O&M _ Hazards and control Measures, Isolation & Emergency

Procedures etc. New 300 MLD WTP, T.K halli

| SAFETY |

SUEZ INDIA PVT LTD

New 300 MLD WTP, T.K. HALLI,
OPERATION & MAINTENANCE
O&M _ Hazards and control Measures, Isolation & Emergency
Procedures etc. New 300 MLD WTP, T.K halli
| SAFETY |
Contents
SAFETY..................................................................................................

1 TYPES OF HAZARDS............................................................................

1.a BACTERIOLOGICAL HAZARDS...........................................................

1.b CHEMICAL HAZARDS.......................................................................

1.c ELECTRICAL HAZARDS......................................................................

1.d NOISE HAZARDS..............................................................................

1.e PRESSURE HAZARDS........................................................................

1.f EQUIPMENT WITH MOVING PARTS..................................................

1.g DEEP TANKS...................................................................................

1.h MOVING VEHICLES..........................................................................

1.i MANUAL HANDLING.........................................................................

1.j EQUIPMENT LIFTING AND HANDLING...............................................

1.k CONFINED SPACE.............................................................................

1.l ODOUR POLLUTION..........................................................................

2. HAZARDOUS AREAS IN THE PLANT....................................................

3. PERSONAL PROTECTIVE EQUIPMENT.................................................

4. PROCEDURE FOR WORKING IN A CONFINED SPACE...........................

4.a. MODE OF AERATION / VENTILATION..............................................

4.b. MONITORING OF THE ATMOSPHERE..............................................

4.c. SUITABILITY OF MATERIAL AND EQUIPMENT..................................

4.d. AUTHORIZATION OF PERSONNEL....................................................

5. SAFETY PRECAUTIONS TO BE TAKEN BEFORE DOING ANY ELECTRICAL

WORK............................................................................................
O&M _ Hazards and control Measures, Isolation & Emergency
Procedures etc. New 300 MLD WTP, T.K halli
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6. PERMIT TO WORK.............................................................................

7. LOCKOUT, TAGOUT (LOTO)................................................................

8. CODE OF CONDUCT...........................................................................

9. EMERGENCY PROCEDURES................................................................
O&M _ Hazards and control Measures, Isolation & Emergency
Procedures etc. New 300 MLD WTP, T.K halli
| SAFETY |
SAFETY
Safety is one of the most important aspects of plant operations. Various types of hazards
are present in Water Treatment Plant and hence the safety information given in this
chapter must be read carefully and understood before working. Any ignorance towards the
safety can lead to minor to very major accidents.

1 TYPES OF HAZARDS
1.a BACTERIOLOGICAL HAZARDS
Some of the micro-organisms found in raw sewage, activated sludge tank, handrails,
aeration tank, sludge drying beds are harmful and due attention should be paid to the same.
Wastewater contains a large range of pathogenic germs. The five groups hereafter listed
are the most common:

Class Parasites Diseases Caused

1 Pathogenic bacteria Dysentery, Tetanus, Typhoid and Leptospirosis
2 Viruses Poliomyelitis and Hepatitis A, B, …
3 Mycotoxicosis, Rhinitis, sinusitis, Bronchial asthma,
Mushrooms
Chronic mycosis
4 Algae Gastroenteritis
5 Parasites Parasitic worms and Tape worms

These risks associated can be:

 Diseases
 Intoxication

Therefore, the following remedial measures should be taken:

1. Maintain personal hygiene

2. Clean bathrooms and toilets every day, use bins don’t litter
3. Train people about the hazard and hygiene procedures
4. Use personal protection equipment such as gloves, gum boots/shoes, masks
5. Vaccination

1.b. CHEMICAL HAZARDS

Chemical hazards are present in laboratory while handling preparing the reagents and, in
the plant, while handling treatment chemicals such as Sodium Hypo chloride (hypo), PAC
and polyelectrolyte etc.

The risks associated with chemical handling can be:

 Itching
 Allergy
 Burns
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Therefore, the following preventive measures should be adapted:

1. Chemical should be stored in a suitable and identified places

2. Warning signs / MSDS (Material Safety Data Sheets) to be displayed
3. Entry of unauthorized person to be forbidden
4. People should be trained in handling the chemicals safely
5. Personal protection equipment to be used such as hand gloves, goggles, shoes, shields,
masks, and apron etc.
6. Chemical handling and spill control procedure should be followed

The chemicals use on the plant are,

CHLORINE :
 The substance can be absorbed into the body by inhalation and by ingestion.

 The substance irritates the eyes, the skin, and the respiratory tract. Corrosive on ingestion.

POLY ELECTROLYTE :
 Polyelectrolyte is irritating to skin and eyes

 Polyelectrolyte solution is very slippery and due care shall be taken to avoid spillage and to
clean the surfaces.

ALUM/PACL:
 Irritant to eyes

1.c. ELECTRICAL HAZARDS

Electrical hazard can be in MCC Rooms, Electrical panels, transformer yard, working on
electrical panels, networks and change or repair of electric equipment

The risks are,

1 Electrocution
2 Burns
3 Fire

Therefore, the following electrical safety procedures should be followed:

1. Warning signs to be displayed

2. Forbid entry for non-authorized persons
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3. Train people in safety while working with electricity etc.
4. Use of personal protection equipment such as electrical gloves, safety shoes, UV shield
5. Isolation procedure like LOTO (Lock Out Tag Out), Emergency and first aid procedures
should be followed
6. Permit to work system should be followed.

1.d. NOISE HAZARDS

Noise can be generated in Blower rooms, pump house in annex building and vacuum
chambers in pulsators.

The risks can be

 Deafness

 NIHL (Noise Induced Hearing Loss)

Therefore, the following measures should be adapted:

1. Warning signs to be displayed

2. Forbidden entry without protection if noise is more than permissible limit
3. Check that exhaust outlets are fitted with silencers or mufflers and do not keep machinery
running unnecessary
4. Keep compressor motor covers closed when they are running
5. Follow SOPs & preventive maintenance
6. Train people for Noise Hazards and Controls

Noise Exposure Standard

Noise Levels Effects

< 75 dBA No dangerous effect
80 dBA Information of the worker
Protection if requested
Medical surveillance if requested
85 dBA Training, Measures to plan the work and limit exposure
90 dBA Restricted area signalled
Limited access to the area
Individual protection
105 dBA Increased risks subject to declaration and to appropriate
measures

1.e. PRESSURE HAZARDS

Compressed air is used at high pressure for operating the automatic valves etc. and due to
attention should be paid while working on high pressure air lines etc.

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This hazard can be at

 Compressors
 Air receivers
 Hydraulic equipment
 Pneumatic equipment

The risks can be

 Splashing
 Pressure injuries

Therefore,
1. Do not stand near pressure vessels and related units without protective gear

2. Release the pressure and ensure zero pressure before starting maintenance works or opening
a pressure part

3. Follow Permit to Work and Isolation procedures

1.f. EQUIPMENT WITH MOVING PARTS

Several equipment used in the plant such as Blowers, Pumps, Motors etc. has moving parts
and due attention should be paid to the same while working. Also, many equipment starts
in AUTOMATIC mode.

The risks are

 Crushing
 Pinching
 Entanglement
Therefore,
1. Do not intervene on moving machines
2. Isolation – LOTO (lock out tag out) is must
3. Ensure all moving parts are enclosed with adequate and suitable guards
4. Avoid loose clothing
5. Suitable personal protection equipment such as Helmet, Gloves, Goggles
6. SOPs etc.

1.g. DEEP TANKS

There are several tanks which are deeper such as Pulsator, AQUAZUR V Filter, Flash
Mixer, wastewater balancing tank, distribution channels & chambers etc.
The risks associated with the deep tanks include:
 Drowning
 Slip and fall

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 Risks related to confined space

Therefore
1. Do not lean or jump over the handrails provided. Wherever, permanent handrails are not
provided, suitable temporary guarding should be provided
2. Warning signs are displayed and the same should be noted and followed.
3. Train people about drowning risk
4. Ensure life buoys and life jackets available and maintained properly
5. Harness
6. SOPs for working near water

1.h. MOVING VEHICLES

This hazard can be due to movement of vehicles coming to plant to deliver chemicals,
materials etc.

The risks are

 Hit-by
 Run over
 Collision
 Severe injury and/or damages

Therefore

1. Follow traffic rules –Traffic sign & signals, speed limits, no alcohol / phones while driving.
2. Prepare traffic plan – Consider Diversion, barricading of work in progress areas, sign posting
and lighting
3. Follow strict safety rules – Obey signaling man, SOP, parking, loading / unloading etc.
4. Training for driver & persons working in traffic
5. Use PPE – Fluorescent jacket, Helmet, safety shoes
6. Maintain fitness of vehicles, install reverse alarm, do not park vehicles in slope, immobilize
vehicles using wheel chocks once parked etc.

1.i. MANUAL HANDLING

The risks are MSD – Musculoskeletal Disorder

Therefore
1. Minimize manual handling
2. Train workmen in manual handling & occupational health hazards in handling / lifting
3. Ensure workmen follow basic rules

7.1.10 EQUIPMENT LIFTING AND HANDLING

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Mechanical Hazards can be at lifting activity utilizing crane, monorails chain pulley block
or other mechanical devices

The risks are Fall of material causing damage or injury, Therefore

1. Do not walk or stand under the suspended load
2. Ensure use of tested certified, and visually inspected lifting tools and tackles
3. Only authorized persons should operate lifting machines
4. SWL (Safe Working Load) is displayed on all lifting devices and therefore no overloading
and use of SOP
5. Use of necessary PPE such as Safety helmet, safety shoes, hand gloves etc is mandatory
6. Permit to work and toolbox talk

1.j. CONFINED SPACE

Confined Space is a tank or pit which is closed partially or fully and has restricted
entry/exit, where there can be lack of oxygen and chances of presence of toxic and
flammable gases such as Hydrogen Sulphide (H2S), Methane, Carbon Monoxide (Co)
etc.
Examples of confined spaces:
1. sludge storage pits such as manholes and wet wells
2. closed storage tanks such as Low-Level Reservoirs
3. Large size pipes
4. Vacuum chambers in pulsators.

Hazardous gases may generate from the confined space network:

 Nitrogen compounds and sulfides, Septic effluents, and Hydrogen Sulfide etc.
 Volatile pollutants, solvents, hydrocarbon gases may be found due to accidental or illegal
discharge.
 Gases may also be formed on the installation, mainly in bad aired sumps and pits further to
fermentation (H2S).
 An increase in CO2 and NH3 concentration may be followed by a shortage of oxygen.

The risks are

Physical injuries, Intoxication, Asphyxia

Therefore
1. Use Safe Operating Procedure – Isolation, Flushing, Ventilating the confined space and test
for gases / pollutants before making entry
2. Use of anti-sparking tools and suitable equipment for working in ATEX
3. First-aid, Emergency procedure and means of communication with signaling man at the
entrance of confined space
4. Training and accreditation for working in confined spaces
5. Follow procedures such as Permit to work, Confined Space Risk assessment and control
card

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Procedures etc. New 300 MLD WTP, T.K halli
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An intervention procedure shall be imposed, as follows:
 The person visiting the tank must be equipped with a safety harness.
 Another person shall remain in the open air ready to help him if necessary.
 Make sure beforehand nothing prevents an unconscious person to be lifted out (i.e., ladder
with safety cage)

1.k. ODOUR POLLUTION


Odor pollution is bad for the environment and has effect on the workers and affects the
relationships with the neighborhood leading to tensions of whatever nature leading to
complications.
 Odors on worksite reveal improper operation and presence of a gas which may be corrosive
(for example H2S changed into hydro sulphuric and sulphuric acid). Apart from the
structures (concrete and metal parts), odors can also have long-term effects on public health.
 Pre-treatment is the first source of odor. The nitrogen compounds and sulfides that are
commonly found in the raw sewage come from bacterial decomposition and volatile
pollutants; they are released at the first aeration stage (screening, oil removal…).
Reminder:
A regular and careful cleaning, along with waste removal is generally the rights means to
reduce odour pollution.

2. HAZARDOUS AREAS IN THE PLANT

Area in the plant and related hazards:

S. No Name of the treatment unit /

Potential Hazards
building
− Confined space with presence of
hazardous gases like H 2 S (Hydrogen
Flash mixer, Inlet Chambers, Sulphide), CO (Carbon Monoxide),
1)
Pulsators CH 4 (Methane)
− Biological hazards
− Drowning Hazard
− Electrical shock
Transformer yard, MCC/PCC
2) − Burns
Rooms
− Fire
− Burns
3) Chemical dosing room
− Irritation
− Drowning hazards
4) Filtration − Biological Hazard
− Overhead material movement
5) Blower Room, Pump Room − Noise hazard
− Moving machines
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O&M _ Hazards and control Measures, Isolation & Emergency
Procedures etc. New 300 MLD WTP, T.K halli
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− Pressure hazard (pneumatic)
6) Chlorine building − Toxic chemical (Chlorine)

3. PERSONAL PROTECTIVE EQUIPMENT

The following personal protective equipment should be used depending upon the nature of
the hazard:

PPE Sign Hazard

Safety goggles/glasses flying particles, dust, sawdust, corrosives, or intense

(eye protection) light

Face shields (face

dust, splashes, or sprays of hazardous liquid
protection)

Welding shields (face

radiant light, flying sparks, spatters, slag chips
protection)

Hard hats/helmets (head injury from impact, falling objects, flying objects,
protection) electrical shock or burns (if helmet is insulated)

hot, wet, or slippery surfaces; heavy objects falling

Safety shoes (feet
or rolling against the foot; exposure to nails or
protection)
molten materials (e.g., paving materials or

Gloves and sleeves (hand burns, bruises, abrasions, cuts, punctures, fractures,
and arm protection) amputations, chemical exposure

Vests, coveralls, body

intense heat, splash of hot metals or liquids, impact
suits, aprons (body
from tools or machinery, cuts, hazardous chemicals
protection)

Full Body Harness While working at height

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Procedures etc. New 300 MLD WTP, T.K halli
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4. PROCEDURE FOR WORKING IN A CONFINED SPACE
Organisation of work in Confined Space
Procedure for works in confined spaces.
 As a minimum, this procedure will include following points:
 Appointment of a Qualified Works Manager. The operation must always be supervised and
managed on site by a manager having the appropriate skills in the domain.
 Appointment of at least 4 employees who are authorized for these types of works. Two
persons (Entrants) enters confined space to perform work, one person (Attendant) is there
at outside of confined space for monitoring the job, and another one person is entry control
supervisor, who coordinate with attendant& entrants.
 Measures specific to certain facilities (tunnels, tanks with stirring devices…).
 Isolation of equipment.
 Cordoning off/tagging the working area

4.a. MODE OF AERATION / VENTILATION

 Opening all the possible accesses to the confined space. Addition of monitoring personnel if
these accesses cannot be monitored by a single person.
 Natural or mechanical ventilation depending on the space and possible releases of
pollutant(s) (density and concentration). The ventilation flow rate must be fixed beforehand
by the manager.

4.b. MONITORING OF THE ATMOSPHERE

 Prior testing of the atmosphere inside the confined space, by introducing the controller into
the space from the outside. The atmospheric controller must measure the following
elements: oxygen content, explosiveness, partially released toxic gas content (H2S,
CO…). The measuring points will take the density of the potentially released gases into
account,

 If the controller’s alarm is triggered, the space should be re-ventilated, and its atmosphere
re-checked. Repeat this operation until the air is clean. Never enter the confined space if the
atmospheric test is not satisfactory,
 The atmosphere must be continuously monitored during the work. As soon as the alarm
sounds, the operator must evacuate the confined space making use of the self-contained
breathing apparatus (SCBA).

Individual protective equipment to be provided (see below)

 Permit to work including clearance prior to entry.
 Welding and cutting permit during hot spot works.
 Organization of emergency assistance: before the intervention begins, provide for an
emergency assistance procedure in the event of an incident or accident.
 Training and information for personnel.
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4.c. SUITABILITY OF MATERIAL AND EQUIPMENT
Equip personnel with all the necessary working and protective equipment, which is
regularly checked, and which is checked prior to all interventions according to quality
assurance specifications. As a minimum and for every person involved in interventions,
this equipment will include:
 Atmospheric controller,
 Self-Contained breathing apparatus (SCBA),
 Lamp protected against the risk of explosion,
 Protective device against falls (harness, safety strap…),
 Communications device
 Hard hat, safety shoes or boots and glove

4.d. AUTHORIZATION OF PERSONNEL

Authorize every person working in confined spaces medical check qualification

As a minimum, training will include the following aspects:

Procedure
 Risks generated by works in confined spaces
 Use of protective equipment to protect against falls (harness, safety strap …)
 Use of atmospheric controller
 Use of a self-contained breathing apparatus or
 Use of a self-contained mask
 Emergency assistance procedure and means

Inform all executives, supervisors, technicians, or employees working in the activity for
which works in confined spaces are performed about the risks created by these activities
and preventive and protective measures to be taken.

Note: Wash thoroughly before eating or drinking

5. SAFETY PRECAUTIONS TO BE TAKEN BEFORE DOING ANY ELECTRICAL

WORK.
 Only Authorized personnel should carry out electrical related works.
 Work Permit is mandatory for carrying out electrical maintenance works.
 All electrical installations such as transformer yard, MCC/PCC rooms etc should be
properly closed and only authorized persons should work in such areas.
 Before doing any electrical maintenance during breakdown
o Isolate the Supply,
o Remove the fuses in the feeder (MCC Panel).
o Remove Control fuses, if any.
 DO NOT use cutting pliers and screw drivers without insulation.
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 Before starting of the work, check the line again for power supply.
 Ensure sand and proper fire extinguishers are available near the place of electrical work.
 Check electrical equipment for proper earthing and while meggering ensure there is no
supply.
 Use Electrical Safety Gloves while working in HT line. Check the rating of the gloves and it
should be without any damages and discarded after expiry date, if any.
 During working on HT line and capacitor banks, isolate the supply and discharge with earth
bar.
 DO NOT do any work in electrical line with wet hands / in wet conditions.
 While making electrolyte for battery, pour acid into water and not water into acid.
 While working on HT feeder, draw out the breaker and remove close fuses. Also take line
clearance from the Mechanical operator & Plant Head before taking shut down.
 Close the HT Room with lock and keep the key with the operator, while doing work on HT
lines in the Transformer or in the PCC panels.
 DO NOT place your head in front of switch fuse units in MCC panels & PCC panels.
 When Earth Fault Relay occurs wherever in DG Sets, PCC panels and HT panels DO NOT
ENERGISE the feeder. Inform the supervisor and Plant Head immediately.
 DO NOT renew a blown fuse until you are satisfied as to the cause and have rectified the
irregularity.
 DO NOT close any switch unless you are familiar with the circuit, which it controls and
know the reason for its being open.
 DO NOT touch or tamper with any electrical gear or conductor unless you have made sure
that it is dead and earth.
 DO NOT work on live circuit without the express orders of the supervisor. Make certain that
all the safety precaution has been taken and you are accompanied by second person
competent to render First Aid and artificial respiration.
 DO NOT disconnect earthing connection or render ineffective the safety gadgets installed on
main and apparatus.
 DO NOT open or close switch or fuse slowly or hesitantly do it quickly and positively
 DO NOT use wire with poor insulation.
 DO NOT touch an electric circuit when your hand is wet or bleeding from a cut or abrasion.
 DO NOT throw water on live electrical equipment in case of fire.
 DO NOT use fire extinguisher on electrical equipment unless it is clearly marked for those
purposes.
 DO NOT attempt to disengage a person in contact with a live apparatus which you cannot
switch off immediately. Insulate yourself from earth by standing on the rubber mat or dry
board before attempting to get him clear. Do not touch his body; Push him clear with a dry
piece of dry wood.
 DO NOT discontinue artificial respiration until recovery.
 DO NOT allow visitors and unauthorized person to touch or handle electrical apparatus or
come within danger zone of HV apparatus
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 DO NOT test circuit with bare finger.
 DO NOT CHANGE THE OVERLOAD SETTINGS without PLANT MANAGER’S
PERMISSION.
 If any feeder trips don’t energize without thorough check.
 Observe motors, cables, and panels for over heating

6. PERMIT TO WORK

To start any type of maintenance work in this facility, you must ensure that a permit issues
and you are instructed to carry out the same

Work permits are issued as per following categories:

 Hot Work:
Required before start of hot works e.g., Welding / flame cutting, electrical induction pre-
heating, grinding etc

 Cold Work:
This permit shall be used for a task, which does not involve hot work but has a high-risk
potential e.g., working at height, near deep tanks, on busy roads / traffic, material handling
with the help of cranes etc.

 Confined Space:

Required before start of any activity in Confined spaces e.g., entry, opening of manholes/
inspection etc.

 Electrical Permits:
Required before start of any works e.g., any maintenance of electric panels etc.

Work clearance is required for all maintenance work at the plant.

7. LOCKOUT, TAGOUT (LOTO)

To prevent harm to personnel working with any type of energy – electrical, mechanical,
hydraulic, pneumatic or any other energy source, power to equipment / system must be
locked and tagged in the OFF or de-energised position to the start or any inspection,
routine maintenance, or repair work.

A warning tag on the lock is used to provide information:

 The nature of the work
 Work location
 Date
 Person responsible for the lockout
Caution: Isolation of machine or system does not guarantee of ZERO energy. Please
ensure ZERO energy before starting your work.
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8. CODE OF CONDUCT
 Consumption or carrying of alcohol or drugs is not permitted on site.
 All rubbish to be placed in bins provided.
 You must leave your work area clean after finishing the job.
 Read and comply with safety signs and notices on site.
 Do not carry out any works that you are not licensed to perform.
 No radios permitted on site, avoid use of mobile phones while working.
 No glass bottles and polythene bags are allowed to bring without permission.
 Smoking is not allowed in the workplaces.
 No working from rung ladders, use platforms & PPE’s for working at height.
 Use toilets provided on site and keep them clean.
 No private vehicles are allowed without permission on site. Park in designated areas.
 All vehicles must have valid documents including insurance.
 Speed limit 20km or as indicated near entry gate of the site.
 No removal of guardrails without written approval.
 Theft, horseplay or fighting on site is punishable.
 No refusal to act on safety instruction.
 Do not remove any tags or locks not issued by your authority.

9. EMERGENCY PROCEDURES
In case of any emergency such as fire, accident etc, the following procedure should be
followed:

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