GENERAL MANUAL_GM, Part 1 – Safety and first aid
1. PLANT SAFETY
INSTRUCTIONS
Warning!, Caution! and Note!
In the text there are used certain
notes emphasized with a specific sym-
bol to draw the readers attention, if
there is a possible danger or other
things to take notice when performing
a stage of operation.
Z
NOTE!
This guidance is valid only for the
Operator’s manual. In any other
manual including in the binder set,
same symbols may be used in
other purposes or these notes are
marked in a different way.
General
The purpose of the safety guidelines is
to eliminate or minimize all potential
hazards and to avoid accidents involv-
ing injury to personnel or damage to
property. The plant safety instructions
have been prepared to provide some of
the basic rules and procedures neces-
sary to avoid injury and damage to
equipment and material. These safety
instructions does not cover each imag-
inable situation arising during opera-
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Below are definitions of these three
grades of notes:
‹
WARNING!
Warning is used in text whenever
there is a risk of injury to the per-
sonnel.
! CAUTION!
Caution is used in text whenever
there is a risk of damaging equip-
ment.
Z
NOTE!
Note is used in text for highlight-
ing certain information or require-
ments.
tion. Should you have any doubt re-
garding safety on your job, do not hes-
itate to consult your foreman for guid-
ance and advice.
Safety is your responsibility
Attitude is the key factor in accident
prevention. Develop a positive and
continuing concern for safety, both on
and off the job, by making safety a
matter of personal commitment.
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1. PLANT SAFETY INSTRUCTIONS
Accidents often inflicts suffering and
loss. Therefore it is good for each and
every employee to know that even the
smallest contribution towards safer
working methods and environment re-
duces the risk of accident.
Your safety and the safety of your fel-
low man depends on the interest and
concern each individual shows by ob-
serving these rules and regulations.
Supervisors are responsible for under-
standing and observing the safety pro-
cedures and will always work in ac-
cordance with accepted safety
practices.
+ Improve safe work on site and make
safety suggestions
+ Report all unsafe practices and un-
safe conditions
+ Use the personal protective equip-
ment provided and/ or required by
the nature of work
Use of personal protection equipment
Hard hat
You are required to wear a safety hel-
met whenever working at
construction site or power
plant.
Hearing protection
Ear plugs or muffs shall always be
used in all areas designated as a high
noise area or in any other operation
when hearing can be impaired.
Goggles & facial protection
Safety glasses shall be used: when
buffing or grinding when chipping
paint or welding slag when handling
strong cleaning agents, corrosives, or
acid when blowing pipe lines with
compressed air for cleaning purpose.
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+ Teach safety to new employees and
set a good example Report any in-
jury or accident immediately
Make safety a part of everyday job!
Training
Often when accidents occur, the rea-
son is wrong working methods, faulty
tools, vague working descriptions, i.e.
things that could have been elimi-
nated by proper training.
Tidiness
One big factor in improving the safety
is tidiness. Keep the tools at their own
given places. Keep corridors free from
material not belonging there. Keep
floors clean from oil spills etc.
Tidiness creates safety.
Re-install warning signs, fences and
other protections that has been re-
moved for service work once the work
is finished.
Contact lenses
Contact lenses may absorb chemical
vapors and other foreign matter,
thereby causing eye injury. When the
work environment entails exposure to
chemical fumes, vapors or splashes,
intense heat, molten metals, or a
highly particulate atmosphere, contact
lens use shall be restricted.
Gloves
Always use gloves, not only when han-
dling very hot or very cold materials
or tools.
Protective shoes
You are required to wear a safety foot-
wear whenever working at construc-
tion site or power plant. Use
hard-toed, leather-soled footwear.
Avoid rubber-soled.
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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
Dress code
Necklaces and bracelets should not be
used, especially when working with
live electrical equipment or assem-
bling / overhauling of engines and me-
chanical equipment.
For your personal safety:
Leave finger- and ear-rings, wrist
Tools
Hand and power tools
Accidents arising from the use of hand
and power tools are frequently caused
by human error, misuse of tools, or
using a defective tool. Hence, all per-
sonnel shall select and use the correct
tool for the job. as the poor quality
hand and power tools increase the
risk of accidents, high quality tools
shall be used.
Hand and portable tools
Always use tools and equipment
which are in good condition and are
right size and type of tools for the job.
Tools and material shall not be
thrown or tossed from one person to
another.
Tools and material shall not be placed
or permitted to remain on narrow
pathways or on scaffolding where they
can become stumbling hazards or be
placed in a position where they may
fall.
Carrying tools
Do not carry tools in your pockets.
They shall be carried in a tool kit or
in hand in such a manner as to pre-
vent injury by stabbing, dropping,
pinching, and the like.
Electric and pneumatic power
tools
Inspect tools regularly so that they
are safe for use.
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watches, bracelets, and neckties at
home
To avoid burns, wear a long sleeved
garment with buttoned cuffs so that
the arms are fully covered.
Change dirty overall regularly.
Tools shall be used only by personnel
who have been instructed to use tools
safely. Metal body of the portable elec-
tric tools shall be grounded when con-
nected to electric circuits.
Portable extension cords shall be
maintained in safe condition Lamp
sockets shall be adequately insulated
and equipped with suitable guards.
Hose and hose connections for the
compressed air tools shall be main-
tained in safe condition. All tools shall
be disconnected from the power sup-
ply before cleaning and changing the
bits, blades, discs etc.
White finger
‹
WARNING!
High vibration from handheld drills
and grinders can damage the
blood capillaries and nerves in the
operators’ fingers, causing the fin-
gers to change colour and go
numb.
Compressed air
‹
WARNING!
Never use compressed air to blow
clean your working clothes or any
part of your body. To do so is to
risk your life! (Air may enter your
bloodstream through small cuts
etc.)
Always use proper blow guns and eye
protection when using compressed air
for cleaning purposes.
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1. PLANT SAFETY INSTRUCTIONS

Working environment
Noise The average value of the sound during
a working day must be below this
There is no distinct limit between dis-
level to limit the risk of damage to
turbing and non-disturbing sound
hearing. Noise should
which applies to everyone. The limit
preferable be below 75
for dangerous noise is considered to be
dBA during the working
85 dBA. Habitual exposure to noise
day.
above 85 dB will cause a gradual
hearing loss in a significant number of Always use hearing pro-
individuals, and louder noises will ac-
tection when working in noisy spaces.
celerate this damage.
Once hearing ability is lost it can
never be restored !
Noise level (dB) Maximum time for
exposure Get hearing protectors that you are
85 8 hours really comfortable with. See to it that
all parts are functional
88 4 hours
91 2 hours Ordinary cotton balls or tissue paper
wads stuffed into the ear canals are
94 1 hour
very poor protectors; they reduce noise
97 30 minutes only by approximately 7 dB.
100 15 minutes
8 minutes
Damage of hearing
103
4 minutes
The longer you are exposed to a loud
106
noise, the more damaging it is. Also,
109 2 minutes the closer you are to the source of in-
112 1 minute tense noise, the more damaging it is.
115 Prohibited
When noise is too loud, it begins to
kill the nerve’s endings in the inner
The longer you are exposed to a loud ear. As the exposure time to loud
noise, the more damaging it is. Also, noise increases, more and more nerve
the closer you are to the source of in- endings are destroyed. As the number
tense noise, the more damaging it is. of nerve endings decreases, so does
your hearing. There is no way to re-

dB 140

120 POSSIBLE TO HEAR

100
2

MUSIC
dB 2 x 10 N/m

80
Sound level
-5

CONVERSATION
60

40

20

10 Hz 20 Hz 50 Hz 100 Hz 200 Hz 1 kHz 2 kHz 5 kHz 10 kHz 20 kHz 100 kHz

Frequency

Fig. 1 The hearing range of the human ear

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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
store life to dead nerve endings; the
damage is permanent.
Range of hearing
The hearing range for human beings
is between 20 Hz and 20 kHz. The
range is however reduced with higher
age.
Air pollution
In addition to dust different ashes and
gases exists i.e. in exhaust gas boilers
and silencers. Be observant of leaking
flue gas from the exhaust gas boiler
piping.
In order to improve the air quality:
+ increase the ventilation
+ handle dangerous liquids and solids
in a closed space to avoid spreading
+ stop using dangerous liquids and
solids if possible
+ always use proper safety equipment
+ improve working methods
Illumination
The human eye can adapt to the ac-
tual illumination, while we often are
not reacting to a poorly illuminated
working areas.
Working in poorly illuminated areas
makes it more difficult to perform the
working task and increases the risk of
Operation & Maintenance
General
Before working on a system, discon-
nect mains or lock main switches.
Always lock the main breaker of a
unit before starting any work. Put a
tag with your name on the breaker in
case someone would need to start the
unit. Don’t forget to unlock and re-
move the tag when the work is com-
pleted.
Put up a warning sign “Men at work”
on concerned valves and breakers.
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accidents. This is why it is of utmost
importance to keep the illumination at
an adequate level.
By improving the illumination many
benefits are achieved. Studies show
that by doing that, the productivity
increase, faulty performance decrease
and the accidents decrease.
To improve the illumination is one of
the cheapest ways to improve the
working environment.
The illumination deteriorate as a re-
sult of:
+ pollution of surfaces
+ aging of light sources
+ pollution of light sources
Therefore the light sources shall be
cleaned at regular intervals and re-
newed when necessary. Repaint walls
and floors when necessary.
Climate
The climate in a power plant differs a
lot from different working areas. In
the control room the temperature is
perhaps lowered by means of air con-
ditioning while the temperature in the
boiler room on the other hand can be
very hot.
Continuous and hard work in hot or
cold areas can have serious health ef-
fects on the human being.
Men at work
Always reset to original positions af-
ter the work has been completed.
Before attempting to start a unit or
system, make sure that no work is be-
ing performed and that the unit/sys-
tem is ready to start.
Do not operate a unit with safety
shields removed. Ensure that all ro-
tating parts are protected from unin-
tentional contact.
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1. PLANT SAFETY INSTRUCTIONS
Never attempt to re-start any equip-
ment automatically shut-down with-
out investigating the reason for the
safety shut down.
Genset
Before starting any work on the en-
gine, make sure that the main valve
on the starting air bottle is closed and
preferably locked. Carefully release
any remaining air from the system be-
fore attempting to open up any part of
it. Never attempt to start or run the
engine with any parts removed or dis-
mantled.
Never open up the crankcase inspec-
tion covers to investigate an over-
heated main bearing unless the en-
gine has cooled off for at least 20
minutes. Air entering an overheated
crankcase may cause an explosion.
Do not touch any part of the exhaust
piping when an engine is running.
The exhaust gases are hot, and may
cause severe burns.
Never enter any part of the exhaust
gas system without having it well-ven-
tilated first! The nitrogen oxide gases
in the exhaust are harmful, and lack
of oxygen may cause suffocation.
When working on or in the generator
it is essential to ensure that the en-
gine cannot be started either automat-
ically or by accident.
Heaters
Always drain a heater before opening
it for service or inspection. Having hot
oil in a pressurized vessel may cause
it to splash onto unprotected body ar-
eas, causing severe burns.
Separators
Stop the separator immediately if un-
usual noises or vibrations occur. Do
not loosen any part before the bowl
has come to a complete standstill.
When cleaning the separators, obtain
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regulations for handling of fuel and
lube oils as described on page 1-12.
Welding
Leather gloves, sleeves, aprons, spat
and leggings shall be used when weld-
ing and cutting operations are being
done.
Only qualified personnel is allowed to
use welding equipment (gas and elec-
tric). The use of this equipment must
follow the safety instructions due to
danger of fire.
Ensure that there is sufficient ventila-
tion, especially if welding with gas in
small places.
Use of compressed gas cylinders
The gas hoses used must be in good
condition. The hoses should be held by
clips. Cylinder valves are to be prop-
erly closed after the use.
Storage of the compressed gas cylin-
ders
Reserve clearance enough for remov-
ing cylinders out of the building in
case of fire. A portable type fire extin-
guisher must be available. The cylin-
ders shall be stored at safe distance
from combustible material.
Radiation
Obey all warning signs, barriers and
flashing lights during radiography.
Working at heights
Falls are a serious threat to your
safety, and falls from heights are even
more so.
There is potential for falls from eleva-
tions in most workplaces. Just about
anyplace where there are steps or
stairs, ladders, mezzanine storage ar-
eas or large vehicles. Some jobs regu-
larly involve serious risks of falls from
heights:
+ maintaining towers,
+ loading tank cars,
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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
+ monitoring large vessels
+ and, of course, painting and con-
struction to name a few.
For many workers, avoiding falls from
heights is just a matter of using com-
mon sense and a few basic safety
rules such as these:
+ Never use a makeshift ladder or
scaffold.
+ Use handrails, and use caution
when traveling on steps and stair-
ways.
+ When climbing in and out of high
vehicle cabs, maintain “three point
contact” at all times. This means
having two hands and one foot or
two feet and one hand firmly in con-
tact with the vehicle at all times.
+ Wear safe footwear to reduce
chances of slipping and tripping.
+ Don’t let horseplay, inattention, or
hurrying put you at risk when you
are at heights whether on a balcony,
staircase or stepstool.
If your job involves working at heights
in a serious way, you must use fall
protection equipment. You may have
to use a personal lifeline system,
which may consist of a body harness,
a lanyard with a shock absorber, and
a lifeline attached to an anchorage
point. These devices may be part of a
system to prevent you from stepping
off the edge, or to catch you in case of
a fall.
No matter what kind of fall arrest
equipment is assigned to you, it is im-
portant that you understand fully its
use and its limitations. Know how to
maintain it properly to prevent wear
and damage. Carefully follow all the
procedures you learn in your training
for anchoring and tieing off fall pro-
tection equipment.
Ladders
On any job requiring a ladder, use
only approved sturdy ladders that you
can place on a firm base.
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Secure the ladder
at the bottom
Extension ladders shall be kept from
slipping or tipping by tying off the
ladder at the top and securing the lad-
der at the bottom.
The ladder should reach at least three
feet above the landing. Whenever pos-
sible, angle out the base one-fourth of
the ladder’s working length.
Never stand on the top two steps of
any ladder. This could cause you to
become off-balance resulting in a fall.
Face the ladder while climbing and
use both hands. Lift equipment and
materials with a rope specifically for
that purpose—don’t carry the equip-
ment up a ladder with one hand.
Only fiberglass or wood ladders shall
be used near electrical hazards. Mark
metal ladders with signs or decals
reading “CAUTION-DO NOT USE
NEAR ELECTRICAL EQUIPMENT.”
Standing on metal ladders or wearing
metal hard hats near high voltage
electrical power can result in death or
serious injury.
Electrical safety
The power plant feeds a complex net-
work of medium and low voltage dis-
tribution lines. All electrical switching
operations must be carried out strictly
in accordance with the procedures de-
tailed in the switchgear operating in-
structions.
‹
WARNING!
Failure to correctly sequence
switching either in the field or
within the power plant may cause
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1. PLANT SAFETY INSTRUCTIONS

personnel injury and serious + Use warning signs, tape etc.

equipment damage. + Don’t believe, don’t assume, use a
Before starting any maintenance: meter
+ Think over the work and prepare to + Use right kind of tools
the risks it involves, am I a danger + Put the maintained object to earth
to other with my work? if possible
+ Get acquainted with the working + Are the scaffolds adequate for the
spot, the emergency exits, where to purpose?
switch off the voltage etc. + Are there risk for explosions, protec-
+ Ask, if you are not certain about the tive voltage will not eliminate the
safety regulations risk of sparks
+ Aim at a tensionless working envi- + Lock doors and hatches when you
ronment, use protections leave
No electrical work should be per- + Act fast but deliberated in case of
formed “hot” when it can be done accidents
“cold”.
+ Also remember fall arrest equip-
‹
WARNING!
ment Standing on metal ladders or
Current range Duration Physiological Effects
Long - Usually results immediate loss of life
Several
amperes Short - Serious internal burns will carry waste products to the kidneys.
This may after some days cause dangerous toxic symptoms
Longer than a - Heart stopping, that may recover after the current is cut off
heartbeat cy- - Unconsciousness
cle - Traces on skin caused by current
500 mA
Shorter than - Ventricle fibrillation possible. Depends decisively on the heart-
a heartbeat beat cycle’s stage with respect to the connecting time of electric
cycle voltage
Longer than - Ventricle fibrillation
- Unconsciousness
50…500 mA - Traces on skin caused by current
Shorter than - Ventricle fibrillation possible.
- Strong shock-effect
From seconds - The Ventricle fibrillation is possible near the maximum limit at
to minutes long time periods
- Unconsciousness
30…50 mA
- Strong cramps
- Increase of blood pressure
- Irregularity in action of the heart
Minutes - Tolerance limit
- Increase of blood pressure
15…30 mA
- Breathing difficulties
- Cramps in arms
Not significant - Withdraw not possible with own help because the threshold of
1…15 mA cramp will be exceeded at the current’s maximum limit
- Strong pain in finger- and arm muscles
0…1 mA Not significant - The flow reaches the absolute threshold i.e. sense of touch

Table 1 The influence 50 Hz alternating current has on the human being. The duration of
a heartbeat cycle is 0,8 s.

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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
wearing metal hard hats near high
voltage electrical power can result
in death or serious injury.
Lifting
Do not attempt to lift
heavy or bulky objects
that are beyond your ca-
pability. Size up the load
and get help if needed.
Keep your back vertical
and knees bent; lift with
your leg muscles, keep-
ing the load close to Lift with your
your body. leg muscles.
Using a hoist
Hoisting equipment shall be visually
inspected before each use and shall be
removed from service for testing if
weakness is apparent or suspected.
A minimum of two persons shall be
required to use overhead cranes to
move large or heavy loads, one to op-
erate the crane controls and one to di-
rect and guide the load.
The load shall never exceed the rated
capacity of the hoisting equipment.
Fig. 2 Signals used to guide the hoist driver
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Never leave suspended loads unat-
tended.
Do not ride loads, hooks, and slings
suspended from hoisting equipment.
The use of an approved bosun’s chair
is permissible.
Carry loads as near to ground level as
possible, never over the heads of per-
sonnel. All personnel shall stand clear
of suspended loads.
Never run out the the cable to a
length exceeding the perpendicular
distance between the floor and the
crane cable drum. At least two full
wraps of the lifting cable shall remain
on the drum at all times.
Training
Only personnel having the required
training and the authorization of the
supervisor shall be permitted to oper-
ate a crane- or hoist-supported per-
sonnel-lifting device.
Control of lifting equipment
Check all lifting equipment such as
chains, belts, hooks and wires visu-
ally before use, to determine wear and
other defects. Measure chain links,
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1. PLANT SAFETY INSTRUCTIONS
hook gaps and proof load lifting equip-
ment at regular intervals.
Working in confined spaces
Confined spaces include, but are not
limited to, storage tanks, pits, vats,
reaction vessels, ventilation and ex-
haust ducts, boilers, silos, sewers,
manholes, tunnels, trenches, under-
ground utility vaults, and pipelines.
One of the most significant hazards of
working in a confined space is the dif-
ficulty associated with rescue from the
space.
Always have a standby person/atten-
dant to assist the person working in
the confined space.
Communication
The standby person/attendant shall
maintain constant verbal communica-
tion with the authorized entrant. If
voice communications are inadequate
because of noise, distance, personal
protective equipment, or other condi-
tions, an alternate communication
system such as visual contact, rope
signals, radios, light, or other electri-
cal or electronic alarm devices shall be
used.
Test to confirm the communication
system effectiveness between the en-
trant and the standby person/atten-
dant immediately after entering the
confined space.
Hazardous Atmospheres
Flammable/oxygen-enriched atmo-
sphere
A flammable atmosphere is generally
due to enrichment with oxygen (which
increases the flammability range of
combustibles), vaporization of flamma-
ble liquids (such as acetylene, butane,
propane, hydrogen, methane, natural
gas, liquid hydrocarbons, etc.), byprod-
ucts of work procedures (such as
spray painting or welding), chemical
reactions, concentrations of combusti-
1-10
ble dusts, and desorption of chemicals
from inner surfaces of the confined
space.
Toxic atmosphere
A toxic atmosphere can result from a
product stored in the confined space,
from the operations being performed
(such as welding or spray painting), or
from chemicals brought into the space
(such as cleaning fluids).
Irritant or corrosive atmosphere
Irritants include primary irritants
such as chlorine, acids, and ammonia
as well as secondary irritants such as
benzene, carbon tetrachloride, and
trichloroethane.
Oxygen-deficient (asphyxiating) at-
mosphere
The normal atmosphere is composed
of approximately 20,9 % oxygen and
78,1 % nitrogen. An oxygen level be-
low 19,5 % can result in oxygen depri-
vation. A reduced oxygen level may be
caused by consumption of the oxygen
during chemical reactions (e.g., by
combustion in welding, heating, cut-
ting, or brazing or by rusting), by mi-
crobial growth, or by the displacement
of oxygen by another gas such as ar-
gon, helium, nitrogen, or carbon diox-
ide.
Physical Hazards
General physical hazards
General physical hazards must be
considered when determining appro-
priate precautions for entry into a
confined space. These types of hazards
include possible entrapment or engulf-
ment, ladders or scaffolding, surface
residues in the confined space, protru-
sions, baffles, bends in tunnels, and
overhead structural members. These
types of hazards not only put the
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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
worker at risk but also can impede
rescue attempts.
Temperature
Work in hot and cold environments
requires the use of protective, insu-
lated clothing. Therefore, in addition
to the physical hazards of hot and cold
conditions, the worker has added bulk
that must be considered when allow-
ing for movement in the confined
space and for exit time.
Chemicals
Some chemicals can be absorbed
through the skin. Therefore, personal
protective equipment, engineering
controls, and appropriate work prac-
tices must be used to prevent skin ex-
posure to these chemicals.
Noise
Noise problems are typically intensi-
fied in confined spaces because the
noise can reverberate within the
space. The increased intensity of the
Dangerous liquids & solids
General
The presence of dangerous solids and
liquids in a power plant is inevitable.
It is necessary for the persons han-
dling different kinds of dangerous
substances to be aware of their char-
acteristics and risks and also what to
do if an accident occurs.
All containers containing dangerous
substances must be marked with
warning signs, the name of the sub-
stance and what it can cause.
Ammonia
Preventive actions
Read and follow the preventive ac-
tions listed below.
+ Ensure that unauthorized personnel
not have admission to the ammonia
plant.
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noise within the confined space can
also disrupt the communication be-
tween the entrant and the standby
person/attendant.
Vibration
Vibration causes added stress to the
worker inside the confined space and
may decrease his ability to note poten-
tially dangerous situations.
Electrical and mechanical equipment
If activation of electrical or mechani-
cal equipment could cause injury, each
piece of equipment shall be manually
isolated, locked out and tagged out to
prevent inadvertent activation. If com-
bustible or flammable gases, vapors,
or particles may be present in the con-
fined space, all electrical equipment
used shall be explosion-proof . All
electrical equipment brought into the
confined space shall have a ground
fault circuit interrupter (GFCI) at the
power source. If hand tools are used,
they shall be nonsparking.
+ Train personnel in handling of am-
monia. Inform the personnel about
deleterious effects and first aid.
+ Equip the personnel that is respon-
sible for the ammonia plant with
private protective equipment.
+ Use protective goggles, face protec-
tion and protective gloves, whenever
there is a risk of getting into con-
tact with ammonia.
+ Use protective clothing when
needed.
+ Always use a respirator, with a gas
filter for ammonia when there is a
risk of exposure to ammonia va-
pours.
+ Provide the working area with
proper ventilation.
+ Keep tanks and systems carefully
sealed.
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1. PLANT SAFETY INSTRUCTIONS
+ Develop working methods in order
to minimize or avoid exposure to
ammonia.
+ Never blend ammonia with other
fluids without knowledge of conse-
quences and whether it is safe or
not.
+ Always keep eye showers close to
places where there is a risk of am-
monia exposure.
+ Observe the greatest caution when
welding, causing sparks or fire.
Measures at ammonia leakage
Use protective clothing.
1 Stop the ammonia flow! Shut off
the feed valve to prevent more am-
monia to reach the place for leak-
age.
! Smoking and welding is forbid-
den when an ammonia leakage
has occurred.
2 Stop everything that may cause
sparks, grinding with emery for in-
stance.
3 Evacuate unnecessary personnel;
4 At considerable leakage, contact lo-
cal authorities, fire brigade.
5 Water the place for leakage to
rinse away and dilute the ammo-
nia.
6 Investigate what caused the leak-
age, repair and evaluate the inci-
dent in order to develop better
working methods.
Additives, chemicals
It is prudent to consider all chemicals
hazardous until proven otherwise.
Chemicals occur in three physical
states-solids, liquids, and gases-and
can be dangerous in all three states.
Information on the physical and
chemical characteristics of any chemi-
cal can be obtained from the manufac-
turer’s Material Safety Data Sheets
1-12
(MSDS) and also from the labels
found on the containers.
Handling of fuel and lube oil
As a result of the deterioration in
quality of fuel oils, the danger has
arisen that the heavy oils contain
greater amounts of substances injuri-
ous to health. These include:
+ Polycyclic aromatic hydrocarbons
+ Lead compounds
+ Chemical residues
An increased amount of polycyclic aro-
matic hydrocarbons is also present in
in used lube oils (waste oils).
The health hazards depends on:
+ the concentration of the dangerous
substances
+ the ambient air (inhalation of oil va-
pours/oil mist)
+ the intensity and duration of the
contact with the skin or mucous
membrane
Avoid skin contact with heavy oils and
lube oils if possible. Wear suitable
protective gloves and apply a protec-
tive ointment to the skin.
Avoid breathing in oil vapours if pos-
sible. If possible, improve the ventila-
tion in the room.
Wash affected areas of skin frequently
and thoroughly. Apply protective oint-
ment to the skin.
Personal hygiene is of utmost impor-
tance
Possible short-term effect
Possible short-term effects are:
+ Headaches
+ Dizziness
+ Nausea
+ Itching or burning of the skin
Possible long-term effect
Possible long-term effects are:
+ Allergic reactions, especially skin al-
lergies
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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
+ Festering inflammation of the skin
pores (oil acne)
+ Damage to the central nervous sys-
tem after inhalation over a long pe-
riod of time
+ Skin cancer caused by direct skin
contact over a long period of time
Oil drums
Oil drums should always be stored in-
doors. If the drums will be stored out-
Battery systems
Vented batteries and battery cells, re-
gardless of electrode type, contain
dangerous electrolytes that are subject
to spillage. Overcharging or too rapid
charging can cause boiling and spew-
ing of electrolytes and production of
explosive gases. The following precau-
tions shall be observed in handling
these devices:
+ Face shields, rubber gloves, and
protective rubber aprons shall be
used whenever batteries or cells are
being handled, filled, or charged.
+ An eye wash station shall be located
near each battery bank.
Traffic
Trucks, vehicles and equipment are
allowed to be driven and operated
only by nominated and trained per-
sonnel. Arrange regular checks for
brakes, controls and alarm devices.
Do not drive a mobile equipment be-
ing out of order, inform your superior
immediately upon noticing of defects.
Driving a truck with lifted bed is
strictly forbidden.
Other traffic is required to give way to
loading and transportation vehicles.
When equal vehicles pass each other,
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doors, there are four major recommen-
dations that apply outdoor storage:
+ Provide at least temporary shelter
or tarpaulins against the weather.
+ Place drums so they cannot breathe
through the bungs.
+ Make sure bungs are made tight if
you are going to move drums.
+ Before opening, dry and wipe bungs
thoroughly as well as surrounding
surfaces.
+ Ample water shall be available to
flood any electrolyte spill occurring
in battery operations.
+ Battery charging shall take place in
well ventilated areas.
+ No smoking, open flames, or spark-
ing devices shall be permitted in a
battery area.
If the electrolyte should come into
contact with skin or clothing, immedi-
ately treat it with water or a weak
neutralizing solution. Electrolyte in
the eyes, however, is a very dangerous
situation; immediately flush the eyes
with profuse amounts of water and
SEEK MEDICAL ATTENTION.
the vehicle coming down is required to
give way.
Drive your vehicle with speed and
load that you can control in every con-
dition and situation.
Be careful when reversing.
Do not leave bucket of excavator or
loader up when stopping work or leav-
ing equipment. When leaving the
equipment, driver must put bucket
down. Riding of personnel in buckets
is strictly forbidden.
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1. PLANT SAFETY INSTRUCTIONS

Fire protection
General Tidiness
The fire risk in a diesel generating Tidiness is an important to avoid un-
station cannot essentially be described necessary fire hazard. Paint, deter-
as high. gents and other flammable liquids
must be kept in a metal sheet locker.
However as with any other similar
type of operation involving the han- Keep oily rags in a metal container
dling, heating, and combustion of provided with a cap, do not leave
quantities of inflammable liquid such them in your pockets.
as fuel oil it must be recognised that Check that flammable material is not
there is a risk of fire or in the event of left close to hot areas.
fire the existence of a mechanism that
could support a fire and intensify it.
The risk areas in diesel generating Obey non smoking signs!
stations lie mainly in the fuel treat-
ment areas, when considering residual
fuel operation, and in the areas of the
engines themselves, their lubricating
oil and fuel oil systems. There is also
the risk of fire as a result of crankcase
explosions.
Fire extinguishers
Secondary risks also arise from elec- There must be sufficient amount of
trical causes cable faults etc. fire extinguishers for first extinction
A major source of fires can be due to at site. Check the location of fire
bad housekeeping. extinguishers in beforehand and study
their use by reading the instructions.
Main fuel storage tanks are not con- Do not move extinguishers from their
sidered to constitute a high risk and marked places. Emergency exits are to
do not warrant protection unless they be marked inside the buildings.
are in the proximity of buildings or
plant that do constitute a high risk Emergency exits and fire extinguishers
and might cause a fire to spread to should be clearly marked up.
the tanks. Service tanks particularly
where used for the storage of heated
fuel can constitute a risk particularly
if adjacent to buildings or plant.

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 GENERAL MANUAL_GM, Part 1 – Safety and first aid
In case of fire
‹
WARNING!
Do NOT put out a gas fire with
water or fire extinguisher. A gas
fire should be put out exclusively
by closing the main gas valve. If
gas fire is extinguished by other
means, a gas explosion may oc-
cur when the gas makes contact
with glowing residues.
1 Close tha main gas valve.
(In case of gas fire)
2 Call the fire department
Give the following information:
! Your name, and that you wish to
report a fire
! The exact location of the fire
! What is burning
! Do not hang up until released by
the operator.
3 Rescue the injured persons in dan-
ger.
4 Sound the fire alarm.
5 Extinguish the fire or try to limit
it by removing flammable mate-
rial, liquids or gases to a safe
place.
6 Guide the fire department to place
in fire.
When fire alarm sounds
1 Close tha main gas valve.
(In case of gas fire)
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2 Evacuate the building immediately
via nearest exit.
3 Close all doors as you leave—do
not lock doors.
In case of gas leak, open all doors
and windows and ventilate the
space properly.
4 If fire is small, attempt to extin-
guish it—but don’t take chances.
Fire extinction
Extinguisher Use Instructions:
1 Check the label to be sure you
have the appropriate equipment to
extinguish the fire and carry the
extinguisher to vicinity of fire.
2 Remove the ring pin by pulling.
3 Direct discharge nozzle at base of
fire.
4 Squeeze discharge lever.
5 Be sure all fire is out before stop-
ping discharge.
6 Back away from extinguished fire.
Remember to recharge the extin-
guisher afterwards.
Testing of equipment
Check and test fire alarm systems,
smoke detectors, sprinkler systems,
fire extinguishers and fire hoses on a
regularly scheduled basis at least once
a year to make sure they are working
properly in case of a real fire.
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1. PLANT SAFETY INSTRUCTIONS

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