Content .. 52 53 54 55 ..

INDIAN RAILWAYS MAINTENANCE MANUAL FOR DIESEL LOCOMOTIVES - PART 54

Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 208 of 303

briefed through organized training courses so as to know what are the special
precautions that he has to take.

9.7.12

The supervisor and some of his men should be trained in firefighting & first aid.
Periodic refresher courses should be used to keep them in readiness.

9.7.13

Sufficient nos. of safety precautions/posters shall be displayed prominently in shed.
Some sample safety precautions in different areas of working in shed are at
Annexures-9.3.1 to 9.3.14.

These are only illustrative and not exhaustive ones.

9.7.14

Unsafe working conditions should be completely eliminated. Tools, machinery and
plants which help in reducing staff fatigue can be used to improve safety. These can
be pneumatic, hydraulic and electrical tools for torquing, slackening, etc.

9.7.15

Material handling equipment like forklifts, battery operated platform trucks,
hydraulic trolleys etc. should be maintained by following laid down maintenance
schedules.

9.7.16

Points and crossings in shed area should be attended/renewed as per laid down
periodicity. Electrically operated points in place of manually operated points should
be provided.

9.7.17

Staff involved in safety related activities like: Welding, EOT crane operators, M&P
maintainers, etc., should have competency certificate, issued by Authorized
Agency.

9.7.18

Indian Electricity Rules 1956: Compliance to Indian Electricity Rules 1956 need
to be ensured. Some of the vital requirements are:-

9.7.18.1 Certification of electrical installations in shed every five years.

9.7.18.2 Staff working on electrical installation to have Competency certificate

9.7.18.3 Measurement of IR of HV and LV circuits of electric installations.

9.7.18.4 Proper earthing of all electrical devices.

9.7.18.5 Checking of earthing devices of shed once in two years.

9.7.19

A safety review committee shall be formed consisting of: Officers, Supervisors,
trade union representatives and interested staff. This review committee shall
conduct a thorough inspection of shed floor once in a month and take corrective &
preventive action for deficiencies noticed.

9.7.20

A multi-disciplinary team of JS/SS of Civil, Mechanical and Electrical departments
should carry out checks and identify the actions to be taken for improving safety.
The periodicity of such checks should be once in a year.

9.8 Prevention of Fire: With fire preventing units disbanded from most of the sheds, proper

planning needs to be done for prevention of fire.

Home

Ch-9

Draft

Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 209 of 303

9.8.1

The SSE/General of Diesel Shed will be responsible for the provision, maintenance
and operation of the fire prevention and firefighting equipment and organization in
the Diesel sheds.

9.8.2

Proper network of approach roads, static tanks and hydrants at suitable locations
shall be available. If not included in the original plan, these measures should be
designed and completed as early as possible.

9.8.3

Sufficient water supply arrangements in Static Tanks & Hydrants shall be ensured.

9.8.4

Hoses for use in fire hydrants shall be provided near the hydrants. These hoses shall
be housed in a box with glass front.

9.8.5

Fire extinguishers shall be conspicuously available at strategic points. Periodic
maintenance, testing and refilling of Fire Extinguishers shall be ensured. The date
of last inspection done and next due date shall be painted on inspected/ maintained
fire extinguishers.

9.8.6

Adequate number of Fire Alarm boxes shall be provided at various locations of the
shed.

9.8.7

A layout plan of the shed indicating availability of fire fighting facilities: fire
extinguishers, sand buckets, Hydrants, Static tanks, fire alarm boxes, etc., shall be
displayed at three prominent locations in the shed.

9.8.8

Proper record keeping of operational history, inspection and maintenance of fire
extinguishers, working of water supply and pumping out arrangement in Static
Tanks and of Hydrants provided in different places of shed shall be maintained.

9.8.9

Apart from the regular fire fighting staff of SSE/General, supervisors and a nucleus
staff in every section should be trained to handle ‘ABC’ class fires. Regular
refresher courses for such staff should also be arranged.

9.8.10

The SSE/General shall make periodic inspection of the premises to check correct
working practices, particularly stocking of combustible materials and accordingly
take corrective action, if required.

9.8.11

Fire extinguishers suitable for ‘BC’ Class equipment have to be provided on locos.
Timely and correct maintenance of these fire extinguishers should be ensured by
SSE/General.

9.8.12

The large stocks of combustibles such as HSD, oils, lubricants, solvents, etc., in a
typical maintenance depot are specific responsibilities of the SSE/General. He
should be fully associated in the construction stage and follow up through regular
works progress to upgrade the stocking and handling facilities, as and when
required.

9.8.13

Shed floors should be kept clean – free of oil/muck. Habit of spillage free handling
of oil/grease on floor should be inculcated in the staff. This will not only improve
work environment, but also curtail the chances of fire accidents.

Home

Ch-9

Draft

Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 210 of 303

9.8.14

All electrical fittings/Circuit breakers, etc., shall be checked as per schedule for
avoiding any short circuits. The “electrical earthing” of shed should be checked as
per schedule. No hanging or loose wires shall be allowed in the shed.

9.9 Safety Management System: Diesel sheds shall have integrated safety management

system in line with provisions of OHSAS so that an assured safety management system is
in place in the shed.

9.9.1

Identification and Control of Hazard: Diesel Sheds shall establish and maintain
a system for ongoing identification of hazards, the assessment of risk and
implementation of necessary control measures of various activities in Diesel Sheds
to facilitate setting up of occupational health and safety targets.

9.9.1.1 While identifying the hazards not only the routine and non-routine activities shall

be taken into consideration, but also identification of the hazardous activities of
all personnel having access to the workplace shall be taken into account.

9.9.1.2 A cross functional team shall be used for identification of hazards. The team shall

consider process flow diagram, select activity and use work activity
information, its effect on safety and health of employees, requirements of
relevant acts and reactive monitoring data to identify hazards.

9.9.1.3 The hazards are reviewed and the risk of each of these hazards is determined by

estimating the likelihood and potential severity of harm. While estimating the
likelihood of harm, the existing adequacy of control measures already
implemented is considered.

9.9.1.4 Risks are identified and classified according to their estimated likelihood and

potential severity of harm, as mentioned below:

a) Severity of risk will be assessed as follows:

Severity

Remarks

Slightly harmful Injury of very minor nature where there is no incapacitation from

work place.

Harmful

The cases of injury in which loss of man days takes place and/or
permanent disability

Extremely
harmful

The cases of fatal injury

b) Probability of occurrence is assessed as follows:

Probability

Remarks

Highly unlikely

There is no occurrence in the past and no such possibility in the
future as well.

Unlikely

There are very few cases reported in the past

Likely

There are cases which have occurred in the past & there is
likelihood of occurrence in the future also

Home

Ch-9

Draft

Document No:

Chapter –9 Safety & Environment

Version No: 1.0-d0

Date Issued: dd/mm/yyyy

Document Title: MANUAL MAINTENANCE FOR DIESEL LOCOMOTIVES

Revised 2013

Printed: 2015/03/08

Page 211 of 303

c) The various risk levels are shown in the following table. These risk levels in form the

basis for deciding whether improved controls are required and timetable for action.
The outcome of risk assessment is treated as inventory of actions, in priority order, to
devise, maintain or improve controls.

Risk Level

Remarks

Trivial

No action is required and documentary records need to be kept for
data analysis.

Acceptable

No additional controls are required. Monitoring is required to
ensure that the controls are maintained.

Moderate

Efforts may be made to reduce the risk, but the cost of prevention
should be measured and limited. Risk reduction measures should
be implemented within a definite time period.

Substantial

Work should not be started until the risk has been reduced.
Considerable resources may have to be allocated to reduce risk.
Where the risk involves work in progress, urgent action should be
taken.

Unacceptable
Risk

Work should not be started or continued until the risk has been
reduced. The work has to remain prohibited until the risk is
reduced. There is no consideration for limitation of resources.

9.9.1.5 Operational Control Procedures shall be implemented to control the significant

risks. Management programme are drawn up to introduce time bound action
plans to reduce risks and also to monitor the action plans.

9.9.1.6 Risk assessment provides input to facility requirements and identification of

training needs.

9.9.1.7 Control of Hazard: For moderate risk levels, management programme are

planned to reduce risk level in a definite time period. The result of this
assessment is considered while setting up objectives. In case any new activity is
added or the existing one is changed, it shall be taken into account and the risk
assessment again done for this risk. The hazards associated with the same are
identified and risks assessed. The process of risk assessment is carried out once
in a year to assess the effectiveness of control measures and to see if the hazards
and risks have been significantly controlled over the period.

9.9.2

Monitoring and Measurement of OHSAS performance: Diesel Shed shall
establish and maintain a system for monitoring and measurement of OHSAS
performance on a regular basis and following plan be followed:-

9.9.2.1 Procedure has been established which identifies the measures of performance to

be measured and monitored.

9.9.2.2 Both quantitative and qualitative measures have been considered, where

appropriate

9.9.2.3 Proactive measures of performance that monitor compliance of OHSAS

arrangements through surveillance and inspection have been identified

Home

Ch-9

Draft

Content .. 52 53 54 55 ..