STANDARD OPERATING PROCEDURE (SOP)

Tata Steel, Meramandali

SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 1 of 10

All risk mitigation mentioned below to be followed without compromise while executing this job.

Sl Hazard Mitigation
No
1. House keeping
2. Slippery or wet surfaces may causes of slip
1 Slip trip and fall while working 3. Follow proper pathway and stair way while climbing to the maintenance platform.
4. 3 Point contact to be maintained at all times while using any stairway approach to minimize the chances of injury
due to fall. Stairways and walkways to be always kept free from any debris
1. Use of Calibrated Gas Detector is mandatory for initial monitoring of Gas Levels at the gas work location
2. Work below 50 ppm only
2 Gas and other Hazards
3. Close the line valve.
4. All employees should be full stomach
1. Use FR jacket
2 Heat Hazard 2.
3.
1.
Use leather gloves
P
Do not touch anything with bare hand. Keep safe distances from hot surface

O
All preconditions to be met as per safety standard
3 Fall Hazard 2.
3. S
Take all necessary precaution as per permit check list.

d
Use standard Safety Belt and lock the hook at proper place.
4 Emergency contacts 1.
i
In case of any emergency contact officer in charge and control room

a l
Control Room: 7077758072
Area In-charge: 7077762552
5 Dos and don’ts at
V Do's
Enter area with mandatory PPE
Don’t
Do not walk over open drain area and running
equipment
Enter in the area prior permission / work permit. Don’t remove full body harness
Keep safe distance from rotating equipment Do not walk while speaking in mobile
Check positive isolation.

P
Do not enter the working area without supervision of
In-charge

O
d S
PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 2 of 10

Step No Details of Activity Associated safety Hazards/ Responsibility (WHO) Safe process (tools & Equipment, PPEs, Remarks /
(WHAT) Env. Impacts/ Quality Training etc.) (HOW) Reference
Requirements (Document &
Records)
1. ➢ Safety induction training by Officer/
Maintenance in charge must be given to
TSBSL technician (Agency) and contractor’s
workers’ before starting the job & to be
documented.
➢ Discuss and identify hazards at workplace.
Pre Start-up job ➢ SOP discussion by Officer/ Maintenance in
activities charge to be done with TSBSL technician
SAFETY:
1. Safety training, (Agency) and contractor’s workers’ before
1. Follow the COVID 19
TOOL BOX starting the job.
guidelines as per
TALK, SOP
instruction by company. ➢ All workers must use proper PPE during
training
2. Six directions
hazard
2. Wet surface, slippery
3. Slip, Trip, Fall
O P shifting of Tools and tackles from contractors’
store to site
➢ All tools and tackles which have to be
checking 4. Be away from that
running equipment.

d S ➢ Maintenance In
required for executing the job must be
accumulated in the working zone area for

i
charge/ Technician checking. After checking/auditing, it should

a l Contractor Supervisor be documented.

➢ All contractor workers’ PPE to be check by

V
TSM employee during TOOLBOX TALK.
ENVIRONMENT: no ➢ Tools and tackles required for the job:
QUALITY: SL. Tools & Capacity/Size Nos.
No. Tackles
Condition of PPEs 1 Cutting Set NA 01
2 Welding NA 01
Machine
3. Ring & D-
spanners
16-32 1 sets

O P
4
5
Hammer
Chain pulley
1-3 kg
1-3 ton

d S 01
02

i
block

PREPARED BY APPROVED BY
a l
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
Printed on - 30-Oct-2024
V SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 3 of 10

6 Spirit level NA 01
/digital level
7 Manila rope 15 mtr 01
List Of PPE’ s

Safety Safety Safety Florescent Safety Positive Isolation

Ear Plug Co Detector Dust Mask
Helmet Shoe Goggles Jacket Gloves Lock
During Pre Start-
up Job activity. × ×
During On Job

O P × ×

S
List Of PPE’ s

l i d
During Pre Start-
up Job activity.
Full Body Hardness Gas Welding Eye Glass

V a Welding Eye Shield Fire Protection Jacket Shin Guard Oxygen Detector

×
SCBA

×
During On Job
× ×

O P
d S
PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
Printed on - 30-Oct-2024
V SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 4 of 10

Step No Details of Activity Associated safety Hazards/ Responsibility (WHO) Safe process (tools & Equipment, PPEs, Remarks / Reference
(WHAT) Env. Impacts/ Quality Training etc.) (HOW) (Document &
Requirements Records)
2 SAFETY: System hazard, be ➢ Permit to be taken with ESI document
careful from rotating from operation.
equipment’s. ➢ Take clearance from area mechanical
Permit and operation supervisor.
ENVIRONMENT: ➢ Put safety personal lock at the source of Follow the TSL
➢ Maintenance In Work Permit
charge/ Technician energy after isolation keys are in the
QUALITY: Counter check and System
verify the no. of keys ➢ Contractor isolation box and group lock is there.
➢ Physically cross verify complete energy (TSL/SED/GW/F-
available in group isolation Supervisor
box and energy source source isolation done by area supervisor 26)
isolation no. mentioned at
work permit form, also
isolated energy source valve
lock no. after
depressurization.
O P
3 SAFETY: System hazard, be
careful from rotating
d S ➢ For this job we need not to isolate any
equipment.

Positive isolation as
equipment’s.

ENVIRONMENT:
a l i ➢ Additional sheet to be attached for
positive isolation for special cases which
will be isolated after discussion with
Follow the ESI
document if directly

V
per ESI chart for operation and mechanical InCharge.
that job work involve with
QUALITY: Counter check and ➢ Take the work permit in the form equipment.
➢ Maintenance In
verify the no. of keys TSL/SED/GW/F-26 TSL_MM_BF1_PCM
charge/ Technician
available in group isolation ➢ Fill Six directional hazard form by
➢ Contractor
box and energy source inspection of east, west, north, south,
Supervisor
isolation no. mentioned at top & bottom directions.
➢
work permit form, also
isolated energy source valve
lock no. after
Give the training to the workers about
SOP before starting the job and keep
training record.
O P
depressurization. ➢

➢
on floor with tools & tackles.

d
Use hand gloves and safety shoes.S
Always keep one hand free while moving

PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 5 of 10

➢ Use dust mask to avoid inhaling of dust.

➢ Use FR jacket.
➢ Ensure that Positive Isolation done
following ESI Positive Isolation.
4 SAFETY: ➢ Use PPE’S as per TSL safety rule.
• Injury due to tools ➢ Tools shall only be used for the purpose
slippage for which they were designed.
• Tools and tackles may fail ➢ When using hand tools, the person shall
Working with tools • All machinery must be place himself in such a position that he
turned off when will avoid injury if the tool slips.
/ tackles
unattended. ➢ Tools which are not in use shall be
➢ Maintenance In
placed where they will not present a
ENVIRONMENT: charge/ Technician
tripping or stumbling hazard. Follow the TSL safety
QUALITY: ➢ Contractor
Supervisor ➢ Inspections of tools and equipment, if tools standard.
• Employees shall make
frequent inspections of
tools and equipment, and
➢

O P ➢
any items found defective. Make remove
from frequent, and immediately service
Make sure your grip and footing are
immediately remove
from service any items

d S secure when using large tools

found defective.

l i
• Use only tested tools and
tack
a
5 SAFETY:
V
• Falling of material due to
improper sling/f-15 hydra
crane signalling.
➢ Maintenance In
charge/ Technician
➢ Ensure to operate all the lifting

➢
equipment below their safe working
load value.
Ensure that all the required parts of the
➢ Contractor lifting equipment are well lubricated. Follow safety standards
• Only one person should
Handling of Supervisor ➢ Slings shall not be shortened with knots document:
give signal
materials.
• Use of manila ropes,
fibre ropes in rigging
➢
or bolts or other makeshift devices.
Every sling used for raising or lowering
on lifting appliance shall be secured
O P
CMM/FM/01 Rev. 00

activities is strictly
prohibited for heavy
attached to the appliance and the

S
method of attachment shall not be a

d
i
loads. method likely to result in damage to any

PREPARED BY APPROVED BY
a l
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 6 of 10

• Hands and fingers shall part of the sling or to any lifting gear
not be placed between supporting it.
the sling and its load ➢ Provide proper instruction to crane
while the sling is being driver.
➢ ➢ Apply padding while using sling
tightened around the
➢ No bird caging, kinks or core protrusion
load.
shall exist in the wire rope.
ENVIRONMENT: ➢ Fill up the sling check list
• Oily and dusty, uneven
floor

QUALITY:
• Check slings and other
lifting tools before use.
• No one should be under
the load when it is being
raised or lowered or
O P
being shifted.
• Never work beneath the

d S
load

l i
• Use proper tested rigging

a
tools and tackles e.g.

6 SAFETY:
V
chain block, wire rope
sling etc.

• Skin burns by cutting

➢ Use flash back arrestor cutting
torch.
flame, heated surface, & ➢ Use good quality hose pipe, leak
molten metal. ➢ Maintenance In proof connection & proper Follow the TSL Safety
Gas cutting • Explosion in cylinder, fire
in hose due to leakage in
➢
charge/ Technician
Contractor
Supervisor
➢
regulator.
Avoid clamping the hose with wire,
do it with jubilee clamp. P
standard:
BSL/SS/ENGG/05

O
S
hose connection,
➢ Use of proper pressure regulator
damaged or faulty with double pr. Gauge (2stage
regulators, leakage

i d
regulator for proper pr. Control).

l
Name and Designation :
Signature with Date :
PREPARED BY
Name and Designation :
Signature with Date :
APPROVED BY

V a
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024 Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 7 of 10

cylinder, clamping of ➢ Sparks must be arrested on spot.

hose with cutting nozzle ➢ Keep DA/LPG cylinder always
&regulator vertical and at 3-meter distance
• Effect/damage of eye from each other.
with flame & flying ➢ Remove any inflammable material
from working site
particles.
➢ Always keep fire extinguisher or
• Bursting of hose pipe &
suitable arrangement nearby work
fire with excessive line area. Ensure the fire extinguisher is
pressure. ➢
in operable condition.
• Fire due to falling sparks. ➢ Remove all inflammable materials
• Chance of liquid entering from site to avoid fire
the hose

ENVIRONMENT:
• Presence of inflammable
material – clean before
gas cutting/ welding.
O P
QUALITY: -

d S
i
• Spark and spatter must

l
be arrest at place.

a
• Keep fire extinguisher,

7
Welding
site.
SAFETY:
V
sand bucket, water at

• Electrical shock to
➢ Before starting welding activities
ensure about the surrounding area
welder. are free from grease and oil which
• Fire in nearby area due ➢ Maintenance In may easily catch fire Follow the TSL Safety
wrong ear thing.
• Burn due to spark/weld
➢
charge/ Technician
Contractor
Supervisor
➢
➢
➢
Use of shock proof gloves.
Properly insulated welding holder.
All power tools must be properly P
standard.
BSL/SS/ENGG/05

O
S
spattering. grounded before their use.
• Radiation effect on body. ➢ Proper welding cable without any
• Inhaling of toxic gases damage.

l i d
Name and Designation :
Signature with Date :
PREPARED BY
Name and Designation :
Signature with Date :
APPROVED BY

V a
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024 Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 8 of 10

from the welding flux ➢ Rubber shoes/nail-less shoes.

➢ Extension of welding cable by socket
ENVIRONMENT: joint.
• Oily and dusty area. ➢ Use shield glasses/face shield
• Uneven floor. helmets.
• Slip, trip and fall ➢ Use double welding lead/cables for
• Falling in cable trench welding with separate ear thing
cable from job to m/c.
QUALITY: ➢ Use of shock proof gloves & thick
Free of waste materials such cotton clothing for weld
as slag, free of porosity, leak
proof joint having strength.
SAFETY: ➢ Cutting of structural materials as per
side condition or as per drawing.
➢ Hand & leg injury during ➢ Mark the area to be removed.
➢
➢
job
Slip/Fall of Person
Slip/Fall of Material
O P ➢ Barricade the area to avoid any un
authorize person entry.

8 Removal of old /
➢ Wet of clothes and body

d S Maintenance in-
charge/Technician
Contractor supervisor/
➢ Cut the damaged plate / structure
by gas cutter and hold / support
damage structure. ENVIRONMENT:

Quality:
a l i team properly to avoid fall.
➢ Remove the cut structure from its
position.

V
Use standard and good
quality tools & tackles.
➢ To arrest falling spatter from
height, proper arrangement to be
made.

O P
d S
PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 9 of 10

Step No Details of Activity Associated safety Hazards/ Responsibility (WHO) Safe process (tools & Equipment, PPEs, Remarks / Reference
(WHAT) Env. Impacts/ Quality Training etc.) (HOW) (Document &
Requirements Records)
SAFETY ➢ Shift the structure materials as per
requirement
➢ risk of cut, burn & strikes ➢ Cut the structural materials as per
injury due to blunt face site / drawing.
9 ➢ Injury due to hit at the ➢ Maintenance In ➢ Weld the structural component as
Fabrication Follow the cooling
charge/ Technician per requirement.
time of shifting and lifting. tower SMP:
➢ Contractor
SSTG/SMP/MECH/0076
Supervisor
ENVIRONMENT NA

QUALITY:

O P ➢ Shift

S
SAFETY: structural materials /
fabricated structure at designated
➢

➢
Hand & leg injury
during job

l i
Slip/Fall of Persond place if erection will be done by
lifting tools / machineries or

10
Erection
➢
a
Slip/Fall of Material

V
➢ Maintenance In
charge/ Technician
➢ Contractor
directly at position if erection by
manually.
➢ Position the fabricated structure
materials with proper support and
ENVIRONMENT: Supervisor tack weld.
Quality: ➢ After checking final position weld
properly as per requirements.
Use standard and good
quality tools & tackles
➢ To arrest falling spatter from
height, proper arrangement to be
made.
O P
d S
PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel, Meramandali
SOP NO. IMS/BF1/MM/PCM/SOP-12 Effective Date 01-01-2022 REV. No. 00
SOP DESCRIPTION Structural works: fab, erection & SECTION MM
maintenance
DEPARTMENT BF-1 PAGE Page 10 of 10

Step No Details of Activity Associated safety Hazards/ Responsibility (WHO) Safe process (tools & Equipment, PPEs, Remarks / Reference
(WHAT) Env. Impacts/ Quality Training etc.) (HOW) (Document &
Requirements Records)
SAFETY: ➢ Clean all scraps from work place.
➢ Finger cut due to strike ➢ All tools & tackles to be loaded on trolley
with sharp hidden edges & shifted out from site
of scrap materials. ➢ Remove all man powers from site before
Housekeeping and ➢ Hand & leg injury due to return the clearance.
11 slipping on stairway. ➢ Open all the isolation lock which was
Return work permit
locked before starting this job.
➢ Maintenance in- ➢ By releasing the lock of group isolation
ENVIRONMENT: charge/Technician box, open all inlet and outlet valves.
➢ Hot water Contractor supervisor/ ➢ Work area is to be cleared of all
QUALITY: team personnel after return of work permit.
➢ Post execution of ➢ Designated route to be followed for
housekeeping.
All parameters should be
filled properly of the permit
O P ➢
return of work permit.
Removed scraps to be exposed in
respective designated bin.

d S ➢ All parameters to be filled properly in

work permit form in the time of

a l i returning.

O P
d S
PREPARED BY APPROVED BY
a l i
Name and Designation :
Signature with Date :
Printed By -Manas Kumar Das(910528) Print valid till - 09-Nov-2024
Name and Designation :
Signature with Date :
V
Printed on - 30-Oct-2024 SOP Valid Till - 30-Jun-2025