18002-HSE-MG-022-00-Workshops Management

WORKSHOP MANAGEMENT
DOCUMENT: 18002-HSE-MG-022-00
405 MW dc SOLAR PV PLANT,SAKAKA- KSA
Owner / Client ACWA POWER
Owner’s Engineering
Principal contractor MAHINDRA SUSTEN
Name & Designation Signature Date Signed
Dibu. MK
Prepared by:
HSE Manager
A u t h o r i z e d b Muneer Nwairan
y: Project Director
The latest version of this document is available in electronic format for consultation and document management.
Document: 18002-HSE-MG-022-00
WORKSHOP MANAGEMENT
Approved by ACWA POWER
Rev. No. Purpose of Issue Date Issued Remark
0 Initial release for approval 03/10/2018
WORKSHOP MANAGEMENT
1. Introduction..............................................................................................................................................4
2. SCOPE.......................................................................................................................................................4
3. GENERAL INFORMATION..........................................................................................................................4
3.1 Glossary of Terms.................................................................................................................................4
4. Responsibilities.........................................................................................................................................5
4.1 Specific Responsibilities........................................................................................................................5
4.1.1 Construction manager.............................................................................................................................5
4.1.2 Supervisor................................................................................................................................................5
4.1.3 Workshop operatives..............................................................................................................................6
5. OPERATIONAL CONTROLS........................................................................................................................6
5.1 RISK ASSESSMENT.................................................................................................................................6
5.2 HIERARCHY OF CONTROLS....................................................................................................................7
......................................................................................................................................................................... 7
5.2.1 Level 1 Control measures..................................................................................................................7
6. SAFETY MEASURES...................................................................................................................................8
6.1 Housekeeping.......................................................................................................................................8
6.2 Emergency Procedures (displayed clearly in Workshop)......................................................................8
6.3 Fire Extinguishers..................................................................................................................................8
6.4 Gas Cylinders - Compressed & Liquefied Gasses..................................................................................9
6.4.1 Moving Cylinders..............................................................................................................................9
6.4.2 Storage of Gas Cylinders...................................................................................................................9
6.5 Lone working......................................................................................................................................10
WORKSHOP MANAGEMENT
1. INTRODUCTION
The purpose of this procedure is to provide a strategy for the management of workshop activities during
the construction phase of the Project. This document describes the manner in which the workshop
activities to be carried out safely and effectively disposed in order to ensure that pollution of the
environment is prevented and to ensure the health and well-being of persons at the Project .
This manual does not describe all of the procedures necessary to repair and service the vehicle in detail.
This procedure is applicable to all contractors and persons involved in the construction of the Project,
including Principal Contractors and their Contractors, working within the area.
2. SCOPE
This procedure applies to Sakaka Project for which MSPL assumes responsibility for H&S Management,
whether as principal contractor or as part of a Temporary Joint Venture or Consortium.
The workshop contains many potential safety hazards. However, with proper control these hazards can be
eliminated.
3. GENERAL INFORMATION
3.1 GLOSSARY OF TERMS
Lubricants: Proper vehicle lubrication is critical to safe operation. Failure to maintain proper lubricant levels
or to use the proper type of clean, new lubricant, can lead to an engine or transmission seizure with
subsequent accident, serious injury or death. Use latex gloves for the maintenance operations that require
contact with used oil.
Engine oils: If the engine oil pressure warning light LED remains on (when the engine is running), or if it
comes on during the normal running of the engine, this means that the oil system is not developing
sufficient pressure. Failure to heed this warning can lead to engine seizure, upset, and serious injury or
even death.
Fork oil: By changing the damper settings and/or the viscosity of the oil contained in them, the suspension
response may be altered partially.
Coolants: Coolant is poisonous. Do not ingest coolant under any circumstance. Should you get coolant in
your mouth, rinse with cool water and immediately seek medical attention. Coolant is also very dangerous
to your skin and eyes.
Gearbox oil: Gear box oil can cause serious skin damage if handled on a daily basis over a long period of
time.
WORKSHOP MANAGEMENT
You are advised to wash your hands thoroughly after handling the oil. Do not dispose of the oil in drains,
water courses or the soil. Take the oil to (or have it collected by) the nearest used oil disposal agency or the
supplier.
Brake fluid: Brake fluid can cause irritation if it comes into contact with the skin or eyes. Thoroughly wash
any parts of the body that come into contact with the fluid and contact an eye specialist or doctor if the
fluid comes into contact with the eyes.
Carbon Monoxide: If a servicing operation has to be carried out with the engine running, make sure this is
done in the open air or in a well-ventilated area. Never run the engine in enclosed spaces. If you have to
work in an enclosed space, use an exhaust fume extraction system.
Components at high temperatures: The engine and the exhaust system components get very hot and stay
hot for a certain time after the engine has been switched off. Wear heat-proof gloves if you have to handle
these components, or else wait until the engine and exhaust system have cooled down.
Batteries: Batteries, when charged, give off hydrogen gas, which is highly explosive. Therefore, do not
smoke while working on or around the battery, and keep naked flames or sparks away from the battery.
Keep gasoline and other flammable substances well away from the battery, since a battery spark could
easily ignite them and cause a devastating fire. Battery electrolyte is toxic and caustic and can severely burn
your eyes or skin. Always wear tight fitting goggles and protective clothing when handling battery
electrolyte.
Recharging the batteries: The battery gives off noxious and explosive gases; keep it away from flames,
sparks, cigarettes and any other sources of heat. During the recharging or the use, make sure that the room
is properly ventilated and avoid inhaling the gases released.
4. RESPONSIBILITIES
4.1 SPECIFIC RESPONSIBILITIES
4.1.1 CONSTRUCTION MANAGER
To achieve compliance, construction managers should:
 Ensure that all the operatives receive the appropriate information, instruction and training
necessary for them to perform work safely
 Ensure that all staffs and operatives receive an induction that includes information pertaining to
emergency response procedures and personnel
 Ensure that health and safety procedures are developed, documented and issued to staff as
appropriate
 Ensure that the facilities and equipment provided for operatives are safe and suitable for the
types of work to be carried out
 Ensure that hazard identification and risk assessment procedures are developed, documented
and maintained for the use, handling, storage, transport and disposal of equipment, materials
and substances and that appropriate risk controls are implemented and maintained
WORKSHOP MANAGEMENT
4.1.2 SUPERVISOR
Supervisors should:
 Control the risks associated with the work that they supervise using a documented risk
management process
 Ensure that safe work practices are developed and maintained at all times
 Arrange for their operatives to be instructed in safe and healthy work procedures, and ensure
that they are fully informed about particular hazards, and how to avoid, eliminate or minimize
them
 Ensure that good housekeeping standards are developed and maintained in the areas under
their control
 Ensure that the crew members under their control use safety equipment provided in a correct
manner
 Ensure that all crew members understand the disciplinary procedures that will be invoked for
non-compliance with occupational health and safety instructions, policies and procedures
 Ensure that all incidents, hazards and near miss incidents that occur are reported on time
4.1.3 WORKSHOP OPERATIVES
All operatives who undertake work in the workshop must take reasonable care of their own health and
safety and the health and safety of others by:
 Taking action to avoid, eliminate or minimize hazards of which they are aware
 Complying with all occupational health and safety instructions, policies, and procedures
 Making proper use of all safety devices and personal protective equipment
 Complying with the instructions given by emergency response personnel
 Seeking information or advice where necessary before carrying out new or unfamiliar work
 Appropriate protective clothing and footwear must be worn at all times
 Always wear eye protection when using power operated hand or machine tools that could lead
to eye damage.
 Only consuming or storing food and drink in designated areas. Food is strictly forbidden in the
workshop.
 All lifting equipment, including chain blocks, pendant hoist controls, and abbey lifting frames are
to be used by technical staff only unless training and authorization has been approved.
 Being familiar with emergency and evacuation procedures and the location of, and if
appropriately trained, in the use of, emergency equipment
 Ensure that all incidents, hazards and near miss incidents that occur are reported on time
5. OPERATIONAL CONTROLS
5.1 RISK ASSESSMENT
WORKSHOP MANAGEMENT
As in all cases, the control measures required to mitigate any risks that arise from workshop activities
shall be identified from the risk assessment and the measures applied accordingly. In each case, the
overriding aim is to ensure that no person is being injured accidentally or otherwise.
The control measures therefore need to be so designed that they fail to safety, which is commonly
known as fail-safe.
5.2 HIERARCHY OF CONTROLS

As in all cases of managing HSE risks, the hierarchy of controls needs to be applied where risk avoidance
and elimination should take greater priority over risk reduction and control measures.
5.2.1 LEVEL 1 CONTROL MEASURES

The most effective control measure involves eliminating the hazard and associated risk. The best ways to
do this are by either removing the hazard completely (e.g. getting rid of trip hazards, disposing of
unwanted chemicals), or not introducing the hazard into the workplace in the first place (e.g. work at
ground level, not at height, to eliminate the risk of a fall).

It is not reasonably practicable to eliminate the hazards and associated risks, you should minimise them
using one or more of the following:
 Substitute the hazard with something safer (E.g. replace noisy machinery with quieter models)
 Isolate the hazard from people – physically separate people from the source of harm by distance
or using barriers (E.g. install guard rails around service pits, store chemicals in a fume cabinet)
WORKSHOP MANAGEMENT
 Use engineering controls – introduce a mechanical device or process that is physical in nature
(E.g. use trolleys or hoists to move heavy loads, place guards around moving parts of machinery,
install residual current devices)
These control measures do nothing to control the hazard at the source, relying instead on human
behaviour and supervision. Used on their own, they tend to be least effective in minimising risks.
Two approaches to reducing risk in this way are:
 Administrative controls – work methods or procedures designed to minimize hazard exposure

(E.g. develop procedures on how to operate machinery safely, limit exposure time to a
hazardous task, use hazard warning signs)
 Personal Protective Equipment (PPE) – which limit exposure to the harmful effects of a hazard,
but only if worn and used correctly (e.g. ear muffs, respirators, protective eyewear).
6. SAFETY MEASURES
6.1 HOUSEKEEPING.
Housekeeping is an important component in the workshop to ensure risks of injury from potential hazards
in the environment are controlled. The following precautions are to be taken to ensure the safety of
personnel within workshop:
 Floors are to be kept tidy and dry

 Benches are to be kept clean and free from chemicals
 Accesses and exits are to be kept free from obstructions.
 Access to all emergency equipment’s (fire extinguishers, first aid kits) is to be kept free from
obstruction.
 Work areas and equipment are to be thoroughly cleaned after use.
 If last to leave the workshop, make sure all equipment is turned off.
 If other contractors are nearby, make known to them any hazards that may exist in the area, i.e.
flammable liquids, dusts, combustible material.
6.2 EMERGENCY PROCEDURES (DISPLAYED CLEARLY IN WORKSHOP)
In the event of fire or other emergency that may endanger employees the following procedures may apply
 In the event of a fire, alert others in the immediate area

 Inform the workshop supervisor.
 When an alarm is raised proceed quickly to the nearest exit, as directed by the building warden.
 After leaving the building proceed as directed to the nearby assembly area.
6.3 FIRE EXTINGUISHERS
WORKSHOP MANAGEMENT
This equipment is provided in the workshop to extinguish minor fires only. If there is any risk from the fire
the personnel should be evacuated. Before using a fire extinguisher read the instructions ensuring that it
is appropriate to the type of fire.
Water Type Extinguisher - Colour coded red. For use on solids fires only. Not to be used on electrical or
chemical fires.
Carbon Dioxide Extinguisher [CO2] - Colour coded red with a black band. For use on electrical and
flammable liquids fire - It should be noted that this extinguisher can be safely used on all types of fires,
however when gas dissipates re-ignition can take place.
6.4 GAS CYLINDERS - COMPRESSED & LIQUEFIED GASSES

Compressed, liquefied or dissolved gases are categorised as Class 2 dangerous goods and sub-categorised
as:
 Class 2.1 Flammable gases identified by a red dangerous goods diamond (e.g. Butane)
 Class 2.2 Non-flammable and non-toxic gases identified by a green dangerous goods
diamond (e.g. Helium)
 Class 2.3 Poisonous gases identified by a white dangerous goods diamond (e.g. Ammonia)
6.4.1 MOVING CYLINDERS
The majority of accidents involving gas cylinders occur while moving them from one location to another.
The following control measures should be used to reduce the potential for an accident:
 The use of purpose-built trolleys or other suitable devices for gas cylinder transportation.
 Securing the gas cylinder’s valve, disconnecting and removing associated distribution
equipment.
 Shutting the cylinder’s valve, disconnecting and removing associated distribution equipment.
 A requirement that only properly trained personnel are permitted to move cylinders.
 Use properly designed lifting equipment for the movement of larger gas cylinders
6.4.2 STORAGE OF GAS CYLINDERS
The following precautions shall be observed for minor storage and handling of gas cylinders:
 Gas cylinders are to be kept away from artificial sources of heat, i.e. radiators, boilers or steam
pipes and kept clear.
 Gas cylinders shall be provided with adequate ventilation at all times.
 Classes of gas cylinders shall be segregated within the store, but need not be separated.
 Outdoor storage of Class 2 cylinders shall be separated from other dangerous goods by 3
meters. They shall not be less than 1m from any door, window, air vent or duct.
 All gas cylinders are to be secured in the upright position by chain or other means to prevent
falling
WORKSHOP MANAGEMENT
Indoor storage of gas cylinders should be avoided wherever possible. However where it is not reasonable
to have an outdoor cylinder and reticulation system, the keeping of gas cylinders shall incorporate a risk
management approach. Specific precautions, which a risk assessment is to include, would be:
 The total capacity of gas in cylinders allowed for any particular indoor location shall include
cylinders in use, spare cylinders not in use, and used cylinders awaiting removal.
 The total capacity of the gases kept shall not exceed one minor storage quantity per 200 m 2 of
floor area. Where the floor area exceeds 200m2 any arrangement which results in an undue
concentration of cylinders shall be avoided.
 Indoor minor stores of gases in cylinders shall be separated from other minor stores of gases or
other dangerous goods stores by a minimum distance of 5 m.
 Where cylinders are kept inside a building or a confined area, e.g. a shipping container, that
building or area shall be adequately ventilated by natural air movement or equivalent
6.5 LONE WORKING

Working alone refers to situations where people may be exposed to risks because;
 the area they are working in is remote from others or isolated from the assistance of others
because of the nature, time or location of their work; or
 it involves the operation or maintenance of equipment, or the handling of a hazardous
substance; or
 the work is dangerous for a person to perform alone
Where any of the above is applicable, working alone must be avoided.
For working alone, the following apply:

 Operatives may work alone in office environments, however, they must have obtained prior
authorization
 Emergency assistance-a means of communication to gain assistance in an emergency is available
(The telephone in the workshop can be used to contact the emergency services-if available)

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WORKSHOP MANAGEMENT

Owner / Client ACWA POWER

Principal contractor MAHINDRA SUSTEN

Name & Designation Signature Date Signed

Approved by ACWA POWER

Rev. No. Purpose of Issue Date Issued Remark

0 Initial release for approval 03/10/2018

3.1 GLOSSARY OF TERMS

4.1 SPECIFIC RESPONSIBILITIES

4.1.1 CONSTRUCTION MANAGER

To achieve compliance, construction managers should:

4.1.3 WORKSHOP OPERATIVES

5.1 RISK ASSESSMENT

5.2 HIERARCHY OF CONTROLS

5.2.1 LEVEL 1 CONTROL MEASURES

5.2.2 LEVEL 2 CONTROL MEASURES

5.2.3 LEVEL 3 CONTROL MEASURES

Two approaches to reducing risk in this way are:

 Administrative controls – work methods or procedures designed to minimize hazard exposure

 Floors are to be kept tidy and dry

6.2 EMERGENCY PROCEDURES (DISPLAYED CLEARLY IN WORKSHOP)

 In the event of a fire, alert others in the immediate area

6.3 FIRE EXTINGUISHERS

6.4 GAS CYLINDERS - COMPRESSED & LIQUEFIED GASSES

6.4.1 MOVING CYLINDERS

6.4.2 STORAGE OF GAS CYLINDERS

6.5 LONE WORKING

Where any of the above is applicable, working alone must be avoided.

For working alone, the following apply:

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