccessful, tickle
back of patient's throat with finger. Obtain medical
attention if stomach discomfort persists.
14. All moisture should be eliminated from control fluid
system otherwise; the control fluid forms acid
components when in contact with water.
15. Chlorine presence in control fluid clauses erosion-
corrosion at the edges of control components.
Therefore all traces of solvents containing chlorine
should be removed.
16. Before charging of control fluid system, confirm that all
drains are closed.
17. In case of control fluid leakage it should be absorbed
by using saw dust or oil binding granules and
should be removed quickly.
18. For disposal control fluid may be mixed with saw dust
and burned in incinerating plant or mixed in small
quantities of used oil for burning.
19. In case of any major control fluid leakage, FIRE
PROTECTION should be activated to give a
complete shutdown to the control fluid system.
G-26-4
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any leaks. Subsequently the rate can be
increased.
7. Maintain oil tank temperature well below its flash point.
8. Rate of pumping should be within the maximum line
carrying capacity.
9. Start the pump always with re-circulation valve full
open. throttle re-circulation valve after confirming
flow & no oil leak.
10. All heat tracing circuits should be ON so that no part of
the LSHS line becomes cold. This is to avoid
solidification of the LSHS within the line.
11. While draining the LSHS tank care should be taken to
monitor the tank temperature.
12. Transfer oil to other tanks as fast as possible to avoid
wastage when a tank leak occurs.
G-26-5
G-26-6
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Post Start Checks - The following shall
be checked/observed:
Check all instruments, observe readings at
regular intervals and compare the
performance of equipment with
manufacturer’s data.
Check vibration readings for any
abnormality and take necessary corrective
actions.
Check temperature rise and pay attention to
any abnormal sound from bearings.
G-26-7
G 26-8
G 26-9
9. General Safety Guide Lines for
Various valves in Thermal Stations
1. Follow all Common Guide Lines of safety.
2. Check mode of operation of valve i.e. motor operated,
pneumatically operated, hydraulically operated
manually operated etc.
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3. Check the position of valve i.e. close/open/in between
and confirm with remote and local feed back/ check
back. If the positions are not matching inform
respective maintenance department.
4. After or during the operation of any valve if any
abnormality like gland leak etc. is observed then
restore the original position of valve or keep the
valve in position where the abnormal behaviour is
minimised and inform respective maintenance
department.
5. Check the housing of the area in the vicinity of valve
to be operated, if not proper then inform respective
maintenance department or Main Control Room.
6. Check the type of valve i.e. isolating, control etc.
7. Confirm valve is easy to operate.
8. Gate valves are always to be operated in full open or
full close condition.
9. Avoid frequent operation of high-pressure valves as
for as possible to avoid any gland leak.
10. For Motor Operated Valve
Confirm from working party or Main Control Room
whether valve operation is to be done electrically or
manually.
For electrical operation check the direction of operation
by giving an impulse command if possible and if
direction is ok then operate it fully.
If manual operation is to be done then first confirm that
motor breaker is off and then valve can be
operated in the similar way as that of manual valve
as given below for manual valves.
11. For Pneumatically Operated Valves
Check instrument air supply isolating valve is open and
thus air is available for valve operation.
Reset pneumatic air lock, if any and check the direction
of valve by giving small command from remote or
local and then valve can be further operated from
remote or local as per requirement.
If valve operation is not possible pneumatically then it
can be done manually in the same as given for
manual operating valves by isolating its instrument
air supply.
12. For Hydraulically Operated Valves
Check hydraulic circuit is properly lined up and enough
hydraulic pressure is available for valve operation.
Check for any leakage during or after the operation of
valve in hydraulic circuit.
13. For Manually Operated Valves
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Arrange right size of spanner as per size and location
of valve and also arrange hand gloves and other
safety accessories as per specific requirement of
the valve to be operated.
Fix the spanner in such a way so that enough space is
available for spanner movement and also confirm
that spanner grip is proper and there is no slipping
or sliding of spanner. This can be confirmed by
applying smaller force initially. Change the spanner
if required.
Gradually start operating the valve (close/open as per
requirement).
G 26-10
G 26-11
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11. General Safety Guide Lines for Lub.
Oil Systems
1. Follow all Common Guide Lines of safety.
2. Do not store inflammable material like wooden plates,
plastic sheets, cotton waste and sawdust near
lubrication oil system.
3. Check healthiness of fire fighting system for lub. oil
system periodically.
4. ‘No Smoking, welding or cutting’ sign board and
‘Emergency telephone number of fire department
and control room’ should be displayed in vicinity of
lubrication oil system.
5. Leakage or spillage of oil should be cleaned and
attended immediately.
6. Leaked oil should be prevented from coming in contact
with any high temperature system or electrical
equipment.
7. Sudden rise of oil temperature or any drop in
lubricating oil tank level should be checked
immediately.
G 26-12
GENERAL INSTRUCTIONS -
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5. Before disconnecting cylinder from header after cylinder is
empty.
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matter how trivial it may seem, should
receive prompt first-aid treatment.
G-28 ELEVATORS:
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E ELECTRICAL OPERATIONS
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(2) ALL ELECTRICAL CIRCUITS ARE TO BE
TREATED AS LIVE AND NO WORK
(MAINTENANCE, REPAIRS, CLEANING) IS TO
BE CARRIED OUT ON ANY PART OF
ELECTRICAL APPARATUS OR CIRCUIT UNLESS
SUCH PARTS ARE
(a) Dead
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(2) All rubber goods shall be of high-grade material,
bearing ISI mark and carefully inspected, stored
and cared for.
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(1) Before starting any work on dead lines or
equipment where there is a possibility of their
becoming energised from any source, such line or
equipment should be short circuited and grounded
between the locations of work and all possible
sources of energisation.
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(10) Conductors used for temporary grounding shall be
kept clear of the working area and the workmen
should be warned not to handled those conductors
without adequate safety precautions while they are
connected to H.T. equipment or lines.
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(e) All line crew shall ensure use of ‘Fall Safe
equipment’. Utmost care shall be taken by the first
person climbing the multi- circuit tower by carrying
rope with him as he shall not have advantage of
‘Fall Safe equipment’.
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(3) Linemen shall wear their safety harness while
working on the poles and towers.
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(4) When working in the vicinity of fuses, circuit
breakers or buses use every precaution to avoid
injury from arcing.
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4. Before draining of draft tube and penstock of
pumped storage units, it is necessary to have
maximum number of drainage and de-watering
pumps in working condition since these drains are
located below ground level.
E-17 TRANSFORMERS
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prevent any possibility of transformer being made
live through synchronising or voltmeter plug.
E-19 GENERATORS
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(3) Before any one enters a manhole, ascertain that
the air is safe enough. If harmful gases are
present, they should be expelled and frequent
checks made during work progress to determine
the condition of the air.
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cable. Also cable back charge indicator voltage is
used for checking phasing of both incomers safely.
E-26 SCADA
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4. The Master Computers and Front End Processors
use an auxiliary supply of 230 V AC.
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(b) Personnel carrying out the task will record above
details in SCADA register kept in the Control
Room.
E-27 COMMUNICATION
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6 It is essential that proper drawings of the panels,
circuits and Interconnecting cable schedule to
identify source and destinations of the cables are
available with the personnel before starting any
work. A written step by step procedure for the job to
be done on communication equipment, approved
by the concerned authorities, should also be
available with the working personnel.
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9 Working on transmission tower joint boxes may
require outage of 220/110/33/22 KV line. The
working parties will co-ordinate the outage
requirements with the concerned departments
after providing details of work.
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ST-3 DESIRABLE CHARACTERISTICS OF TAGGING
SYSTEM
ST-4 TAGS
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RELEASE : Pink tag, with
ORDER blue printing.
:
RELEASE RELEASE : Red tag, with
TAGS PERMIT black printing
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(5) Placement and removal of the tags must be done
by authorised personnel of operating organisation
in-charge. Persons on probation or under training
apprentices, trainees, shift mazdoors, etc. are not
authorised to place, remove or fill up safety tags.
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In case the working party is close to the
operating party, then the ordering party may
authorise the operating party to hand over
the equipment, e.g. Load Despatcher may
authorise the control room engineer on duty
to hand over a turbo-generator to a working
party. In such a case the operating party
should follow the above-mentioned
procedure of handing over.
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The working party will fully familiarise with
the operations that are planned in
connection with the outage. He/she will be
responsible for checking that the isolation
and safeguarding that is proposed to be
carried out would be adequate and
sufficient for the work planned. If any
special safeguarding or tagging is required
he/she should advise it to the operating
party.
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(c) Giving Clear.
(1) PURPOSE
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clear for temporary short stopping of work is
necessary.
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Whenever multiple outages at a station are planned
it will be the duty of the operating party and the
working parties concerned to plan and arrange the
timing of the operations in such a manner that the
operating party can carry out the sequence of the
switching operations for the outages without undue
interruptions.
RELEASE NOTICE
(2) CROSS-CHECK
TATA POWER
RELEASE NOTICE
MEN AT WORK
DO NOT CLOSE
THIS SWITCH
RELEASE PERMIT
(1) PURPOSE
(1) PURPOSE
TATA POWER
CAUTION NOTICE
DO NOT CLOSE
THIS SWITCH
(1) PURPOSE
(1) PURPOSE
(19) Before starting work, the person for whom the line
or equipment is tagged shall check in the presence
of another person whether the line or equipment is
de-energised and effectively grounded by one or
more of the following methods:
Case 1:
Case 2:
Case 6:
CONSTRUCTION:
C-1 SCAFFOLDS
C-7 EXCAVATIONS
TRANSPORTATION
T-2 DRIVING
a. Control Speeds.
Speeding is dangerous. A few minutes
saved at the cost of an accident is no
bargain.
T-3 PARKING
F. FIRST AID
F-6 BURNS
(1) General Rule for the Treatment of Burns:
(a) Apply running water over the burnt area till pain
stops or for 30 minutes.
(b) Avoid frequent handling of the part affected by burn.
(c) Cover the burnt area with clean or prepared sterile
dressing (Burn dressing).
(d) If sterile dressing is not available, use a freshly
washed & sun-dried cloth to wrap the area.
(e) Immobilise the affected part.
(f) Treat circulatory shock.
F-7 SHOCK
Shock is a condition of severe depression of
vital functions. In this condition patient has cold moist skin,
nausea pallor and giddiness. This circulatory shock is
different from electric shock. Every electric shock need not
lead to circulatory shock.
2) Electric shock:
Act at once- delay may be fatal, send for doctor
immediately but never wait for him.
Switch off the current. If this is not possible, remove the
casualty from the contact with the current by help of a dry
rope, a walking stick, rubber gloves, folded newspaper or a
dry garment. While doing so, rescuer should stand on
insulating material like wooden board, piles of newspapers
or rubber soled shoes.
Unless casualty is breathing normally, give artificial
respiration and continue till doctor declares death of
casualty. Give artificial respiration by 1) mouth to mouth
method or 2) Holger-Nielson method or described
elsewhere.
Also check the carotid pulse and give external heart
massage as described under ‘external cardiac massage’
2) Alkali burns:
a) Thoroughly flood the part with water
b) If alkali is in powder form, brush it off from the skin
before flooding the part with water.
c) Bathe the part freely with weak acid solution
prepared as follows: equal quantities of lime juice or
vinegar and water mixed together.
d) Remove alkali contaminated clothing by cutting it
with scissors