Apex Manual 5.10.2013

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ed &
Issued By
Reviewed
By
Approved
By

Name S.D. Arade Name M.M.Kulkarni Name A.G.Kshirsagar
Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Issue No : 09 Doc.No :HSE AM/01/01
Rev. No : 00 Date : : 20.08.2013
Cl. No : NA
Title

COVER PAGE
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MANUAL CONTROL

This manual is the property of

THERMAX LIMITED CHINCHWAD, PUNE

And is a OCCUPATIONAL HEALTH AND SAFETY & ENVIRONMENT document
(hard copy), is issued to the person mentioned below. This shall be returned to the
Management Representative, whenever, the person holding the manual has no
further use or applicability and / or whenever leaving the employment of Thermax
Limited.
Electronic copy of this manual is available to all identified users.

HSEAM Hard Copy No:

Issued to (Name of copy Holder):

Designation:

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Title

COVER PAGE
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Sr No
ISO14001
:2004-
Cl ause No
OHSAS
18001:
2007
Clause
No.
Document No TITLE
Page
No.
Rev
No.
Implement
ation date
1. - - HSEAM/01/01 Cover Page 1 00 15.09.2011
2. - - HSEAM/01/02 Table of Contents 2 00 15.09.2011
3. - - HSEAM/01/03 Amendment Sheet 4 00 20.03.2012
4. - - HSEAM/01/04 Abbreviations 6 00 15.09.2011
5. - - HSEAM/01/05 List of Copy Holders 8 00 15.09.2011
6. 3 3 HSEAM/01/06 Terms & Definitions 9 00 15.09.2011
7. - - HSEAM/01/07
Introduction of
Organization
14 00 20.03.2012
8. 4.0 4.0 HSEAM/01/08 Scope of HSEMS 18 00 15.09.2011
9. 4.1 4.1 HSEAM/410/01
General
Requirements
20 00 15.09.2011
10. 4.2 4.2 HSEAM/420/01 HSE Policy 23 00 15.09.2011
11. 4.3 4.3 HSEAM/430/01 Planning 25 00 15.09.2011
12. 4.3.1 4.3.1 HSEAM/431/01
Hazard/ Aspect
Identification,
Assessment of
Risks/
Environmental
Impacts &
Determining Control
Measures
27 00 15.09.2011
13. 4.3.2 4.3.2 HSEAM/432/01
Legal & Other
Requirements
36 00 15.09.2011
14. 4.3.2 4.3.2 HSEAM/432/01
Register of Legal &
Other Requirements
41 00 15.09.2011
15. 4.3.3 4.3.3 HSEAM/433/01
Objectives, Targets
& Management
Programs
48 00 15.09.2011
16. 4.3.4 4.3.4 HSEAM/434/01
HSE Management
Programmes
50 00 15.09.2011
17. 4.4 4.4 HSEAM/440/01
Implementation and
Operation
53 00 15.09.2011
18. 4.4.1 4.4.1 HSEAM/441/01
Resources, Roles ,
Responsibility ,
Accountability &
Authority
58 00 15.09.2011

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Title

COVER PAGE
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Sr No
ISO140
01
:2004-
Clause
No
OHSAS
18001:
2007
Cl ause
No.
Document No TITLE
Page
No.
Rev
No.
Implementa
tion date
19. 4.4.1 4.4.1 HSEAM/441/02
List of
Responsible
Personnel
66 00 20.03.2012
20. 4.4.2 4.4.2 HSEAM/442/01
Training ,
awareness &
Competence
69 00 15.09.2011
21. 4.4.3 4.4.3 HSEAM/443/01
Communication,
Participation &
Consultation.
72 00 15.09.2011
22. 4.4.4 4.4.4 HSEAM/444/01
HSEMS
Documentation
75 00 15.09.2011
23. 4.4.5 4.4.5 HSEAM/445/01
Document
Control
80 00 15.09.2011
24. 4.4.6 4.4.6 HSEAM/446/01
Operational
Control
85 00 15.09.2011
25. 4.4.7 4.4.7 HSEAM/447/01
Emergency
Preparedness &
Response
88

00 15.09.2011
26. 4.5.1 4.5.1 HSEAM/450/01
Performance
Measurement &
Monitoring
90 00 15.09.2011
27.
4.5.2 &
4.5.3
4.5.2 HSEAM/452/01
Incident, Major
Injury Incident
Investigation,
Nonconformity
and corrective &
preventive
actions
93 00 15.09.2011
28. 4.5.4 4.5.3 HSEAM/453/01
Records &
Records
Management
98

00 15.09.2011
29. 4.5.5 4.5.4 HSEAM/454/01 HSE Audit 100 00 15.09.2011
30. 4.6 4.6 HSEAM/460/01
Management
Review
103 00 15.09.2011
31. 4.4.6 4.4.6 HSEAM/446/02
List of Common
Formats
106 0 10.08.2009

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AMENDMENT RECORD SHEET

Sr
No.

Document No.
(Present Issue &
Rev. No.)
New
Issue
No.
New
Rev
No
Amendment Details/ Reasons

Date

1
Issue No. 04
Rev.0
5 0
The Apex Manual for HSE
management system is revised to
meet requirements of OHSAS
18001: 2007 and to cover the
changes in Organizational
structure and management
system & reissued.
30.04.2008
2
Issue No 5-
Rev. 0
5 1
5 S processes included with new
HSE System, Legal register
updated with format`
15.05.2009
3
Issue No 5-
Rev. 1
6 0
Revision of Apex Manual done,
legal register updated, HSE
formats reviewed &
Organizational changes
incorporated, 5S Process
removed.
Changes as per standard done
wherever necessary.
10.08.2009
4
Issue No 5-
Rev. 1
6 1
Organization structure changed,
Separate Legal register
summarized HIRA , aspect &
Impact register
1.04.2010
5
Issue No 6-
Rev. 1
6 2
Scope of HSEMS
11.10.2010
6
Issue No 6-
Rev. 2
6 3
Scope of HSEMS
30.03.2011
7
Issue No 7-
Rev. 0
7 0
Legal register updated, new
departments incorporated
incorporated, procedures
modified, changes of scope,
addition of locations and changes
as per standard done wherever
necessary
15.09.2011
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8
Issue No 7-
Rev. 0
7 1
Legal register updated, Heating
MED department incorporated ,
incorporated
20.03.2012
9 Issue No 8 8 0
Legal register updated, B&H
Welding Cell, B&H MED,
B&H - IR departments
incorporated , Organizational
changes incorporated
25.09.2012
10 Issue No 8 9 0
The Apex Manual for HSE
management system is revised to
meet requirements of OHSAS
18001: 2007 and to cover the
changes in Organizational
structure. Legal register and
management system & reissued.
20.08.2013

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Issue No : 09 Doc.No : HSEAM/01/04
Rev. No : 00 Date : 20.08.2013
Cl. No : NA
Title

ABBREVIATIONS
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Abbreviations

B& H - Boiler & Heater
C& H - Cooling & Heating
C - Cooling
CNC - Computerized Numerically Controlled
CPCB - Central Pollution Control Board
DECO - Departmental Coordinator for HSEMS
Dept. - Department
DG - Diesel Generator
DISH - Directorate of Industrial Safety & Health
DH - Divisional Head
ER - Employee Representative
ETP - Effluent Treatment Plant
FH - Functional Head
FI - Factory Inspector
FMG - Factory Management Group
FM - Factory Manager
FR - Frequency Rate
H - Heating
HOD - Head of Department
HSE - Occupational Health, Safety & Environment
HSEMS - Occupational Health, Safety & Environment Management System
I/C - Plant Incharge/ service Incharge / Sectional Incharge
IR - Industrial Relations
LTI - Lost time injury incident
MAT - Material
MAINT - Maintenance
MFG - Manufacturing
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ABBREVIATIONS
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MHL - Man-hours Lost
MIG - Metal Inert Gas
MO - Medical Officer
MPCB - Maharashtra Pollution Control Board
MA - Management Appointee
MSDS - Material Safety Data Sheet
OCP - Operational Control Procedure
OHS - Occupational Health & safety
AM - Apex Manual
HSEMP - Occupational Health, Safety & Environmental Management program
PPE - Personal Protective Equipments
QAC - Quality Assurance, Control
RTIC - Research Technology Innovation Center
SAW - Submerged Arc Welding
S.I. - Safety Index
S.R . - Severity Rate
SUP - Supervisor
TBT - Tool Box Talk
TIG - Tungsten Inert Gas
TPH - Ton Per Hour
TR - Ton of Refrigeration
WI - Work Instructions

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LIST OF COPY HOLDERS
Page No : 1 of 1

Soft copy of HSE APEX Manual availablewith Factory Manager, Management Representatives,
and All HODs of all Department & Departmental Co-coordinators (DECO). Copy of APEX
manual is availableon Intranet (Lotus Notes Database.)
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TERMS & DEFINITIONS
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Following definitions apply for the purpose of standards of per OHS 18001:2007 and
ISO14001:2004 and integrated Management system for Occupational Health, Safety &
Environment, of the organization:
Terms and Definitions

3.1 Acceptable Risk: Risk that has been reduced to a level that can be accepted by the
organization, having regard to its legal obligation, and its own HSE policy.

3.2 Audi t: Systematic examination to determine whether activities and related results
conform to planned arrangement and whether these arrangements are implemented
effectively and are suitable for achieving the organizations policy and objective.

3.3 Correcti ve action:
Action to eliminate the cause of a detected non conformity

3.4 Continual Improvement: Process of enhancing HSE management system to achieve
improvement in overall occupational health and safety performances in line with the
organizations HSE policy

3.5 Document:
Information & its supporting medium.

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TERMS & DEFINITIONS
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3.6 Emergency: An emergency situation is a particular type of incident

3.7 Environment
Surroundings in which an organization operates, including air, water, land, natural
resources, flora, fauna, humans, and their inter-relation.

3.8 Environmental Aspect
Element of an organizations activities, products or services that can interact with the
environment.
NOTE: A significant environmental aspect is an environmental aspect that has or can have
a significant environmental impact.

3.9 Environmental Impact
Any change to the environment, whether adverse or beneficial, wholly or partially resulting
from an organizations environmental aspects.

3.10 Hazard: Source or situation or act with a potential for harm in terms of human injury or
ill health, or a combination of these.

3.11 Hazard Identi fication. Process of recognizing that a hazard exists
And defining its characteristics.

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TERMS & DEFINITIONS
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3.12 ILL health: - Identifiable adverse physical or mental condition, arising from and/or
made worse by a work activity and /or work related situation

3.13 Incident: work related event (s), in which, an injury, or ill health or fatality occurred
or could have occurred.

3.14 Interested Parties: individual or group within, or outside the work place, concerned
with or affected by the HSE performance of an organization.

3.15 Near miss / near hit/Close cal l / Dangerous Occurrence:
Is an incident, where no injury. Ill health, a fatality has occurred.

3.16 Non-conformity: any deviation from related work standard, practice, procedure,
regulation, management system performance etc. that could either directly or indirectly lead
to injury or illness, damage to the workplace environment, or a combination of these.

3.17 Objectives: goals, in terms of HSE performance, that, an organization sets itself to
achieve. NOTE: objectives should be quantified, wherever practicable; and are consistent
with HSE policy

3.18. Occupati onal Health and Safety (OHS)
Conditions and factors that affect the health of employees, or other workers, contractor
personnel, visitors and any other person in the workplace.

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TERMS & DEFINITIONS
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3.19 HSE Management System: part of the overall management system that facilitates the
management of the OHS risks/ environmental impacts, associated with the business of the
organization. This includes the organizational structure, planning activities, responsibilities,
practices, procedures, processes and resources for developing, implementing, achieving,
reviewing and maintaining the organizations HSE policy.

3.20. Organizati on: company, operation, firm, enterprise, institution or association, or part
thereof, whether incorporated or not, public or private, that has its own functions and
administration.
NOTE: for organizations with more that one operating unit, a single operating unit may be
defined as an organization.

3.21. HSE Performance: measurable results of HSE management system, related to the
organizations control of health and safety risks, and Environmental aspects, based on its
HSE policy and objectives.
NOTE: performance measurement includes effectiveness of the organizational Controls,
against set objectives & other performance requirements.

3.22. Occupational Health, Safety & Environment Policy
Statement by the organization of its overall intentions and directions in relation to its HSE
performance which provides a framework for action and for the setting of its environmental
objectives and targets.

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TERMS & DEFINITIONS
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3.23. Procedure:
Specified way to carry out an activity or a process.

3.24. Preventi ve action:
Action to eliminate the cause of potential nonconformity, or other undesirable potential
situation.

3.25 Record:
Document, stating results or providing evidence of activities performed.

3.26. Risk: combination of the likelihood of a hazardous event or exposure (s) and the
severity of injury or ill health that can be caused by the event or exposure(s).

3.27. Risk Assessment: process of evaluating the of risk(s), arising from a hazard(s)
taking into account the adequacy of existing controls and deciding whether or not the risk(
s) is acceptable.

3.28. Safety: freedom from unacceptable risk of harm.

3.29. Statutory: - Legal & other requirements applicable to organization.

3.30 Work Place: -- any physical location, where the work related activities are performed
under the control of organization.

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Introduction Of Organisation
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Thermax Ltd is a group of companies, well-known in field of Industrial Boilers, Heaters,
Chillers and environmental products, for more than 43 years.
The Registered Office of the Group company, with its manufacturing facilities, is located at
D-1, Block Plot No. 7, 12, 13, 21, 25 & 26, MIDC, Chinchwad, Pune -19.
The company is in the business of wide range of products, projects & services for Industrial
Heating & Cooling products, Boiler & Heater projects, Environmental products and projects
and cogeneration Projects:
The manufacturing premises for Boilers, Heaters and Chillers are located at M.I.D.C. in
Industrial belt of Chinchwad at Pune in an area of 2, 05,414 sq. m.

The manufacturing facilities include sophisticated processes like CNC machines for Plate
Cutting tube plate drilling, CNC drum drilling ,and coil forming ; and equipments like plate
rolling, tube bending, CNC, automatic & semi-automatic
MIG / TIG / SAW / projection welding, panel bending and panel-welding machines etc. The
manufacturing systems conform to national & international standards such as ASME, S,
U, PP & R stamps & other codes like IBR, ISO, DIN, GOST, BS & ABS. The layout of
manufacturing facilities is enclosed.

To ensure quality of products, the manufacturing facilities are complying with system
requirements as per standards ISO 9001:2000, ISO14001:2004 and OHSAS18001: 2007.
There are two main Business Groups, Cooling & Heating Products and Boiler & heaters
(Projects) working at Chinchwad factory & their products are:-

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Steam boilers: forced & natural circulation water tube & smoke tube on oil, gas, lignite
& husk
Fluidized bed combustion packaged boilers on coal & low-grade fuels like husk &
bagasse
Liquid & vapour phase thermic fluid heaters on oil, gas & solid fuels
Hot air / hot water generators on oil, gas & solid fuels
Oil / gas burner systems for boilers, heaters & furnaces
Steam-based fluidized bed tea dryers
Mobile, containerized hot water generators
High temperature thermic fluid heating systems
Oil fired shell type boilers
Conversion of old boilers to high efficiency fluidized bed boilers
Waste fuel & waste steam fired boilers on carbon monoxide, black liquor, turbine
exhaust gas, process & smelter exhaust gases
Heat recovery steam generators
Exhaust gas boilers on DG sets, gas turbines & furnaces
Process integrated boilers for sulfuric acid, nitric acid, caprolactum & sponge iron plants
Vapour absorption machines fired on steam, hot water & oil / gas (direct) upto a capacity
of 3000 TR.
Modular Vapour absorption machines , having 30 to 70 TR capacity range
Power Boilers ,
Packaged water tube FM boilers (upto 80 TPH)

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The products & services of other divisions of group of companies, at other locations, are:-
Waste water treatment, Water management, Air pollution control, Chemicals for water
treatment & oils, etc.

The company has regional offices all over India & also at U.K., U.S.A., Thailand, Malaysia,
Kenya, Indonesia, U.A.E., & Russia for Sales & Services.

Manufacturing Process flow, for Products manufactured in Chi nchwad factory

1. Procurement & receipt of Raw Materials, Consumables and components
2. Shot Blasting of Tubes/pipes./ plates/ in- process products
3. Cutting to size of Raw materials ( Plates, tubes/pipes )
4. Drilling/ boring of holes on tube plates
5. Welding of plate to plate / tube to tube
6. Rolling of plates to shell/ bending of tubes /pipes
7. Assembly & fabrication of pressure parts of boiler / chiller
8. Stress Relieving of Boiler Pressure parts
9. Hydraulic testing of boiler pressure parts /
10. Pneumatic & vacuum testing of chillers.
11. Performance Testing
12. Painting of Pressure parts/ chillers
13. Insulation / lagging
14. Packing of units
15. Shipping of Products to customers.

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INTRODUCTION OF
ORGANISATION
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Factory l ayout:-

Refer the copy of layout for factory available with HSEMA / Civil section of FMG.

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E. Cl. No : 4.0
O. Cl. No : 4.0
Title

SCOPE OF HSEMS
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The HSEMS system is applicable to Thermax Limited : Manufacturing facilities of Thermax
ltd. Group Businesses of (i) At Chinchwad Works Research, development, manufacture
and supply of industrial boilers, vapour absorption machines, heaters, Pressure vessels,
Heat exchangers and Thermo containers , located at D-1, Block Plot No. 7, 12, 13, 21, 25
& 26, MIDC, Chinchwad, Pune 411019, India. (ii) Savli Works : Manufacturing and supply
of industrial boilers, Heaters, Pressure Vessels and Heat Exchangers located at Plot No
21/1, 2&3, GIDC, Manjusar, Taluka- Savli, Vadodara 391775, India. (iii) Mundra works :
S.No. 169/P Village- Dhrub, Taluka Mundra, Dist Kutch, Gujrat. 370421, India.

The system is designed to meet the environmental Management standards of
ISO14001:2004 and Occupational Health & Safety Assessment series standards
OHSAS18001:2007 for activities of Research, Development, Manufacture & supply of
Industrial boilers, Vapour absorption Machines, Heaters, Pressure Vessels, Heat
exchangers, and Thermo containers and manufacturing supply of Industrial boilers,
heaters, pressure vessels, and heat exchangers etc.
Activities of contractors, suppliers, such as Civil construction, Electrical maintenance, water
& management, Insulation , lagging , shot-blasting ,painting , radiography, transport and
material handling , or those activities which have impact on health & safety of personnel
within / near premises, are included, in HSEMS.
The scope excludes: Design, Project sites & Site activities at customers, Regional Offices;
Design & Commercial activities at Head office & Corporate Office.

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Followi ng Departments Function at Chinchwad:
Sr.No. Name of the Department
1 Heating -Shell Production
2 Heating - Coil Production
3 Heating Maintenance
4 Heating QAC
5 Heating Stores & Shipping
6 Heating MED
7 B & H Production (Plant 5,12,15)
8 B & H Maintenance
9 B & H QAC
10 B&H Welding Cell
11 B&H MED
12 B & H ( Materials & Shipping )
13 B&H Employee Relations
14 B&H HR
15 B & H Production (Plant 1,2,3)
16 B & H HSE
17 Cooling Production
18 Factory Management Group (FMG)
19 FMG - Common Maintenance
20 Welding Engineering Department
21 Employee Relations
22 Human Resource
23 RTIC
24 Corp. HSE

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Title

SCOPE OF HSEMS
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E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title

General Requirements
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1. PREFACE:

The organization has established & documented the HSEMS for
Maintaining, and continually improving it.

2. PURPOSE

To establish, document, maintain & continually improve the Occupational Health, Safety
& Environmental Management System, based on specifications of OHSAS 18001: 2007
and ISO14001:2004.

3. SCOPE

(i) At Chinchwad Works Research, development, manufacture and supply of industrial
boilers, vapour absorption machines, heaters, Pressure vessels, Heat exchangers and
Thermo containers , located at D-1, Block Plot No. 7, 12, 13, 21, 25 & 26, MIDC,
Chinchwad, Pune 411019, India. (ii) Savli Works : Manufacturing and supply of industrial
boilers, Heaters, Pressure Vessels and Heat Exchangers located at Plot No 21/1, 2&3,
GIDC, Manjusar, Taluka- Savli, Vadodara 391775, India. (iii) Mundra works :
Manufacturing of Boilers located at S.No. 169/P Village- Dhrub, Taluka Mundra, Dist
Kutch, Gujrat. 370421, India.

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4. RESPONSIBILITY

4.1. FH and Dy. General Manager (Heating Operations) has the overall responsibility
for establishing & maintaining the system
4.2. HSE MA, HSECO, FH & HODs of various functions, Safety Officer, DECOs,
Employee Representative, shall comply with the HSEMS requirements, as applicable to
them.

5. PROCEDURAL DETAILS

5.1) Occupational Health, Safety & Environmental Management System shall be
established & maintained, by addressing all the requirements of OHSAS 18001 : 2007 and
ISO14001:2004. The effective implementation of the system shall be done , through the
following activities :

To bring about awareness of HSEMS to all Employees, and contractors.
Effective communication of Occupational Health ,Safety & environmental
Policy to all employees & training them.
To organize identification of Health and Safety related hazards & Assessment of
risk, environment related aspects and impacts in a structured manner.

To establish & document the HSE management Objectives & Targets and
management programs, Operational Control Procedures and Plans for handling
On-site Emergencies.

This takes into account requirements of the following:
* HSE Risks assessed...
* Companys HSE Policy.
* Applicable, HSE related Legal & other requirements.

5.2 ) To ensure effective implementation of HSE Apex Manual, Departmental Manuals,
Records, as documented.
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5.3) To demonstrate continual improvement in HSE Performance, as per
Organizational policy.

5.4) The HSEMS shall be reviewed as per HSEAM/460/01 for its appropriateness &
adequacy, periodically. Suitable corrective & preventive actions shall be taken by
concerned HOD/ Plant In-charge/ Co-coordinators/HSEMA, in case of any deviations.

6. REFERENCES
1. HSEAM :-- Apex Manual
2. HSE Departmental Procedure manuals

7. RECORDS:- Shall be maintained as per HSEAM/454/01

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Issue No : 09 Doc.No : OHSAM/420/01
Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.2
O.Cl. No : 4.2
Title

HSE Policy
Page No : 1 of 2

The Corporate Policy of Occupational Health, Safety and Environment, is prepared and
approved by Managing Director of the company. It is ensured that the Policy is understood,
implemented and maintained at all the levels in the organization.

The Occupational Health, Safety and Environment Policy has been defined
, such that it

Is appropriate to the nature & scale of organizations HSE risks/hazards.
Includes a commitment to continual improvement and prevention of injury, ill health.

Includes a commitment to comply with current applicable HSE legislation and
regulations, and with other requirements, to which the organization subscribes;

is documented, implemented and maintained and communicated to all employees,
with intent that employees are made aware of their individual HSE objectives, &
HSE performance.

Provides framework for setting & reviewing HSE objectives.

Is recommended to all persons working under the control Of the organization.

is displayed for employees and contractors; and made available to interested
parties., and public, on demand

is reviewed periodically to ensure , it remains relevant and appropriate
to the organization.

A copy of HSE Policy duly signed by the Managing Director, is enclosed

Note: 1) The Environmental Policy for the Chinchwad factory was originally
Issued in April, 2000.
2) The Occupational Health and Safety policy for the Chinchwad factory,
Was originally issued in J uly .2002.
3) The Corporate HSE policy is issued in J uly 2007 and is adopted in this manual
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.2
O.Cl. No : 4.2
Title

HSE Policy
Page No : 2 of 2

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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.3
O.Cl. No : 4.3
Title

Planning
Page No : 1 of 2

Thermax Limited, Chinchwad, has established a well defined system for planning
for identification of HSE hazards and assessment of associated risks, and, risk
control by deciding the HSE Objectives, and, setting up HSE management
programs, in which, it will be considered to achieve the set Objectives and Targets.
The Scope encompasses all relevant operational areas.

The respective HOD is responsible & accountable for identification of hazards,
assessing risks/impacts and deciding HSE Objectives and HSE Management
Programs; and implementing and monitoring them. These will be reviewed as per the
procedure for Management Review.

4.3.1 : HSE Hazards identification , risk/ Environmental Aspects impact
assessment & control

Thermax Limited has established & implemented Procedure for Hazard Identification
& Risk / Environmental Aspects impact Assessment of its activities. The identification
of hazards cover routine and non-routine activities, activities of personnel having
access to the work place and all facilities at the work place, considering human
behaviors, capability & other human factors .

The HSE hazard/risk- assessment is done, such that, Thermax Limited, can have
control over them. The HSE hazards and risk are reviewed to determine the
Significant Environmental Impacts and Unacceptable OHS Risks. The Significant
environmental impacts & unacceptable risks are considered in setting the HSE
Objectives and necessary control measures. The information regarding the HSE
hazards and Significant /unacceptable HSE Risks are kept up-to-date by conducting
internal HSEMS reviews, by considering the changes in organization/ facilities &
management system & application of their controls , prior to change.
Results of these hazard/ risk assessment are considered, when determining
controls.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.3
O.Cl. No : 4.3
Title

Planning
Page No : 2 of 2

4.3.2 : Legal and other requirements:
Thermax Limited has established Procedure for identifying Legal and other HSE
requirements, which are applicable to the HSE aspects of its Activities & Processes.
The information regarding legal and other requirements are made available by
subscribing to them and are kept up to date. Relevant information on these
requirements is communicated to employees and relevant interested parties.

4.3.3 Objectives And Management Programs

Thermax Limited, has established, documented and maintained a procedure for
identifying HSE Objectives & Management programs at relevant functions and levels
within organization. They are established through study of unacceptable OHS risks/
significant environmental impacts and deciding their control measures through HSE
management System Reviews, and are consistent with the HSE Policy.
Objectives shall be consistent with HSE policy, and measurable, where practicable
and shall include the commitments for prevention of injury and ill health and comply
with applicable legal and other Requirements, and continual improvements.

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Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Hazard Identification Risk
Assessment And
Determining Control
Measures Page No : 1 of 9

1. Preface:
Thermax Limited shall establish Procedure for Hazard Identification of OHS Hazards &
Environmental Aspects, Risk /impact Assessment of its activities.

The HSE hazard/risk- assessment shall be done, such that, Thermax Limited, can have
control over them. The HSE hazards and risk are reviewed to determine the
unacceptable OHS Risks and environmental impacts. The unacceptable risks and
impacts shall be considered for setting the HSE Objectives and other necessary control
measures. The information regarding the HSE hazards and Significant /unacceptable
HSE shall be kept up-to-date by conducting internal HSEMS reviews.

2. Purpose

To identify HSE aspects /hazards & assess HSE risks/impacts of the organization's
activities, in order to determine unacceptable OHS risks / environmental impacts, and
decide control measures, to reduce them to acceptable level.

3 . SCOPE
Covers all activities done in Chinchwad Works & Savli Works factory, which are under
direct control.

4. Responsibil ity

4.1 HSE MA, alongwith HSEMS Coordinator & Safety Officers, is
Overall responsible and accountable for documenting and
Implementing this procedure.
4.2 .Respective Departmental Heads are responsible and
Accountable to adhere to this procedure.
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Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And Determining
Control Measures
Page No : 2 of 9

5. Procedure : -

Sr.
NO.
ACTIVITY / TASK
RESP
ONSIB
ILITY
REF.
DOCUMENT
5.1 Assessment of unacceptable Environmental
Impacts and determining Control Measures

5.1.1 Identify & list all activities, operations, services of
department that have, or could have influence on
environmental aspects & impacts. Include all relevant
activities of employees /contractors / suppliers at
workplace, or outside workplace.
HOD &
Core
Team
memb
ers
List of activities
5.1.2. Identify the environmental aspects of activities
(identified) as ;
i) pollution of air/ water/ soil
ii) waste generation
iii) leakages/ spillages of oil/ chemicals
iv) resource wastage and consumptions
v) adverse effects on plants, animals and
human beings
vI) adverse effect on global environment ( like
Ozone depletion/ global warming )
Mention all identified aspects in Env. Aspect
Register.
HOD &
Core
Team
memb
ers
Aspect Register
format No
HSEAM/F/01
5.1.3 Assess the impacts of the Environmental aspects
identified by considering: A) their quantity, B)
occurrence, C) severity, D) legal impact , E) detection
mechanism available, and F) existing controls, as per
legends given in format of aspect Register and enter
every aspect in register
HOD &
Core
Team
memb
ers
Aspect Register
format No
HSEAM/F/01
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Control Measures
Page No : 3 of 9

5. PROCEDURE : -

Sr.
NO.
ACTIVITY / TASK
RESPON
SIBILITY
REF.
DOCUMENT
5.1.4. Calculate the value of G=A X B X C X D X E X F
5.1.5 Note, the Environmental impact is Unacceptable/
Significant (S), if the value of G exceeds 80. Enter S
& the value of G in register.
5.1.6 Note, the environmental impact is Unacceptable (S),
irrespective of value of G, if it adversely affects/ has
potential to adversely affect :
i) the Legal requirements (compliance to
applicable external laws or company
norms)
ii) Causes accidental / emergency impact, on
human beings /plants / animals , beyond
company norms

5.1.7 Decide the rank of impact as per following table.
5.1.7 Decide Control Measures (Training,
OCP/WI/MP/OSEP) on every aspect, in Register
which has significant environmental impact above 80,
to reduce the impact below 80.
HOD &
Core
Team
members
Register of
Significant
Aspects&
Impacts:- Format
No
HSEAM/F/02
5.1.8 Document the Environmental control measures in
respective formats and get the approval of HOD &
/ FH and circulate them to concerned members for
implementation and reviews. Include all control
measures in departmental manuals.
HSEMP, OCP,
WI, OSEP.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And
Determining Control

5. PROCEDURE: -

Sr.
NO.
ACTIVITY / TASK
RESP
ONSIB
ILITY
REF.
DOCUMENT
5.2 Assessment of unacceptable OHS Risks and
determining Control Measures

5.2.1 Identify & list all activities , operations ,services of
department/plant and their OHS hazards, that could
cause ill health or injury to personnel (employees
/contractors / suppliers etc) within own premises (or
in neighboring premises).Refer past Incidents/ ,
Major Injury Incident/ near misses /events /
emergencies .
HOD&
Core
Team
Memb
ers
List of activities
5.2.2 Note the OHS (Occupational Health & Safety)
hazards of activities (identified) and record them in
Risk Assessment Register.
Consider possible effects on human beings ( ill
health/injuries/ fatalities / disastrous situations )
HOD &
Core
Team
memb
ers
Risk Assessment
Register. format
No
HSEAM/F/03
5.2.2.1 The identification of hazards addresses :
routine and non-routine activistes,
activities of all personnel having access to the
work place, including contractors and
suppliers,
human behavior , capabilities & other human
factors,
Hazards created within and outside premises,
which can have adverse effect on health &
safety of personnel within organization.
existing infrastructure of equipments,
materials and facilities; and changes
proposed in existing activities , equipments ,
materials and facilities ,

HOD&
Core
Team
Memb
ers
Risk Assessment
Register. format
No
HSEAM/F/03

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And
Determining Control

Sr.
NO.
ACTIVITY / TASK RESPO
NSIBIL
ITY
REF. DOCUMENT
5.2.2.1 Changes done or proposed or temporary, in
management system/organization,
Legal obligations,
Design of work areas, processes, installations,
machinery/equipment, operating procedures and
work organization, including their adaptation to
human capabilities

HOD&
Core
Team
Membe
rs
Risk Assessment
Register. format
No
HSEAM/F/03
5.2 Assessment of unacceptable OHS Risks and
determining Control Measures

5.2.3 Evaluate OHS Risks of identified hazards, by
considering: S) their severity of effect on ill
health/injury, P) Probability of occurrence
factor, F) Frequency of operation, D) Duration
of impact, as per charts given below, & enter them
in Risk Assessment Register.
HOD &
Core
Team
membe
rs
Risk assessment
Register format No
HSEAM/F/03
5.2.4 Calculate RAN ( Risk assessment Number) for every
hazard identified ; RAN=S X P X F X D
HOD
Core
Team
membe
rs /
HOD
Register of
Unacceptable
Risks & Control
Measures
HSEAM/F/04
5.2.5 Top 10 activities having more RAN no is
unacceptable.

5.2.6 Note all Unacceptable Risks in Risk assessment
Register, and decide suitable control measures
(OCP/WI/TBT/HSEMP/ OSEP) to reduce the RAN
no, to reduce hazard of body-injury / health
hazard & record them in Register HSEAM/F/04.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Control Measures
Page No : 6 of 9

5. PROCEDURE : -

5.2.8. CHART FOR EVALUATION OF OHS RISK RATING

S. SEVERITY OF RISK Rating
Minor impact :- First aid 1
Moderate Impact: Non LTA incident/ injury 2
Serious impact : ( Away from work for more than 48
hours), or serious possible injury
3
Major Impact :-- LTA incident / fatal injury incident 4
Catastrophic impact :Fatality / permanent disability for
more than 1 person/ major fire/ explosion
5
P. PROBABILITY OF INCIDENT :
1 every 10000 operations 1
Most likely to happen, any time 5
F. FREQUENCY OF OPERATION
Everyday 4
1 to 2 times a week 3
1 to 2 times a month 2
1 to 2 times a year 1
D. DURATION OF IMPACT
1 to 8 hours 2
8 to 48hours 3
More than 48 hours 4
Fatality 6

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And
Determining Control

5. PROCEDURE: -
Sr.
NO.
ACTIVITY / TASK RESPON
SIBILITY
REF.
DOCUMENT
5.2.9 Control measures shall be established before any
operation is started / changes are done in any
operation, to bring down the RAN to acceptable
level. Effectiveness of existing control measures
shall be considered and recorded. Prioritization of
control measures is done, to bring effectiveness of
control in set time frame.
When determining controls, or considering
changes to existing controls, consideration shall
be given to reduce the risks according to following
hierarchy:
a) elimination;
b) substitution;
c) engineering controls
d) signage,/warning and or administrative control;
e) Personal protective equipment.

5.2.10 Guidelines for deciding control Measures:
Value
of
RAN -
range
Rank Control Measure desired Record
a 0- 80 1 Take Quick corrective actions,
conduct Training , set & follow
OCP /WI/ TBT to maintain RAN
below 80
HOD &
Core
Team
member
Training plan/
OCP/WI/TBT
b 80 to
200
2 Take quick corrective measures
and Design OHSMP/OSEP,
Training & OCP/WI/TBT and
comply in set time-frame.
Monitor and do not allow the
RAN to exceed 80 any time.
1)Quick-
Corrective action
to bring RAN
value to <80 and
2) OHSMP,
OCP/WI/TBT;
,Training

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And
Determining Control

Sr.
NO.
NSIBILI
TY
REF. DOCUMENT
5.2.10
Guidelines for deciding control Measures:
Value
of RAN
-range
Rank Control Measure desired Record
c 201 to
600
3 Stop the activity; Take
temporary corrective measures.
Design& install OHSMP/OSEP
and OCP/WI/TBT and comply in
set time-frame. Monitor and do
not allow the RAN to exceed 80,
any time.
HOD
& Core
Team
member
1)Plan of
Temporary
Corrective action
to bring RAN
below 80
2) OSEP/OHSMP,
OCP/WI/TBT;
,Training
5.2.11 The OHS control measures , identified as per this
procedure , shall be documented in Dept. manual
and implemented as per relevant procedures,
to bring the unacceptable risks, to
acceptable level
Review and update the Registers for
Unacceptable OHS Risks (Format no
HSEAM/F/04) and Register for Significant
Environmental Aspects and Impact ( format No
HSEAM/F/02), at least once in a year , or, in
following cases:

Whenever new additions/major modifications are
carried out /planned the activities/ processes/
machines or
After each incident/ accident/near miss for HSE
aspects, or
5.2.12
Amendments/Additions to legislative requirements
as applicable are made.
HOD
& Core
Team
member
1) OSEP,OHSMP,
OCP/WI/TBT;
Training
2) Departmental
HSEMS Review ,
3) Apex
Management
Review

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
Cl. No. of E : 4.3.1
Cl. No. of O : 4.3.1
Title
Assessment And
Determining Control

6. REFERENCES
1) List of activities in a Department,
2) Past Incidents/Major Injury Incident / Near Misses & Emergency Situations.
7. RECORDS.
7.1. Register of Environmental Aspects & Impacts (Format: HSEAM /F/01)
7.2 Register of Significant Environmental Impacts (Format: HSEAM /F/02)
7.3 . Register for OHS -Risk Assessment (Format: HSEAM /F/03)
7.4. Register for Unacceptable OHS Risks & Control Measures (Format
: HSEAM /F/ 04).

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title

LEGAL AND OTHER
REQUIREMENTS
Page No : 1 of 5

1. PREFACE:
Thermax Limited shall establish Procedure for identifying Legal and other HSE
requirements, which are applicable to the HSE aspects of its Activities & Processes.
The information regarding legal and other requirements shall be made available by
subscribing to them and shall be kept up to date. Relevant information on these
requirements shall be communicated to persons working under the control of the
organization (including employees, contractors & suppliers).

2. PURPOSE
To establish and maintain procedures for identification, documentation and compliance of
Legal (legislative, regulatory) and other requirements, as applicable to the HSE related
aspects of the activities and services.
3. SCOPE
This procedure is applicable to all activities & services, at Chinchwad factory.

4. RESPONSIBILITY.
4.1 HSEMA is overall responsible for documentation & compliance of this
Procedure.
4.2. HSECO, HOD( Safety) , Safety officer, and
Concerned HOD are responsible for implementing & reviewing this procedure

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title

Legal And Other
Requirements
Page No : 2 of 5


Sr.
NO.
SIBILITY
REF.
DOCUMENT
5.1 Identify the applicable Legal & other requirements as
per procedure for Hazard identification risk
assessment and determining control measures"
and Register for Intolerable OHS -Risks & Control
Measures (Format :HSEAM /F/ 04 ) and Register of
Significant Environmental Impacts (HSEAM/F/02)
HOD
(Safety) /
HSECO
1)Register
format
HSEAM/F/02
2)Register
format
:HSEAM /F/ 04 .
5.2 Procure/avail all the publications on
Rules/Regulations/ Acts, related to HSE aspects, as
applicable to Thermax Ltd, for applicable Rules.
HOD
(Safety) /
HSECO
List of
Applicable HSE
Legal & Other
Requirements.
5.3 Study the rules, regulations & other requirements /
Licenses,/consents etc.,and their applicability, to the
HSE aspects & their impacts , by referring to the data
from concerned department .
HOD
(Safety) /
HSECO
Applicability of
HSE Rules
5.4 Decide the threshold limits, as per stipulated legal
requirements, for applicable aspects, and the
responsibility, frequency of review etc as per Register
.Fill in the applicable details in Register.
HOD
(Safety) /
HSECO
Register format
HSEAM/F/05
5.5 Decide the threshold limits, as per stipulated legal
requirements, for applicable aspects, and the
responsibility, frequency of review etc as per Register
.Fill in the applicable details in Register.
HOD
(Safety) /
HSECO
Register format
HSEAM/F/05

5.51 Prepare and maintain the Register of applicable Acts
/ Rules & Regulations in format no.HSEAM/F/05,
incorporating applicable legal and other requirements,
related to HSE aspects, of activities.
HOD
(Safety) /
HSECO

Register format
HSEAM/F/05.
5.52 Communicate to all concerned departments,
applicable amendments, in the Acts / Rules, for their
actions and update the Register of applicable Acts /
Rules & Regulations No.HSEAM/F/05, accordingly,
in such cases.
HOD
(Safety) /
HSECO
Register format
HSEAM/F/05
.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Issue No : 09 Doc. No : HSEAM/432/01
Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title

Legal And Other
Requirements
Page No : 3 of 5

5.6 Apply in advance for the renewal of Licenses/
consents / authorizations under statutory
requirements, as specified in the Act / Rules.
HOD
(Safety) /
HSECO

5.7 Team consisting of Factory Manager, HSEMA ,
HSECO, HOD Maintenance & Safety officer, should
evaluate the compliance of the legal and other
requirements, once in three months.
HOD
( Safety )
& Legal
Team
Compliance
status of Legal
Register :
HSEAM/F/05
5.8 Record the findings of evaluation of compliance ,
related to legal and other requirements,
covering :
a) Validity of licenses, consents and
authorizations.
b) Submissions of documents to legal authorities,
such as Reportable Major Injury Incident.
c) Notification / Publication by Government
authorities / Social authorities and replies for
the same.
d) Verification of records, maintained at different
areas / operations.
e) Information to MPCB/DISH in case of
reportable accident/ discharge / emission or
justification with respect to Consent/ Factory
act, exceeding norms,. Compliance to other
requirements. Such as Customer requirements
from Contract review (QMS as per ISO9001:
2000) from relevant dept / authority .Update in
HSE Rules & other requirements and their

HOD
(Safety) /
HSECO
Compliance
status of
Register :
HSEAM/F/05

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title

Legal And Other
Requirements
Page No : 4 of 5


S.
NO.
ACTIVITY / TASK RESPONS
IBILITY
REF.
DOCUMENT
5.9 Take appropriate decisions for corrections, in case of any
discrepancies / non-compliances, observed during the
review, by the team and record the same.
Share the status of compliance of Legal & Other
requirements in Apex Management review.
HOD
(Safety)/
HSECO
MOM of
Apex
Management
review
5.9.1 Identify applicable legal & other requirements, at
department/ plant / section level and train the concerned
person on requirements and how to comply them.
HOD
/Incharge
(Concerne
d )
Legal
Register :
HSEAM/F/05
5.9.2 Review the compliance of applicable legal & other
requirements, at dept. / plant/ section level at least once a
month and report monthly to HSEMA/ HSECO through
monthly report of Dept Review and HSE Performance
Self Evaluation report.
HOD
(Safety)/
HSECO
MOM of
Monthly
Dept Review
and HSE
performance
Evaluation
Report
5.10 Review & evaluate compliances, of legal and other
requirements, every month at factory level & report to
Factory Manager.
HOD
(Safety) /
HSECO
Monthly
Legal
Compliance
Report
Review & revise Register for Legal & Other requirements
1) after each 6 months
2) Whenever changes / additions in laws / public
notifications are released to public.
5.11
3)Other applicable requirements are generated by :
a) Customers (through contract).
b) Stakeholders ;
Membership agreements like Confederation of Indian
Industries/ Maratha Chamber of Commerce
HOD
(Safety) /
HSECO

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By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title

Legal And Other
Requirements
Page No : 5 of 5

6. REFERENCES:
6.1 Register of Significant Aspects & Impacts (Format: HSEAM /F/ 02)
6.2 Register of unacceptable Risks & Control Measures: (Format :HSEAM /F/ 04),
6.3 Register of Legal & Other Requirements ( Format : HSEAM/F/05)

7. RECORD: -
7.1 Register of Legal & Other applicable Requirements: Format No. HSE AM/F/05
7.2. Monthly Compliance report, of Legal & Other requirements.
7.3. MOM of Apex management Review Format No. HSE AM/F/32
7.4 MOM of Monthly Review of Department
7.5. HSE Performance Evaluation Report for Dept / plant

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By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.2
O. Cl. No : 4.3.2
Title
Register Of Legal & Other
Requirements
Page No : 1 of 1
REGISTER OF LEGAL & OTHER REQUIREMENTS Format No. HSEAM/ F/03, Rev.01
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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.3
O. Cl. No : 4.3.3
Title

OBJ ECTIVES , TARGETS
& MANAGEMENT
PROGRAMS
Page No : 1 of 2

1. PREFACE:
The Objectives & targets for HSEMS shall be set in line with HSE
Policy, and will be relevant to the HSE aspects and impacts of activities.

2. PURPOSE
To establish and maintain procedures for setting & achieving Objectives and targets
Of Occupational Health and Safety.

3. SCOPE
The procedure is applicable to all activities, in Chinchwad factory.

4. RESPONSIBILITY
FH (Heating operations) & FM, HSEMA, HSECO, Safety Officer & All HODs.
Sr
NO.
SIBILITY
REF.
DOCUMENT
5.1 HSE objectives and targets shall be set to prevent injury & ill
health and adverse Environmental Impacts & recorded in
Objectives & Targets & HSEMPs format No. HSEAM/F/06 by
HOD & DECO , with help of HSECO and HSEMA , with
consideration of :
Register of Unacceptable OHS Risks/ env. Impacts
Legal concern
Interested Party Concern.
Training Needs
HOD Format No.
HSEAM/F/06
5.2 HSE objectives and targets shall be specific and measurable. It
should have specific responsibility and time frame for
completion
HOD
5.3 While setting the objectives, practical feasibility, technical,
financial, operational and business requirements, shall be
considered.
HOD
Authority , responsibility and accountably for establishing ,
documenting and implementing the Objectives, targets and
HSEMPs shall be clearly identified and Resources shall be
provided for implementation
HOD
5.4 Objectives and targets shall have Performance indicators, set
at various levels, in departments.
HOD

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.3
O. Cl. No : 4.3.3
Title

Objectives , Targets &
Management Programs
Page No : 2 of 2


S.
NO.
ACTIVITY / TASK RESPONS-
IBILITY
REF.
DOCUMENT
5.5 Relevant objectives and targets shall be reviewed
and revised, in case of Incidents, Major Injury
Incident, / near miss, occupation related health
hazards, emergencies, Or new projects,
modifications in existing process, plants, as & when
required.
HOD
5.6 The progress and achievement of objectives of a
department, shall be reviewed and recorded in
MOM of Dept review (format: -- HSEAM/F/30) and
HSEMP Review & Progress Report in format No.
HSEAM/F/10.
HOD 1)Format No :--
HSAM/F/30);
2) Format No.
HSEAM/F/10.
5.7 Progress shall be reported to HSEMA / HSECO
and FH(Concerned) ,every month, by concerned
HOD through MOM of Dept Review and Report of
Self evaluation of HSE performance for the dept
HOD MOM of monthly
dept review/ Self
evaluation report
of monthly HSE
performance
5.8 Progress of Occupational Health And Safety
objectives and targets ,shall be reviewed
quarterly by Management Review Committee, in
Management Review, organized by HSEMA ,
HSECOE, Safety Officer and recorder.
HSEMA MOM of Apex
management
review
6. REFERENCES
6.1. Register of Significant Environmental Impacts & control Measures : Format
No. HSEAM/F/02;
6.2. Register of Unacceptable Risks & control Measures: Format No.
HSEAM/F/04.
7. RECORDS
7.1. Objectives & Targets & HSEMPs: Format No. HSEAM/F/06
7.2. HSEMP -Review & Progress Report: Format No. HSEAM/F/10
7.3 .MOM of Monthly dept review.
7.4. Self evaluation Report of monthly HSE performance
7.5. MOM of Apex management review

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.4
O. Cl. No : 4.3.4
Title
HSE Management
Programmes
Page No : 1 of 3

1. PREFACE: The HSE management Programs shall be taken, based on
Significant/Unacceptable HSE impacts, of activities of organization,
to reduce them to acceptable level and to achieve continual
Improvements. They will be in line with set objectives and policy.

2. PURPOSE
To establish & implement Occupational Health And Safety Management Programs for
achieving set objectives and targets, in line with HSE policy. .

3. SCOPE

This procedure is applicable to all activities, in Chinchwad factory having HSE impacts.

4. RESPONSIBILITIES

4.1. HSEMA & HOD (Safety) is overall responsible for documenting,
Establishing and ensuring compliance of this procedure.
4.2. Respective HODs and DECO & others are responsible for
Implementation of this procedure.

S.
NO.
ACTIVITY / TASK RESPONSIBIL
ITY
REF.
DOCUMENT
5.1 Refer Objectives & targets set as per procedure
no. HSEAM/433/01.
HOD
(concerned )
Format No
HSEAM/433/0
1.
5.2 HSEMP owner to develop HSEMPs, & document them
in Format No. HSEAM/F/08 at departmental level, by
identifying specific responsibility, accountability of tasks
and completion time frame.
HOD
(concerned )
Format No.
HSEAM/F/08
5.2.1 Set the performance parameters for measurement of
objective/s and HSEMPs, under consideration.
HOD
(concerned )
HSEMPs
5.2.2 Consider technological options and priorities of
objectives.
HOD
(concerned )

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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.4
O. Cl. No : 4.3.4
Title
HSE Management
Programmes
Page No : 2 of 3


Sr.
NO
ACTIVITY / TASK RESPONSIBIL
ITY
REF. DOCUMENT
5.3 Organize the special help, if needed from outside
Expert, for development and execution of HSEMP.
HOD
(concerned
)/HSEMA
Format No.
HSEAM/F/08
5.4 For interdepartmental activities, get the agreements done
with concerned & HOD for completing tasks, as per
HSEMP.

HOD
(concerned) &
HSEMA
Format No.
HSEAM/F/08
5.5
Provide necessary financial & manpower support to meet
the set targets/ performance parameters, in time frame.
As planned.

FH /HOD
(concerned )
Format No.
HSEAM/F/08
5.6 Review the HSEMP. HSECO Format No.
HSEAM/F/08
5.7 Approve the HSEMP. HOD Format No.
HSEAM/F/08
5.8
Monitor & review the progress with owner of
HSEMP, at least once in a month , & record it, in format
HSEMP Review & Progress Report format
no.HSEAM/F/05 to HSEMA.. Ensure proper implementation
of HSEMP as per plan. Report compliance status monthly
to HSEMA through MOM of Departmental review and HSE
performance evaluation report fro dept ./ Plant.

HOD
(concerned )
1) HSEAM/F/05 2)
MOM of Monthly
dept review ,
3)HSE -
performance self
evaluation report
5.9
Revise HSEMP, under following situations:
Occurrence of Incident/Major Injury Incident/
Near miss/ Emergencies /addition of New /
modification in the processes /changes in levels
of Risks.
Changes in set objectives, their time frame &
responsibility for completion, etc
.To speed up the achievement of set objectives
Deviations in set norms/ implementation or
request from HODs, in case of abnormal
situations like strikes / delays by contractors/
suppliers / transporters etc.

HOD
(concerned )
Format No.
HSEAM/F/08
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.3.4
O. Cl. No : 4.3.4
Title
HSE Management
Programmes
Page No : 3 of 3


S.
NO.
ACTIVITY / TASK RESPONSI-
BILITY
REF.
DOCUMENT
5.10 Record & communicate any changes/modifications in
HSEMP through Document Change Note format
No.HSEAM/F/18.
HOD
(concerned)
format
No.HSEAM/
F/18
5.11 Review progress of HSEMP every month & report
progress with CA/PA for compliance to
HSEMA/HSECO/Safety officer in format HSEAM/F/10
HOD
(concerned)
HSEAM/F/10
5.12 Inform consolidated status of all HSEMPs in dept/ plant
, once in 3 months, before Apex Management Review
as input to HSEMA/ HSECO , HSEMA to share the
factory level status of all HSEMPs, Objectives & targets
in apex management review ,
HOD
(concerned) &
HSEMA
format
No.HSEAM
5.13 Evaluate the targets/ performance parameters and
Close the HSEMP, after the time frame.
Report the closing status to FH (Dept) & HSEMA.
HOD
(concerned)
HSEAM/F/08

6. REFERENCES:
6.1 .Objectives & targets: Format No. HSEAM/433/01.

7. RECORD: -

7.1 .HSE Management ProgramFormat No. HSEAM/F/08
7.2 HSEMP- Review & Progress Report Format No. HSEAM/F/10
7.3 .Document Change Note format No. HSEAM/F/18
7.4 . MOM of apex management review Format No.
7.5 Monthly MOM of Dept. review,--Format No.--
7.6 Monthly HSE performance evaluation Report: -- Format No.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.0
O. Cl. No : 4.4.0
Title

Implementation And
Operation
Page No : 1 of 5

Thermax Limited shall define a structured framework and provide steps to ensure effective
implementation and control of HSE Management System by providing essential resources.

4.4.1: ORGANIZATIONAL STRUCTURE AND HSE MANAGEMENT
SYSTEM RESPONSIBILITY:

The Organizational structure of HSE Management System, responsible for Implementation
and Review of HSE Management System, is detailed in Organizational Chart.
The HSE system, Responsibility and Authority, with regard to implementation and
continuous monitoring, of, established System activities, are given in HSEAM/441/01
Resources, Roles, Structure, Responsibility, Accountability & Authority

(See attachment)

Chinchwad Factory
HSE Organisation Structure

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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.0
O. Cl. No : 4.4.0
Title

Implementation And
Operation
Page No : 2 of 5

RESOURCES

Thermax Limited shall identify its resources, essential to the implementation and control of
the HSE Management System activities. The resources include Human Resource,
Specialized skills, and Technological and Financial resources. The system ensures
assignment of trained personnel for all these activities.

HSE MANAGEMENT APPOINTEE, SYSTEM-COORDINATOR, AND SAFETY OFFICER

FH (Heating Operations) Mr. A. G. Kshirsagar has appointed Mr. C. A. Darawade as
HSEMR, Mr. Sharad D Arade as HSECO. And Mr. Rupesh Yadav, Saheblal Shaikh, Atul
Mohite, Sachin Gardi , Sudhir Mane, Abhijeet Gawarle as Safety Officers.

4.4.2: TRAINING, AWARENESS AND COMPETENCE

Thermax Limited shall establish, maintain & implement Procedure for Training, Awareness
and Competence, to identify the training needs for the personnel, whose work, involves
SHE hazards and risks. This procedure includes, the Suppliers and Contractors, operating
at Thermax Limited.

4.4.3: CONSULTATION & COMMUNICATION & PARTICIPATION

Thermax Limited has established and maintained a Procedure for consultation &
Communication which ensures:
HSEMA, under guidance of Factory Manager, shall have effective consultation &
communication with employees, at various levels and department functions of the
Company.
External communication with Legal authorities and interested parties, by HSEMA, under
guidance of Factory Manager.
Receiving, Documenting and Responding to relevant communication from
Legal Authorities and interested parties.
Mr. Keshav Gholve is appointed as Employee Representative, who is responsible for
consultation & communication, with workers, on HSEMS related matters.
Dr. Kanitkar & Mr. Bhakare D. N. is appointed as Health Coordinator, who is responsible
for Consultation & Communication on Occupational Health related matters.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.0
O. Cl. No : 4.4.0
Title

Implementation And
Operation
Page No : 3 of 5

4.4.4: HSE SYSTEM DOCUMENTATION:

Thermax Limited, has established and documented the Occupational Health And Safety
Management System, in 4 levels as detailed below :

Level 1: HSEMS Apex Manual - Describes the core elements of the
Occupational HSE Management System and how the requirements of
OHSAS 18001:2007 and ISO 14001:2004 are complied.
This includes common procedures used, HSE registers, formats &
Work Instructions and Registers, like Register for Applicable Rules and
Regulations, On Site Emergency Plan, etc.

Level 2: Departmental Manuals & Documents

Operational Control Procedures: address the method of
monitoring the various operational characteristics, which affect the
HSE aspects.
Work Instructions/ Dos & Don ts/Tool Box Talks: address
individual operations, affecting OHS aspects..
HSE MP addresses the objectives & targets, decided in
department.
Registers/ formats / data/ information:- Register of
Unacceptable OHS Risks & Registers of Significant Environmental
Impacts, Formats , data/ references , used in OCPs / WIs /
HSEMPs.
On-Site Emergency control measures
Records: used for conveying and recording data, essential to
operate & maintain HSEMS.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.0
O. Cl. No : 4.4.0
Title

Implementation And
Operation
Page No : 4 of 5

4.4.5: DOCUMENT CONTROL:

Thermax Limited shall establish and maintain procedure for Document Control for
controlling all levels of Documents to ensure that they are periodically reviewed,
revised as necessary and approved for adequacy by Authorized Personnel and
controlled. The procedure provides for availability of pertinent documents in
authorized locations and for removal of obsolete documents from point of issue or
use. The changes in document are reviewed and approved by the original approving
authority unless otherwise stated as per procedure.

A master list of documents is maintained with HSEMA / concerned HOD giving the
issue and revision status of each of the documents, and is readily available to
preclude use of obsolete documents.

All documents are given unique numbers.

All manufacturing and technical documents, documents of external origin such as
National and International standards, are also covered under the document control
procedures. The standards of external origin are controlled by subscribing to
recognized updating services and circulation within the company.

Where obsolete documents are required to be kept for legality and knowledge
purposes, suitable identification methods are established.

Wherever documents and data are in the form of electronic media, Thermax Limited
ensures adequate data protection and security.

All the Documents are controlled such that they are legible with revision number with
date and are readily identified and maintained in an orderly manner. The retention
period for the specified documents is established in the procedure for Document
Control.
The issuing and approving authorities of documents are mentioned in Document
Control Procedure.
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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.0
O. Cl. No : 4.4.0
Title

Implementation And
Operation
Page No : 5 of 5

4.4.6 . OPERATIONAL CONTROL:

Thermax Limited, Chinchwad, shall establish the procedure for Operational Controls, to
minimize / reduce risks that are evaluated as unacceptable Risks, & Env. Impacts and that
are in line with the HSE Objectives and Targets.

4.4.7. ON- SITE- EMERGENCY - PREPAREDNESS & RESPONSE:

Thermax Limited, shall establish Procedure for Emergency Preparedness and Response to
potential emergencies/ incidental situations, wrt HSE aspects of operations and OHS
hazards to Personnel (within and neighboring area), and damage to Environment;
The procedure deals with preventing and mitigating activity - related HSE impacts of
emergency situations, in factory; and addresses needs have interested parties.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
Resources, Roles ,Structure
, Responsibility
Accountability & Authority
Page No : 1 of 8

ORGANISATIONAL STRUCTURE OF
HSEMS AT THERMAX LTD, CHINCHWAD FACTORY

(See attachment)
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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 2 of 8

Management Responsibi lity:

The Functional Head (Heating Operations), has ultimate responsibility for
Occupational Health And Safety Management System. He is also responsible
for setting policy for Occupational Health, Safety & Environment.

Management Reviews are conducted by Management Review Committee,
every three Months, to assess the effectiveness of HSE Management System.
If necessary, the committee shall allocate resources for taking Corrective and
Preventive actions on Non-Conformances.

The Management Review Committee advises and monitors the establishment
and implementation of HSE Management System.

HODs, Dept. in-charges, Supervisors, HSEMA, HSECO,, Safety Officials are
responsible for implementing Management Programs , at departmental level..
All the employees/ contractors are responsible for implementing and
maintaining HSE Management System.

Verification activities, including internal HSEMS Audit, are carried out at the
direction of Management Review committee and team of Internal Auditors.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 3 of 8

The organization structure for HSEMS, of Thermax Ltd, Chinchwad factory , is as per
Organization Chart. The responsibility and authority of key personnel have been defined
in the following paragraphs:

1. Managing Di rector

He is the Chief Executive of the organization at Chinchwad factory and has overall
responsibility for laying down HSE Policy, and objectives of the organization. He is also
responsible for providing resources and personnel for implementation of policy.

2. FH (Heati ngOperations) & Factory Manager

He has executive responsibility of the organization for design & implementation of
HSEMS, at Chinchwad factory.
He ensures that HSE Policy is understood, implemented and maintained at all levels in
the Organization.
He is responsible to extend support and resources in implementing HSE Management
System and to achieve improved HSE performance.
He is also responsible to review HSE Management System at appropriate intervals, to
ensure its continuing suitability and effectiveness. Monitoring of effectiveness of the
system shall be done through Management Reviews, at specified Interval. He is a
authorized to approve the Apex level documents.
He is responsible for appointment of Management Appointee.
He is Chairman of Apex Management Review Committee
The delegation of authority may also be issued by him, during his absence.

3. FH ( OPERATIONS HEAD COOLING )
He is overall responsible for evaluation of HSE aspects & impacts of operations for
respective production & production services. He will ensure that, the appropriate control
measures to reduce the HSE impacts to tolerable / acceptable level, are designed and
implemented. He will review and monitor the progress of HSEMPs periodically and take
CAPAs to ensure their compliance, in time frame. He will give inputs to HSEMA/HSECO
about compliance of HSE requirements, and continual improvements. He will initiate/
approve CAPA on system Non- compliances and approve the departmental level
manuals/ documents.
He is a member of Apex management Committee.

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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 4 of 8

4 Management Representative (M.R.)

He is a responsible to establish, document, implement and maintain HSEMS
effectively in accordance with OHSAS 18001-2007 and ISO14001:2004 at
Chinchwad Work.
He is a responsible to guide HODs, to set the objectives and authorized to review
progress of objectives and targets.
You are responsible to plan and is authorized to conduct internal HSEMS audit, to
determine the effectiveness of HSEMS and to initiate, co ordinate and verify
corrective and preventive actions to close the non conformance observed during the
audit.
You are responsible to plan and co ordinate Management reviews and report
performance of HSEMS to top Management.
You are responsible to ensure understanding & implementation of HSE policy, at all
levels in the organization and design and implantation/ review & revision of HSEMS
in line with Policy and applicable Standard/s.
You are authorized to initiate necessary changes in the APEX Manuals and
responsible to circulate the controlled copies of the same.
You are responsible in reviewing and assessment of available processes,
equipments and other resources, as well as, to identify, the need for acquisition of
any additional technology, equipment and resources affecting HSE aspects;
conducting training program in accordance with OHSAS 18001-2007 and ISO14001
to crate and maintain awareness among employees.
He is responsible to plan and is authorized to conduct internal HSEMS audit, to
determine the effectiveness of HSEMS and to initiate, co ordinate and verify
corrective and preventive actions to close the non conformance observed during the
audit.
He is responsible to plan and co ordinate Management reviews and report
performance of HSEMS to top Management.
He is authorized to initiate necessary changes in the HSE Manuals and is
responsible to circulate the copies of the same.
He is responsible to guide HODs, to set the objectives and authorized to review
progress of objectives and targets.
He is responsible for liaison with the certifying body for assessment activities.
In his absence Factory Manager, oversees his function. The delegation of authority
may also be issued by him, in his absence.

He is member of Management Review Committee
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5 . HOD - Corporate HSE

He is responsible to ensure understanding & implementation of HSE policy, at all
levels in the organization and design and implantation/ review & revision of HSEMS
in line with Policy and applicable Standard/s.
He is responsible to provide resources maintain the factory premises and ensure
that, legal requirements, of HSE related issues, are met as per Legal Register, and
are communicated with Legal authorities.
He is responsible to ensure & review at appropriate intervals, the continuing
suitability and effectiveness of the HSE Policy.
He is responsible to interact with interfacing functions for cross-functional issues.
He is over all responsible for providing technical support in respect of all HSE
problems.
He is responsible to make policy available to public.
He is responsible in reviewing and assessment of available processes, equipments
and other resources, as well as, to identify, the need for acquisition of any additional
technology, equipment and resources affecting HSE aspects.

6. HOD( RTIC) :- He is responsible for implementing HSEMS
Requirements, relating to developments, testing / trials of products of the
Company. He is responsible for communicating & implementing HSE policy
at departmental level, including contractors. He is responsible for
Assigning roles & responsibilities of various operational controls, to ensure
Compliance to policy
He is responsible for Risk assessment and establishing & implementing HSEMS
requirements, Objectives, HSEMPs, OCPs, WIs, Legal requirements. He will ensure,
Major Injury Incident, incidents are reported & CAPA taken, as per stipulated
procedures. He will ensure, HSE performance of dept is timely monitored as per system
requirements and informed to HSEMA/ HSECO on monthly basis.
He is member of Management Review Committee.

7. HOD (Employee relations)
He is overall responsible for identification of HSE aspects of Security / Fire Fighting,
canteen operations and training of workers and contractors personnel. He will ensure
appropriate control measures are designed and implemented to meet the HSE
requirements as defined in the Apex and departmental procedure manuals. He will
review the HSE related Mps and take CAPA for their compliance.
He is a member of Apex Management committee.
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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 5 of 8

8. HOD (Materials: - Cooling / Heating / B & H / Shipping):--
He is responsible for implementing HSEMS requirements, relating to following
Functions:--
a) Procurement of consumables, raw materials
b) Transport, storage, handling & issue of materials (including Hazardous Chemical) in
factory or outside factory.
c) Final disposal of scrap & wastes from factory.;
He is responsible for communicating & implementing HSE policy at all
Departmental levels, including contractors. He is responsible for assigning
Roles & responsibilities of various operational controls, to ensure compliance to
policy.
He is responsible for Risk assessment and establishing & implementing
HSE MS requirements, Objectives, HSEMPs, OCPs, WIs, Legal requirements,
relating to Materials activities in Chinchwad factory. He will ensure, Major Injury Incident,
incidents and emergencies wrt HSE and CAPA are taken and reported, as per stipulated
Procedures. He will ensure, HSE performance of dept is timely monitored as per system
requirements and informed to HSEMA/ HSECO on monthly basis.

9. HSE Management System Coordinator (HSECO)
He is responsible to assist HSEMA for all his activities related to HSEMS. He is responsible
to plan and co ordinate drafting Apex Manuals, Internal & External Audits and Management
reviews, at specified intervals.
He is responsible to keep informed all concerned, of latest changes and developments
regarding HSEMS, from time to time.He is responsible for providing technical support to
implementation of Objectives and Targets and HSE management programs.. He is member
of Management Review Committee
In his absence for HSEMS activities, HOD HSEMA oversee his function.

10. Safety Officer:--
He is responsible for HSE related activities, drafting, reviewing & revising Apex manuals,
guide departmental Heads & coordinate for implementing the OHS procedures, as per HSE
manuals .He is responsible for reviewing compliance to OHS dept. legal requirements, and
initiate corrective actions. He will coordinate internal audits/reviews, and assist in external
audits .He will assist the HSECO/HSEMA/DECOs, in reporting status and data on HSEMS
implementation, to management, periodically. He will evaluate the OHS related
performance of dept./plant & report to HSECO/HSEMA. He will assist the plant/dept.
member HOD, DECOs for investigation of Major Injury Incident / near miss & guide them for
designing CAPA for prevention. He wills hase with DISH/OHS related authorities for legal
matters in consultation with HSEMA/HOD safety.
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 7 of 8

11. HOD (Heating QAC):-- He is responsible for communicating & implementing HSE
policy at all departmental levels, including contractors. He is responsible for assigning roles
& responsibilities of various operational controls, to ensure compliance to policy
He is responsible for Risk assessment and establishing & implementing HSEMS
requirements of Objectives, HSEMPs, OCPs, WIs, Legal requirements, relating to Welding
and QA activities in Chinchwad factory. He will ensure, Major Injury Incident, incidents and
emergencies wrt HSE and CAPA are analyzed and reported, as per stipulated procedures.
He will ensure, HSE performance of dept is timely monitored as per system requirements
and informed to HSEMA/ HSECO on monthly basis.

12. HOD (RTIC):-He is responsible for assisting FH for compliance to HSEMSrequirements,
during R & D activities. He is responsible for planning & execution R & D projects and trials
of various Energy & Environment related equipments, as per requirements of Business
divisions.
He is responsible for compliance to applicable legal requirements and
System & Procedures, as per Management Review Manual.

13. HOD- Production :-( COIL Products) / (SHELL Products) / Cooling products, or,
HOD B& H- Production : ( ESD Products ) /HOD ( Panels & Coils )
He is over all responsible for manufacturing of respective products. He is responsible to
communicate the HSE policy, roles and responsibility, to all employees in department.
He is responsible to assess the Risks & establish Control measures and document and
maintain records as per HSEMS, at departmental level
(HSEMPs and OCPs and WIs).; He is responsible to provide training to departmental
persons for awareness of HSEMS, operational controls , emergencies etc.,. He is
responsible for, ensuring operational safety, during production and takes necessary
corrective & preventive actions, in case of Major Injury Incident / incidents. He will establish
emergency prevention & control measures, in his dept. He will monitor & improve the HSE
performance as per set objectives.& report the same to authorities . He is member of
Management Review Committee. In his absence, Factory Manager, oversees his function

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1
Title
, Responsibility
Page No : 8 of 8

14. DECO:--
He is responsible for assisting HOD in complying to HSEMS requirements of department/
plant and coordinate with HSEMA/ HSECO./ HSEER and HSE Committee Members . He
will organize reviews at departmental level and internal audits and Safety checks in
department. He will coordinate to conduct analysis of non conformances in HSE system
implementation, investigation/ analysis/ reporting and prevention of incidents/Major Injury
Incident by initiating CA PA on them.

15. EMPLOYEE REPRESENTATIVE
He is responsible for communication of concerns for employees for HSE related
Issues .He will ensure the participation of workers, in the identification of HSE aspects &
impacts , developing and completing management programs and compliance of related

work instructions and relevant emergency handling procedures and plans. He is a member
of Apex management committee.

16. HSE -SHOP -COMMITTEE - MEMBER:
The appointed HSE Committee member at plant / department shall be responsible for
identifying HSE aspects and deciding control measures and their implementation at
operating level, of workers and contractors, at the work place.
He will audit to find out unsafe conditions and unsafe acts / non compliances to
departmental WIs and report to Chairman of Shop HSE committee. He will be a member of
Shop HSE committee.

List Of Responsible Personnel In The HSEMS Organization

List of personnel responsible for HSEMS at Apex and Departmental levels, shall be
maintained, updated and circulated by Management Appointee and concerned
Departmental Head.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 01 Date : 20.08.2013
E. Cl. No : 4.4.1
O. Cl. No : 4.4.1
TITLE

List Of Responsible &
Accountable Personnel
Page No : 1 of 2

List of Responsible & accountabl e personnel in the HSEMS organi zation
Sr No Position Name
1. Operation Head-Heating & Factory Manager (FH) A.G. Kshirsagar
2. Operation Head-B&H (FH) M.S.Patil
3. Operation Head-Cooling (FH) S.K. Wale
4. Corporate Head-HSE B.K.Mathur
5. Head-ER Suhas Ghatwai
6. HOD (HR) Pallavi Rege
7. HOD- (RTIC) V.V.Dubal
8. HOD-B&H Material & Shipping S. K. Raichur
9. HOD-Heating QA&C & WED Ranganathan J oshi
10. HOD(B & H Production 5,12,15) R. Alvares
11. HOD ( B&H QAC) D S Patil
12. HSE Employee Representative (HSE ER) Keshav Gholve
13. HOD(Production Heating Coil products)
14. HOD(Production Heating Shell products)
15. HOD Heating Maint
S.N.Shinde
H.B.Firke
A.N.Deshmane
16. HOD C& H Material Stores & Shipping M.V.Natu
17. HOD ( Cooling Production ) Ravindra Patil
18. HODFactory Maintenance Group M M Kulkarni
19. HOD(B & H Maint) R. Alvares
20. HOD B&H Production (1,2,3) R. Alvares
21. HOD-Training Sujata Deshpande
22. DECO (RTIC) Vinod Bachakar
23. DECO ( QAC) Sanjay Patil
24. DECO ( MAT C&H) Salim Patil
25. HOD B&H Welding Cell Chnadrakant Vaidya
26. HOD B&H MED V.K.Shah
27. HOD B&H -IR Suhas Ghatwai
28. DECO - B&H Welding Cell Hemant Kadam
29. DECO B&H MED Anil Deore
30. DECO B&H -IR G.B.Pote
31. DECO B&H QAC Gautam Kulkarni
32. DECO Heating Maint Mahadeo Gajare
33. DECO B & H -MAT
C. Sasidharan & Saju
Devassy
34. DECO ( ER ) B.Murali
35. DECO ( MAINT B & H MFG)
Kashinath Torkade &
Vinod Shitole
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.1
O.Cl. No : 4.4.1

TITLE
List Of Responsible &
Accountable Personnel
Page No : 2 of 2

LIST OF RESPONSIBLE PERSONNEL IN HSE MS ORGANISATION
Sr No Posi tion Name
36. DECO ( FMG ) Sudhir Suryawanshi
37. DECO B & H -MAT
C. Sasidharan & Saju
Devassy
38. DECO ( B&H Production Plant 1,2 and 3) Sudhir Mane
39. DECO ( B&H Production Plant 5,12 and 15)
Sanjay Madhav &
Chandrashekhar
Wavare
40. DECO ( HEATING -SHELL PRODUCTION) A.V.Railkar
41. DECO (C & H production :COIL products ) U.V.Yenurkar
42. DECO ( B&H Production Plant 5,12 and 15)
Sanjay Madhav,
C.Wavre
43. DECO B&H HSE Sudhir Mane
44. DECO Corporate HSE Sachin Gardi
45. DECO Common Maitenance Kishor Kardile
46. DECO (HR) Yogendra Godse
47. Incharge Security & Fire Officer G.B.Pote
48. HOD (Corporate HSE) Rupesh Yadav
49. HSEMR Madan Kulkarni
50. HSEMS Co-coordinator (HSECO) Sharad D.Arade
51. Safety Officers
Sachin Gardi, Atul
Mohite, Sudhir Mane,
Anand Gangasagar
52. Occupational Health Coordinator D. N. Bhakare
53. Safety Committee Members Of Various Plants
As per departmental
organization

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.2
O.Cl. No : 4.4.2
Title

Training, Awareness And
Competence
Page No :1 of 3

1. PREFACE: - Thermax Limited shall establish and maintain Procedure for Training,
Awareness and Competence, to identify the training needs for the personnel, whose
work, involves Significant Impact on Occupational Health and Safety & Environment .
2. PURPOSE
To identify training needs and provide training, to comply with HSE
Management System requirements.

3. SCOPE
Personnel performing activities related to HSEMSat Chinchwad factory

4. RESPONSIBILITY
4.1. HSEMA - for providing training to staff.
4.2. HOD IR - for providing training to workmen and Contractors
4.3. Concerned HOD & DECO & Plant Incharge
S.
NO.
SIBILITY
REF.
DOCUMENT
5.1 List the employees / group of employees of the
organization including contractors/suppliers, whose work
may create unacceptable HSE, related
hazards/Risk/impacts to personnel.
HOD List of
Employees &
Contractors
5.2 Decide the competency requirement of individuals in the
dept, as per HSEMS (awareness/
knowledge/skills) wrt ;
HSE policy
HSE Risks and its impacts & evaluation
Objective and targets of the organization
Compliance with legal& other requirements
Role and responsibility of employee in
effective implementation of HSE MS
Emergency preparedness and response
HSE Operational Procedures and WIs
And prepare a matrix of competency requirement for
worker, supervisor, Incharge , Manager and contractors,
( whose work has unacceptable / significant HSE
impacts).
HOD Matrix of
competency
requirement.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.2
O.Cl. No : 4.4.2
Title

Competence
Page No :1 of 3

S.
NO.
ACTIVITY / TASK RESPON-
SIBILITY
REF.
DOCUMENT
5.3 Identify the competency level of each person,
against requirement, whose work may create
significant risk / health hazard, and indicate any
training needs required, in Format for
Competency, Training Needs, Plan & Status-
HSEAM/F/11.
HOD Format No
HSEAM /F/11
5.4 Prepare training plan based on training needs ,
identified by HODs ,and circulate to all HODs
HOD Format No
HSEAM /F/11
5.5 Provide formal / informal training resources to all
personnel as per the training plan, to fulfill
training needs. In case of individuals remaining
absent for Training Program, HOD shall take the
responsibility to fulfill the training need and inform
training department accordingly.
Manager
(Training)
& HOD
Format No
HSEAM /F/11
5.6 In case, it is not possible to fulfill the need, HOD
may revalidate the need in the next training
calendar year.
HOD
5.7 Evaluate effectiveness of training, between 1 & 3
months
but ,before 6 months, from the training date..
If an individuals training, is not found to be
effective and could not be retrained, HOD may
revalidate that particular training need.
HOD
5.8
While recruiting /personnel selection, HOD shall
consider the requirements of knowledge and skill with
respect to HSEMS. If his work could create a
significant impact upon the HSE aspects, provide him
necessary training.
For such new recruitment, HOD shall identify the
training need and communicate to training
department. In order to impart knowledge of HSEMS
requirements/its parts , HOD shall ask the new
person, to go through the HSE Apex manual &
Departmental Manual..
HOD
5.9 Maintain records in respective formats, as above,
for any additional training provided.
HOD
( Training)
Format No
HSEAM /F/11

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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.2
O.Cl. No : 4.4.2
Title

Competence
Page No :1 of 3


S.
NO.
IBILITY
REF.
DOCUMENT
5.10 Develop new training modules / reviewed & modify,
whenever, changes in requirement of knowledge or
skill, are attached, due to the changes in activities /
processes / standards / legal & other requirements.
HOD
( Training)
Format No
HSEAM /F/11
5.11 Maintain all the training records. Make these records
available to concerned HOD, periodically and as and
when required.
HOD
( Training)
Format No
HSEAM /F/11
5.12 Develop new training modules .Review & modify
existing ones, whenever, changes in requirement of
knowledge or skill are desired, due to the changes in
activities / processes / standards / legal & other
requirements.
HOD
( Training)
Format No
HSEAM /F/11
5.13 Maintain all the training records. Make these records
available to concerned HOD, periodically and as and
when required.
HOD
( Training)
Format No
HSEAM /F/11

6. REFERENCES

6.1. List of employees & Contractors;
6.2. Competency requirement matrix.

7. RECORDS:

7.1. Competency, Training needs / Training Plan and status:
---Format No. HSEAM /F/11

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.3
O.Cl. No : 4.4.3
Title

Consultation,
Communication &
Participation
Page No :1 of 3

1. PREFACE:
Thermax Limited shall establish and maintain a Procedure for consultation &
Communication which ensures:
HSEMA, under guidance of Factory Manager, has effective consultation &
communication with employees, at various levels and department functions of the
Company.
External communication with Legal authorities and interested parties, by HSEMA,
under guidance of Factory Manager.
Receiving, Documenting and responding to relevant communication from
Legal Authorities and interested parties.
Mr. Keshav Golve employee representative is consulted & on HSEMS related
matters.
Mr. Bhakare D. N. Health Coordinator, who shall be Consultated &
Communication on Occupational Health related matters.
2. PURPOSE
To establish and maintain the procedure for effective consultation, internal and
external communication with employees, ER and interested parties.
3. SCOPE
This procedure is applicable to HSE aspects of activities in Chinchwad factory.
This procedure includes:
a) Consultation with employees, employee representatives.
b) Internal communication with relevant employees and,
c) External Communication with legal authorities and concerned interested
Parties.

4. RESPONSIBILITY
4.1. HSE MA is overall responsible for establishing and maintaining
Documented procedure,.
4.2. Responsibilities of HSECO, HODS, DECOs, Safety Officer &
HOD (Safety & Legal) & others are as per this procedure.
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.3
O.Cl. No : 4.4.3
Title

Consultation,
Communication &
Participation
Page No :2 of 3

5. PROCEDURAL DETAILS:
5.1 : Internal communication:-
S.
NO.
SIBILITY
REF.
DOCUMENT
5.11 Form HSE Committees and establish procedures for
consultation with employees on various activities &
issues in HSEMS at departmental and apex levels.
HOD
5.12 Consult employee Representatives & SC members,
during preparation of various HSE procedures, including
hazard/Risk Assessment.
HOD
5.13 Train employees and contractors as per training plan

HOD Format No.
HSEMA/F/11
5.14 The HSE policy of the organisation shall be conveyed to
all employees, contractors and displayed at common
places, for easy access to all, including visitors and
interested parties.
HSEMA
& HOD

5.14.1 The workers/ representatives shall be involved in hazard
identification & risk assessment exercise and deciding
control measures, accident-investigation and
management reviews.
HSEMA
& HOD /
DECO

5.15 Documented procedures, Work instructions, management
plans & Onsite Emergency plan, shall be communicated
to concern as per Common procedure for HSEMS
documentation, HSEAM /444/01, in soft / printed form.
HSEMA
& HOD

5.16 Other communication -methods such as e-mails, displays,
newsletters, notices, bulletins, Minutes of meetings,
training programs shall be used as appropriate to the
content and target audience.
HSEMA
& HOD

5.17 The communication may be done in form of electronic
media ( e-mail , intranet) or hard ( printed ) form.
HSEMA
5.18 Changes in HSEMSdocuments shall be communicated,
as per procedure no. HSEAM/445/01, for Document
Control.
HSEMA
5.19 Log internal communications in internal communication
Format HSEMA/F/13
DECO Format
No.HSEAM/F
/13
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.3
O.Cl. No : 4.4.3
Title

Consultation,
Communication &
Participation
Page No : 3 of 3

5.2. External Communi cation

Sr.
NO.
ACTIVITY / TASK RESPONSIBI
LITY
REF.
DOCUMENT
5.21 The HSEMA , under guidance of FM, shall establish
suitable procedures for handling enquiries, complaints
from external/ legal & interested parties and
communicating with them & enter them in external
communication register
HSEMA Format No
HSEAM/F/12
5.22 HSEMA to determine, if the legal/contractual & Other
requirements exist, to provide information to relevant
interested party, and shall ensure timely response. He
shall consult with respective business associates,
where required.
HSEMA
5.23 Log communications & response. , in Register for
external communication, in Format No.
Safety Officer Format No
HSEAM/F/12

6. REF. DOCUMENTS:--
6.1 Register for Internal Communication; Format No. HSEAM/F/13
6.2 Register for External Communication No. HSEAM/F/12
6.3. Document Change Notes (Format No. HSEAM/F/18).

RECORDS:
7.1 Register for Internal Communication; Format No. HSEAM/F/13
7.2 Register for External Communication No. HSEAM/F/12
7.3 . Document Change Notes (Format No. HSEAM/F/18).
7.4 . MOM of HSE related meetings,.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.4
O.Cl. No : 4.4.4
Title

HSEMS Documentation
Page No :1of 5

1. PREFACE: Thermax Limited, has established and documented the HSE
Management System, in 2 levels as detailed below:
2 . PURPOSE: To establish procedure for documentation and effective implementation of
HSE Management System.
3 . SCOPE
This procedure is applicable to HSEMS related documents for activities within Chinchwad
factory.
4. RESPONSIBILITY
4.1. HSEMA/ HSECO are overall responsible for documenting this procedure. 4.2.
HODs , DECO & others responsible for the compliance of this procedure.
Sr.
NO.
ACTIVITY / TASK RESPONSIBI
LITY
REF.
DOCUMENT
5.1 Define the levels & contents of documents, in Apex
level & Departmental level documents.. as per table
no 1
HSEMA/
HSECO
Table no 1
5.2 Identify need of HSE operational control Procedure
and document them in the standard format, given as
follows: PURPOSE, SCOPE, RESPONSIBILITY,
PROCEDURAL DETAILS, and REFERENCES.
HSEMA/
HSECO

5.3 All procedures have top block with TITLE, ISSUE
NO.REV. NO., DOC. NO., CLAUSE NO., DATE,
AND PAGE NO.
HSEMA/
HSECO

5.4 The documents shall be in specified formats and
shall be prepared, reviewed and approved, as per
assigned responsibilities. Refer list of Common
formats. Last page of document will be approved, by
authority. Specified.
HSEMA/
HSECO
List of
common
formats
5.5 Code nos shall be used to indicate clause wise
documents , as per ISO14001:2004 and
OHSAS18001:2007, as listed in table No .2
HSEMA/
HSECO
Table No 2
5.6 Identify departments by of various codes as listed in
Table 3.
HSEMA/
HSECO
Table No. 3
5.7 Prepare the departmental documents as per
Formats specified in this procedure.
HOD
( Concerned )
Dept
documents
5.8 Follow the examples given below table no 3, for
identifying Apex & Dept level documents, clause
wise.
HOD
( Concerned )
Examples for
identification

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.2
O.Cl. No : 4.4.2
Title

Competence
Page No :1 of 3

Table 1 : Levels and Contents of documents
Level
of
docu-
ment
Name of
document
Contents
1 HSE Apex
Manual
( HSEAM)
HSE Policy, Objectives, Company profile, Organizational structure
and common procedures addressing the requirements of OHSAS
18001-2007, and ISO14001:2004. This also consists of Legal
Register, List of Objectives, on site emergency plan, Common
Operating procedures, Common Formats, as applicable.
2 HSE
Departmental
Manual
(HSE DPM)
Register of Significant Environmental Impacts & control Measures,
Register of Unacceptable Risks and Control measures,,, List of
Departmental Objectives & Targets, HSEMPs ,Operational Control
Procedures, Work Instructions, Tool Box talks related formats,
lists, Process / Product Standards, MSDS, etc. This also includes
records, maintained and disposed at the departmental level, as
applicable.

Table 2:
Identification of Clause wise Code numbers for documents, in Apex Level &
Departmental level
OHSAS
18001:1999,
Clause Titl e
OHSAS
18001:2007,
Clause No.
ISO14001: 2004,
Clause Title
ISO14001
:2004,
Clause
No.
Code used
in
Numbering
of
Document
OHS Policy 4.2 Environmental
Policy
4.2 420
Planning for
Identification of
hazards & Risk
Assessment &
Risk Control
4.3.1 Environmental
aspects
4.3.1 431
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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.4
O.Cl. No : 4.4.4
Title

HSEMS Documentation
Page No : 3 of 5

OHSAS18001:200
7 Cl ause Title
OHSAS18001
:2007 ,Clause
No.
ISO14001:2004,
Clause Title
ISO14001:
2004,
Clause
No.
Code used in
Numberi ng of
Document
Legal and Other
requirements
4.3.2 Legal and Other
requirements
4.3.2 432
Objectives 4.3.3 4.3.3 433
Management
Programs
4.3.4
Objectives , targets
and programmes

4.3.3 434
Resources ,Roles,
Responsibility ,
accountability , &
Authority
4.4.1 Resources, roles ,
responsibility &
authority
4.4.1 441
Training,
Awareness
,Competence
4.4.2 Competence,
Training &
Awareness.
4.4.2 442
Communication,
Participation &
Consultation ,
4.4.3 Communication 4.4.3 443
Documentation 4.4.4 Documentation 4.4.4 444
Document & Data
Control
4.4.5 Document & Data
Control
4.4.5 445
Operational Control 4.4.6 Operational Control 4.4.6 446
Emergency
Preparedness and
Response
4.4.7 Emergency
Preparedness and
Response
4.4.7 447
Performance
Measurement and
Monitoring.
4.5.1 Monitoring &
Measurement.
4.5.1 451
Evaluation of
Compliance
4.5.2 Evaluation of
Compliance
4.5.2 452
Incident
investigation , , Non
Conformity and
Corrective &
preventive actions
4.5.3
Control of records 4.5.4 Control of Records 4.5.4 454
Internal Audit 4.5.5 Internal Audit 4.5.5 455
Management
Review
4.6 Management Review 4.6 460
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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.4
O.Cl. No : 4.4.4
Title

HSEMS Documentation
Page No : 4 of 5

Table no 3. : Department wise code Nos

Department Dept. Code
Heating Production ( Shell Group) SHELL
Heating Production ( Coil Group) COIL
Production -Cooling COOLING
B&H Production (Pl.5,12,15) B&H
B & H Production TBW Pl.1,2,3 TBW
Heating / Cooling Materials MAT
B& H-Materials B&H- MAT
C & H Quality Assurance , Control QAC
Welding & Training Welding
Factory Maintenance Group FMG
Research Technology & Innovation
Center
RTIC
Industrial Relations IR
HSE Management Appointee HSEMA
HSE Management Representative HSEMR
Human Resource HR
Corporate HSE HSE
B & H Safety B&H HSE
B & H QAC B & H QAC

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Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.4
O.Cl. No : 4.4.4
Title

HSEMS Documentation
Page No : 5 of 5

Examples of identification of Documents:-

1. HSEAM / 445 / 01 where HSEAM=Occupational Health, Safety &
Environmental Apex Manual, 445 =Indicates that the document addresses to
clause 4.4.5 document control, and 01 =indicates that document is one,
under this clause.
2. ESD / OCP / 01 where ESD =indicates department B & H -ESD-
production,
3. OCP: Operational control procedure in the department and
4. 01: Indicates that procedure number is one in the department.

5. FORMATS: Dept. Code / F / Sr. No. of Format in the department

6. WI or DOS & DONTS: Department Code / WI / Sr. No. of Format in the
department

6. REFERENCE: --6.1. List of Common HSE Records/ Formats

7. RECORDS: 7.1. Apex manual
7.2. Departmental manual

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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.5
O. Cl. No : 4.4.5
Title

Document Control
Page No : 1 of 5

1. PREFACE: Thermax Ltd shall establish the procedure for controlling all
System documents and data as per specified standards and shall
Maintain them.
2. PURPOSE
To establish, implement and maintain the procedure for controlling all documents
and data required in HSE Management System.

3. SCOPE
This procedure is applicable to internal / External documents pertaining to the HSE
Management System, in Chinchwad factory.

4. RESPONSIBILITIES

4.1. HSEMR is overall responsible for documenting this procedure.
4.2 Other responsibilities are as given in procedure..
4.3. All members of HSEMS shall follow the procedure.

All the HSEMS documents shall be reviewed and approved by authorized
Persons as per Matrix, given below:

S.
NO.
ACTIVITY / TASK RESPONSI
BILITY
REF.
DOCUMENT
5.1 Follow the control of document as per matrix for
Document control.( refer table no 1). All the HSEMS
documents shall be reviewed and approved by authorized
personnel as per Matrix, for Document control.
HSEMR/
HOD/
Concerned
Table no 1
5.2 The Copies of Manuals after approval HOD shall be
forwarded to HSECO for uploading on Intranet (Lotus
Notes Database). HSEMR shall ensure availability of all
Apex and Dept. manuals on Intranet.
HSEMR/
HSECO/
HOD
Master copy
of Document
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By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.5
O. Cl. No : 4.4.5
Title

Document Control
Page No : 2 of 5

S.
NO.
ACTIVITY / TASK RESPONSI
BILITY
REF.
DOCUMEN
T
5.2.1 The HSEMS documents shall be available in soft copy on
Intranet (Lotus Notes) are authenticate and valid for
reference & use.
All
Employees

5.3 Soft copy is available on Lotus notes server for easy
access to all HODs and DECO of all department.
HSEMR/
HOD

5.4 Uploaded copy on Intranet (Lotus Notes) are in electronic
form need not required signature.
HSEMR
5.5 Prepare a list of Documents generated & maintained,
which have been received by the Department.
Incorporate them in Documents Control Master in
Format No. HSEAM/F/17
HSEMR/
HOD
Format No.
HSEAM/F /
17
5.7 Document - initiator shall maintain a list of documents
with current revision status and upload on Intranet (Lotus
Notes) as per procedure (Document Control procedure)
DECO /
HSECO

5.9 Review the documentation system at least once in a six
month or when any change in procedure. If any change in
document, is required, follow step no. 5.7 of this
procedure.
Concerned
HOD/
HSEMA.

5.10 Maintain list documents of external origin. Documents of
external origin shall be updated through regular
interaction with Law -bookpublishers/ Legal officers/ as
applicable.
HSEMA List of
documents/
Rules of
External
origin
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.5
O. Cl. No : 4.4.5
Title

Document Control
Page No : 4 of 5

Table 1: Matrix for Document control:
Documents
Prepar
ed-ed
by
Revie-
wed by
Approv
ed-ed
by
Issued
by
Amend-
ment
made by
Amend-
ment
approve
d by
Retenti
on
Period
HSE Apex
Manual
HSECO HSEMR FM HSECO HSECO FM 2 years
HSE
Common
Procedure
Manual ,
formats and
lists
Safety
Officer
HOD HSEMA Safety
Officer
Safety
Officer
HSEMA 2 yeas
Departmental
manual , OCP/
WI / TBT/
related
formats and
lists

DECO
HOD FH DECO HOD FH 2 years
HSE MP DECO HOD FH DECO HOD FH 2 years
On Site
Emergency
Plan
Safety
Officer
HOD
(Safety)
FM Safety
Officer
HOD
(SAFETY)
FM 2 years
Legal and
other
requirements
Updation
Nil Nil Nil Safety
Officer
Nil Nil Upto 2
years ..
Applicable
Standards
Updation
(National/
International)
Nil Nil Nil HSECO Nil Nil Upto 2
years ,
MSDS

Nil Nil Nil Safety
Officer
Safety
Officer
Safety
Officer
Till in
use.

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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.5
O. Cl. No : 4.4.5
Title

Document Control
Page No : 5 of 5

6. REFERENCES
6.1. Standard ISO 14001: 2004
6.2 Standard OHSAS 18001: 2007
6.3 List of documents of external origin.
6.4 List of Applicable Legal & other requirements.

7. RECORDS:
7.1. Document Control master, Format No. HSEAM/F/17
7.2. Document Change Note, Format No. HSEAM/F/18.

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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.6
O.Cl. No : 4.4.6
Title

Operational Control
Page No : 1 of 3

1. PREFACE: Thermax Limited shall establish Procedure for Operational
Control on activities having HSE impacts, to eliminate or reduce
Unacceptable HSE
Hazards/ risks to acceptable level.

2. PURPOSE
To establish & maintain documented procedure to
a) To identify operations / activities associated with HSE related hazards and
b) To determine the operating control measures to eliminate the risks/ reduce
Risks to acceptable level.
c) To monitor the same.
3. SCOPE.
This procedure covers all operations /activities, in Chinchwad factory
, having HSE Impact on organization, and applicable to contractors also.
4. RESPONSIBILITY
4.1 . HSEMA is overall responsible for documenting, reviewing his procedure.
4.2. HOD concerned is overall responsible or implementing this procedure.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.6
O. Cl. No : 4.4.6
Title

Operational Control
Page No : 2 of 3


Sr.
NO.
SIBILITY
REF. DOCUMENT
5.1 Decide the operational controls ( as control
Measures from Register of Significant Impacts /
unacceptable Risks and Control Measures )
monitoring and maintaining methods , of identified
activities, operations ( to reduce/ minimize the
significant HSE impacts)done by
employees/contractors/suppliers:
a) Activities, which have significant
Environmental impacts / intolerable
OHS risks.
b) Activities emphasized through policy &
objectives.
c) Activities related to emergencies.
d) Activities related to legal & other
requirements.
e) If desired by HOD, any operation
related to non-significant risk.
f) Purchase & use of equipments or
services or materials
Activities related to consumptions of resources
and waste-generation and disposals
HOD 1)Format:
HSEAM /F/02
2)Format:
HSEAM/F/04
3)OCPs/WIs /
Does & Donts

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.6
O. Cl. No : 4.4.6
Title

Operational Control
Page No : 3 of 3


Sr.
NO.
ACTIVITY / TASK
RESPON
SIBILITY
REF. DOCUMENT
5.2 Document the nature of operational controls for
above identified activities in the form of
Operational Control Procedure / Work
instructions/DOS & Donts / TBT , to cover
situations ,where, their absence could lead to
deviations from the HSE policy and objectives
HOD Departmental OCPs
Format No.
HSEAM/F/14;and
WIs / DOs & DONTs /
TBT:- . HSEAM/F/15 &
16
5.3 Specify the operating conditions/criterias /
acceptance limits/tolerances, in procedures.
Wherever controls are of quantitative in nature,
specify them.
HOD Departmental OCPs/WIs
/ Does & Donts / TBT
5.4 Communicate relevant operational control
procedures and requirements to employees,
suppliers and contractors and monitor their
compliance. They will be displayed at respective
work places.
HOD Departmental OCPs/WIs
/ Does & Donts / TBTs
5.5 Review the HSE aspects & impacts periodically
for effectiveness of operational controls
implemented / performance criterias, and initiate
suitable corrective actions.
HOD 1) Register for
Unacceptable Risks and
Control-Measures Format
no. SEAM/F /04
2)Register for Significant
Aspects & Impacts
Format No HSEAM/F/02
5.6 Report the compliance status in Monthly review. HOD Monthly Dept Review
. HSEAM/F/30 ;
6. REFERENCES
6.1. Register for Significant Aspects & Impacts Format No HSEAM/F/02
6.2. Register for Unacceptable Risks and Control Measures Format No.HSEAM/F/04
7. RECORDS: --
7.1Operation Control Procedure Format No. HSEAM/F/14
7.2. Work Instructions/ TBT Format No. HSEAM/F/15 & 16.
7.3. Deviations & CAPA plan in Dept Review-Format No. HSEAM/F/30
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Issue No :08 Doc. No : OHSAM/447/01
Rev. No :00 Date : 20.08.2013
E. Cl. No : 4.4.7
O. Cl. No : 4.4.7
Fire
Emergency
Preparedness &
Response
Page No : 1 of 2

1. PREFACE:

Thermax Limited shall establish Procedure for Emergency Preparedness and Response to potential
emergencies/ accidental situations, wrt. Occupational Health & Safety of Personnel, and damage to
Environment; The procedure deals with preventing and mitigating impacts of such incident/Major Injury
Incident/ emergencies , in the factory.

Emergency planning is an integral part of the overall control program and is essential for any well run
organization. This is important for effective management of an incident/incident to minimize losses to
people and property, both in and around the facility. The important aspect in emergency management is
to control an emergency by technical and organizational measures

2. PURPOSE

To establish plan and procedure for dealing with responses to emergency situations and to
Minimize risk to human health, damage and environment.

3. SCOPE

Applicable to accidental / emergency situation, which means any significant, non-routine situation, which
endangers the life, health of personnel in factory, or in surroundings environment of other interested
parties. These may arise as a result of undesired events due to Fire & Explosion during activities in
Chinchwad factory.

4. MAJOR SUBSTANCES HANDLED & HAZARDOUS PROCESSES/OPERATIONS

4.1 Foll owing chemicals are being used in manufacturing activiti es.
Sr.No Chemical use
4.1.1 Diesel Used as fuel for DG Set
4.1.2 Acetylene/Oxygen Used in Gas cutting process
4.1.3 Thinner & paint are used in plant
4.1.4 LPG used in company.
4.1.5 LDO (Light diesel oil)
4.1.6 Furnace oil

4.2 Following Hazardous processes / Operations:
4.2.1 Handling of flammable gases such as LPG, acetylene, Oxygen.
4.2.5 Cooking operation

5. EMERGENCY CONDITIONS: -

During HSE risk assessment carried out in plants, following conditions are identified which prone to
fire or explosion. Detail information of the operation carried out and hazards of the specific operation,
risk involved in operation and emergency levels are given below.

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Sr.N
o
Acti vi ty/Operation Hazards Intolerable HSE Risks Emergency Levels
1
Storage & unloading of
LPG
Fire/explosion hazard
due to leakage &
accidental fire
Fire/Explosion causing i)
Loss of life/lives, ii) Loss
of Property
Level 3
2
Storage, handling &
use of paints & thinner
Fire hazard i) Burn injury ii)
Loss of Property
Level 3
3
Storage of fuel oil &
operation of
boilers/Chillers
Fire hazard
Bulk spillage of fuel
oils
i) Burn Injury. ii)Loss
in property. Risk of fire &
burn injury.
Level 3
4
Storage of gas
cylinders (C2H2,LPG)
Fire & Explosion
Hazard
Fire/Explosion causing :
i)Loss of life/lives,
ii)Loss of Property
Level 3
5
Operation of S R
Furnaces in Plant 8/PL-
14
Fire & Explosion
Hazard
Fire/Explosion causing :
i)Loss of life/lives,
ii)Loss of Property
Level 3

6
Cooking Operation Fire & Explosion
Hazard
i) Burn Injury ii)
Loss of Life iii)
Loss of Property
Level 2
7
HT Transformers
Operation &
Maintenance
Fire Hazard/Electric
Shock
i) Burn Injury ii)
Loss of Life iii)
Loss of Property
Level 3
8
Use of electricity Fire Hazard/Electric
Shock
i) Burn Injury ii)
Loss of Life iii)
Loss of Property
Level 2
9
Transportation of
petroleum products
inside factory
Fire/explosion hazard Loss of human Life/Burn
injury & loss of property
Level 2

5.2 Identification of Emergencies
Classification of emergencies
According to our plan the emergency is categorized in three levels i.e.
Level - 1
The level of emergency, which is controllable within the plant premises. Emergency may be due to -
a. Small spot of fire in the plant.
b. Liquefied Petroleum gas leakage for short duration.
c. Collapse of small equipments.
Level 2
The emergency, which is confinable within the Factory premises. Emergency may be due to-
a. Big fire in factory premises
b. Medium scale explosion
c. Heavy leakage of gas for short duration.
Level- 3
Likelihood of vapour cloud with formation of flammable gases drifting and affecting the general public.
This type of emergency arises out of -
a. Explosion in high-pressure vessel containing flammable material.
b. Heavy leakage of toxic material for a long duration from pipeline or storage tanks.
Following priorities are to be born in mind while directing all operations.
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a. Safety of personnel
b. Minimum damage to plant, property and environment.
c. Minimum loss of material.
The major emergencies are defined as under:
Sr.
No.
Type of Emergency Level 1 Level 2 Level 3
1. Fire in Flammable Gas

2. Fire in Flammable Liquid

3. Explosion

The document On-site Emergency Plan is prepared with the objective of defining the functions and
responsibilities of all concerned managerial, operational and supporting services department personnel with
respect to detection and effective implementation of action plan. The ultimate goal is the effective containment
of the situation by taking proper mitigates actions at the place of occurrence, cautioning people in adjoining
affected localities, prompt rescue and medical aid to affected persons and communication to civic / statutory
authorities for rushing in help from outside.

6. RESPONSIBILITIES ( Detail role & responsibili ties of each authoriti es & person involved i n
emergency prepared ness define in OSEP )

6.1.1. HOD Safety: -
1. Overall responsible for establishing and implementing this procedure.
2. Advise the Factory manager about Health, Safety of all serious fire issues.
3. Ensure compliance with statutory legislated acts relating to fire and associated with fire
4. Train all concerned personnel ( e g. security, plant fire fighters, fire emergency response team etc.)
as per on site emergency plan (OSEP) for How to Handle Emergency Situation
5. Conduct regularly on-site emergency drills to check healthiness of the system as well as
competency of emergency crew.
6. Investigation of fire incidences for corrective & preventive actions.
7. Coordinating fire safety audit (Internal & External) of the system.
8. Revise the On-Site Emergency Plan at regular intervals.
9. reporting & communication with all internal & external parties.
10. Compliance of necessary legal & statutory requirements.

6.1.2. HOD FMG (Maintenance)

1. Overall responsible for Maintaining the fire fighting system in healthy condition
2. Periodical maintenance of Fire fighting system
3. Periodical maintenance of Fire extinguishers
4. Periodical checking & inspection of Fire Hydrant line
5. Periodical checking & inspection of Fire extinguishers.
6. Compliance of audit points (External & Internal)
7. Maintaining in working condition of LPG yard gas detection system round O clock.

6.1.3. HOD Security

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1. Overall responsible for responding the situation for fire fighting.
2. Reponses to fire prone site with fire fighting team
3. Approach & coordinate plant trained fire fighter if required
4. Round Oclock guarding of LPG yard area
5. Noting visiting entry of each person & vehicle to LPG yard
6. Maintaining fighting PPE (Self Contained Breathing Apparatus (SCBA) & Fire Suit) in healthy &
neat condition & ready to use for fire fighter.

6. REFERENCES

6.1. Register for Significant Aspects & Impacts Format No HSEAM/F/02
. 6.2 Register for unacceptable Risks and Control Measures Format HSEAM/F/04
6.3. On-site Emergency Plan

7. RECORDS: --
7.1. Training Record for OSEP -- Format No. HSEAM /F/11
7.2. CAPA taken /plan on deviations in Mock Drill -- OHSAM/F/19
7.3. MOM of Management Review Format No. HSEAM/F/31
7.4. Mock drill for OSEP.-Format No. HSEAM/F/19
7.5 Legal compliance & communication with external parties .

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.0
O. Cl. No : 4.5.0
Title
Performance Monitoring
& Measurement
Page No : 1 of 3

1. PREFACE:
Thermax Limited, Chinchwad factory shall establish a procedure for Monitoring and
Measurement, on a regular basis, the Key Characteristics of the Operations and
Activities that have a Significant HSE Impacts. The information to track the
performance, relevant Operational Controls and Conformance with the HSE
Objectives and Targets shall be recorded.
The procedure shall define the method of periodically evaluating compliance with
relevant HSE related, Legal & other requirements

Thermax Limited, Chinchwad factory, shall establish and maintain Procedure for
non-conformances, taking action to mitigate any impacts caused, for initiating and
completing Corrective and Preventive Action and confirmation of the effectiveness of
corrective and preventive actions taken.

Corrective and Preventive actions shall be taken to eliminate the causes of actual
and potential non-conformances, as appropriate to the magnitude of the problems
and commensurate with the HSE Impacts.

2. PURPOSE
To establish and maintain procedure for, measuring & monitoring the key
Performance characteristics of OHSMS.
3. SCOPE
Applicable to the activities of Thermax Ltd, Chinchwad factory, as per the
HSE management system,
4. RESPONSIBILITY
4.1. HSEMR / HSECO / Safety officer are overall responsible for laying
Down and implementation of the procedure, at Apex level;
4.2. HODs, DECO & concerned officials are responsible for compliance
As per Procedure 4. At departmental / operational level.
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.0
O. Cl. No : 4.5.0
Title
& Measurement
Page No : 2 of 3


S.
NO.
IBILITY
REF.
DOCUMENT
5.1 Identify the key characteri stics of activities /
operations / tasks to measure ;
Prepare a Monitoring and Measurement plan (
Format No HSEAM/F/20) and monitor the
performance of HSE Management System,
which include:
a) Relevant Legislation and Regulations
b) Relevant HSE Objectives
c) Relevant Operational Controls
d) HSE Management Programs
e) Major Injury Incident, ill health, incidents
including near misses
f) Emergency preparedness
g) Leakages, spillages , wastages of
materials and chemicals ,
h) Pollution & health related elements

HOD 1)Department
wise: OCP/
WI/OSEP/
HSEMP;
2) Format No
HSEAM/F/20
5.2 Measure and monitor actual performance of key
characteristics identified as per Monitoring and
Measurement plan, Format No HSEAM/F/20. .
Frequency of such measurement shall be mentioned
in the relevant operational control procedure or Work
instruction
HOD Format No
HSEAM/F/20.
5.3 List the measuring instruments/ alarm indicators (e.g.
Gas-Leak sensors & detectors, Pressure Gauges,
Temp. Indicators, sound meters etc) used for critical
HSE applications. Check their reliability and calibrate
for accuracy of measurement and retain the record of
inspection & calibrations.
HOD List of measuring
instruments and
their calibration
records
5.4 Review the results of the conformance with stipulated
criteria, at least monthly, and requirements of
HSEMS.
HOD MOM of Monthly
Dept .Review
HSEAM/F/30
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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.0
O. Cl. No : 4.5.0
Title

& Measurement
Page No : 3 of 3


S.
NO.
IBILITY
REF.
DOCUMENT
5.5 In case of any non-conformance communicate the
results to the concerned HOD for necessary action.
HOD CAPA by HOD
5.6 Record the findings of Evaluation of Compliance
related to legal and other requirements and
communicate to HSEMA, every month. HSEMA to
take up them in Management review, at least once in
3 month, till resolution.
HOD MOM of Apex
Management
review
Meeting -
5.7 Study the magnitude of the non-conformance and
decide corrective / preventive action as per Major
Injury Incident, incidents, non-conformance and
corrective and preventive action procedure. Minute
them in Dept Review proceeding.
HOD MOM of
monthly Dept.
Performance
review

6. REFERENCES:
6.1: Common & Dept. OCPs & Wis
6.2. HSEMPS,
6.3. OSEP Mock Drills
6.4. Register for Applicable Legal & other requirements

7. RECORDS
6.1. Departmental Monitoring and Measurement plan, Format No .
HSEAM/F/20;
6.2 MOM of Monthly Dept. Review HSEAM/F/30
6.3. Inspection & Calibration Record
6.4. Evaluation record of compliance of Departmental Monitoring and
Measurement plan, Format No HSEAM/F/20;
6.5. MOM of Apex Management Reviews- HSEAM/F/31

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.2
& 4.5.3

O.Cl. No : 4.5.2
Title
Incidents, Major Injury
Incident, Nonconformity And
Corrective And Preventive
Action
Page No : 1 of 5
1. Preface:

Thermax Limited, Chinchwad factory, shall establish and maintain Procedure to
report accident/incidents. Non-conformances, taking action to mitigate any impacts
caused, for initiating and completing Corrective and Preventive Action and
confirmation of the effectiveness of corrective and preventive action taken.

Corrective and Preventive actions are taken to eliminate the causes of actual and
potential non-conformances and are taken as appropriate to the magnitude of the
problems, commensurate with the Occupational Health , Safety and Environment
Aspects.

Any changes in the documented procedures resulting from corrective and preventive
action are implemented and recorded.
Thermax Limited, Chinchwad factory, ensures that information arising out of
corrective and preventive actions is submitted for management review as per
procedure for Management Review.

2. PURPOSE

To establish and maintain procedure for defining responsibility and authority for
handling and investigating Major Injury Incident, incidents, non-conformance and
initiating and completing corrective and preventive action to prevent recurrence.

3. SCOPE
Applicable to all areas of operation, including contractors & suppliers

4. RESPONSIBILITY
4.1. Factory manager is overall Responsible for guiding the formulation &
Implementation of this procedure.
4.2. Concerned FH, HOD, Plant In-charge, Supervisors, HOD Safety,
Safety Officer , DECO is responsible for documenting relevant
Procedures and comply them.

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Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.2
& 4.5.3

O.Cl. No : 4.5.2
Title
Incident, Nonconformity
And Corrective And
Preventive Action
Page No : 2 of 5
S.N. ACTIVITY

RESP. REF.DOC
5.1 Handling Of Major Injury Incident / Near
Miss/Inci dents

5.1.1 In case of any injury incident, following steps shall be
taken :

5.1.1.1 Shift the affected person to M.O (M.I. room). HOD/ I.C.
5.1.1.2 Attend the affected person clinically /First aid, as
appropriate. and note the details of injury due to
Major Injury Incident, in Register. Specify if injured
person is
sent to outside hospital.
M.O.
(Medical
officer)
Register of
reported Major
Injury Incident
5.1.1.3 Supervisor / Incharge to Report the incident in format
No. - HSEAM/F/22, duly filled, in triplicate, to M.O
and send a copy to HSE dept & near miss in format
no. HSEAM/F/22 ,duly filled and send copy to HSE
dept.
Sup / I.C. Incident /Near
Miss Report
(format No.
HSEAM/F/22 )
5.1.1.4 Inform Manager (I.R.) about the status and condition
of patient and the nature of effect of incident.
M.O
5.2 M.O. to advise the affected person, for resumption of
duty. In case, the person is medically fit.
M.O.
5.2.1 Injured person to get hospitalized, in recommended
hospital, immediately for further treatment & intimate
the hospital authority.
MO/ I.C.
5.2.2 M.O. to ensure that responsible person accompanies
the affected person, to hospital, through company
ambulance.. Ambulance of external origin is called to
attend injured, in case of emergency.
M.O
5.2.3 In case the person reports to M.O. as having ill-
health/ sickness, such case shall be treated &
recorded separately under head of Reported illness/
Sickness.
M.O. Register of
reported Illness
/ Sickness
5.3 In case of any serious type of injury (likely to be
reportable to Factory Inspector), information to be
immediately given to Factory Manager & HOD (
safety )
S.O.
(Safety
officer)

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Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.2
& 453

O.Cl. No : 4.5.2
Title
Incident, Nonconformity
And Corrective And
Preventive Action
Page No : 3 of 5

5.3.1 SO to further closely monitor & report the case to HOD
(safety) for post- injury incident events,.
S.O
(Safety
officer)

5.4 In case of Near-miss / dangerous event , where no
injury / illness has occurred , it shall be immediately
reported to safety Officials in specified format
Concerned
HOD/ In
charge/
Supervisor

5.5 Investigation Of Incident (Major Injury Incident/ Near
Miss/ Dangerous Event ) & Reporting

Find out the Root-Cause of injury incident by :
Visit to the site of injury incident.
5.5.1
Interview of affected person (if available)
Supervisor.
5.6 Anal ysis , Corrective & Preventive Actions
5.6.1 Analyze the reported causes and establish the root cause
/s by brain storming with concerned personnel and
advise the corrective & preventive actions ,to concerned ,
to avoid reoccurrence of such/ similar Major Injury
Incident in future .Completely fill the report of Injury
incident
HOD Format No.
HSEAM/F/22
5.6.2 Review the cause, analysis done & CAPA decided by IC
for injury incident and decide Common CAPA in system,
and initiate actions, where applicable. Record in Format
HSEAM/F/22

HOD Format No.
HSEAM/F/22
5.6.3 Compliance to CAPA plan will be done by HODs /
Concerned Sup/Incharge and reported to Safety Officer.
HOD
5.64 The incident investigation report and status of
compliance of CAPA planned, will be shared in weekly
Supervisory meeting. System CAPA will be initiated by
HOD (safety) / safety Officer.
HOD /
Safety
Officer

5.7. Reporting Maj or Injury Incident / Dangerous
Occurrence To Factory Inspector

5.71 Decide the injury incident, if it is reportable to Factory
Inspector, by monitoring the injury incident, and using
applicable criteria, as per Factory Act.
HOD
( Safety )

5.7.2 Report the Injury incident / Dangerous occurrence to
Factory Inspector, in consultation with Factory Manager
in format 24 & 24A respectively, within stipulated period.
HOD
( Safety )
Report to FI
format s24 /
24A
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.2
& 4.5.3

O.Cl. No : 4.5.2
Title
Action
Page No : 4 of 5
S.N. ACTIVITY

RESP. REF.DOC
5.7.3 On getting guidance/ remarks from Factory Inspector,
on reported injury incident / Dangerous occurrence,
initiate further immediate CAPA and report the
compliance to Factory Inspector, in agreed time limit.
HOD
( Safety )
Compliance
Report
5.7.4 On getting guidance/ remarks from Factory Inspector,
on reported injury incident / Dangerous occurrence,
initiate further immediate CAPA and report the
compliance to Factory Inspector, in agreed time limit.
HOD
( Safety )
Compliance
Report
5.8 HOD to ensure Prevention of Maj or Injury Incident
/ Incidents / Near Miss/ Major leakage/spillage of
hazardous material:-The concerned persons/
operators ,during execution of the daily activities,
operational control, measurement and monitoring,
abnormal situations, audits, etc shall detect non-
conformance concerned to HSE risks .Such non-
conformance shall be reported to Supervisor. , who
will evaluate the significance and report it to the Plant
Incharge.
The plant-in-charge shall take necessary measures to
eliminate the root- cause (with help of Safety Officer, if
essential.)., and report to HOD & Safety Officer and
HSEMA.
Concerned
HOD

5.9 The records of such corrective & preventive actions
shall be communicated by Safety Officer, to
HSEMA / HSECO.
HOD(
Safety)

5.10 Concerned, shall study any changes required in the
documented procedures, resulting from corrective /
preventive action and ensure changes in the
procedure, if required.
HOD(
Safety)

5.11 HSEMA/HSECO/ Safety Officer shall report the
Incident (Injury incident/ Near Miss/ TCEI) and
corrective preventive actions, in Management
Review.

HSEMA/H
SECO/
Safety
Officer
Incident &
CAPAs taken
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.2
& 4.5.3

O.Cl. No : 4.5.2
Title
Action
Page No : 5 of 5

6.0. REFERENCES:--
6.1. Factory Act (Latest amendment) with Safety officer
6.2. Injury incident/Near miss Report Format No:-. HSEAM/F/09, with HOD;
6.3. Reportable Injury incident to Factory Inspector:--Format 24,
6.4 Dangerous occurrence report to Factory Inspector format 24A
7.0. RECORD:--
7.1. Injury incident Reports Format No :-. HSEAM/F/22 with Concerned HOD &
Safety Officer
7.2 Register of Major Injury Incident/ Illness, reported with Medical Officer;
7.3. Reportable Major Injury Incident to Factory Inspector in format 24 -- with safety
Officer
7.4 Dangerous occurrence report to Factory Inspector in format 24A - with
Safety Officer
7.5 CAPA plan and compliance status of Major Injury Incident with Concerned HOD
7.6 MOM of. Management Review with HOD & HSEMA/Safety Officer

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.3
O.Cl. No : 4.5.3
Title

Records & Records
Management
Page No : 1 of 2
1. PREFACE:
Thermax Limited, Chinchwad factory shall maintain HSE records to demonstrate
the achievement of specified objectives and targets and effective operation of the
HSE Management System. These records also include training records, results of
audits and reviews.

Thermax Limited, Chinchwad factory shall establish and maintain procedure for
Control of HSE Records for the identification, preservation method, maintenance,
retention and disposition.

2. PURPOSE
To establish and maintain procedure for identification, maintenance, and disposition
of HSEMS Records and results of Audits and reviews.
3. SCOPE
Applicable to all relevant records in HSEMS.

4. RESPONSIBILITY
HOD, HSEMA, HSECO, Safety Officer & Concerned
Individuals.
S.
NO.
SIBILITY
REF.
DOCUMENT
5.1 Identify & list all HSE Records which demonstrate
effectiveness of performance of HSEMS, relating to
individuals in dept. (Format No. HSEAM/F/25).
The records shall be maintained as per requirements of
Apex manual and departmental manuals to meet total
HSEMS requirements.
HOD HSEAM/460/
01
5.2 Store and maintain records in such a way that they are
readily retrievable and protected against damage,
deterioration, or loss.
HOD
5.3 Define responsibility for maintenance, preservation,
retention and disposal of HSEMS records.
HOD
5.4 Car Carry out following activities for identification, location, and
indexing, filing, access and retention time of HSEMS
Records: Records / files are identified by numbers or titles.
Records are collected and kept at specified location by the
concerned
HOD
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.3
O.Cl. No : 4.5.3
Title
Records & Records
Management
Page No : 2 of 2

Sr.
NO.
IBILITY
REF.
DOCUMENT
5.4 i) Records are indexed with suitable methods
such as with reference to date, sr. no.,
identification no., activity no., etc.
ii) Records are filed in files / folders and are
maintained properly by storing them in suitable
racks, cabinets, cupboards, etc.
v) Records are accessible to departmental persons,
auditors and persons from other departments
with permission of HOD. Decide retention time
HOD
5.5 Records can be in hard / electronic form. HOD
5.6 All legal records to be retained for life time. HOD
5.7 All non -legal records shall be retained for minimum
period of 3 years.
HOD
5.8 Depending on the need of HSE Management
Systems, system, recording system shall be reviewed
& revised, suitably.
HOD
5.9 List all HSE records, required, & their locations,
retention, disposal method etc, as per format No.
HSEAM/F/25.
HOD Format No.
HSEAM/F/25
5.10 Dispose off HSE records, after the relevant retention
period is over, by suitable means.
HOD
5.11 If the record is maintained on computer, the security is
ensured by keeping back up files regularly and giving
controlled access, to avoid loss/ changes.
HOD
6. REFERENCES
6.1 HSE Records- Format No. HSEAM/F/25
7. RECORDS:
7.1. Departmental Records, as per HSE AM/F/25.

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.4
O.Cl. No : 4.5.4
Title
HSE Audits
Page No : 1 of 3

1. PREFACE:
Thermax Limited, Chinchwad factory, shall establish and maintain procedure for
conducting Internal Occupational Health and Safety Management System Audits,
once in three months.

The Audits shall be conducted to verify whether the HSE Management System
complies with the specified requirements and to determine whether the system is
properly implemented, maintained and is effective in meeting the HSE Policy.

The audits are scheduled on the basis of HSE impacts of the activity / process and
based on previous audit results and carried out by personnel independent of those
having direct responsibility.
HSEMA along with management review committee shall review the audit findings
and ensures effective implementation and maintenance of the HSE management
system.
2. PURPOSE
To establish and maintain procedure and programme for periodic HSE management
audits ,to determine whether HSEMS conforms to planned arrangements ,
objectives, policy and is properly implemented and maintained as per requirements
of OHSAS 18011-1999 and ISO14011:2014.
3. SCOPE
This procedure is applicable to all the areas covered under HSE Management
Systems established by the organization
4. RESPONSIBILITY
HSEMA, HSECO, HODs, DECOs, Safety Officer, Internal Auditors

S.
NO.
SIBILITY
REF.
DOCUMENT
5.1 Audits shall be planned , based on results of risk
assessments of organizational activities and results of
Previous audits, at the frequency of, once in three months.
However, depending on status of audit results /
Circumstances, HSEMA / HSECO may plan additional
audits.
HSEMA/
HSECO

5.2 HSEMA / HSECO in consultation with HODs, & Safety
officer, decides the Audit Plan and releases an Annual audit
plan in Format No. HSEAM/F/26.
HSEMA/
HSECO
Format No.
HSEAM/F/26.

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E.Cl. No : 4.4.2
O.Cl. No : 4.4.2
Title

Competence
Page No :1 of 3

S.
NO.
NSIBILI
TY
REF.
DOCUMENT
5.3 Internal auditors are provided with adequate training by
competent agency and the list of such trained auditors is
Maintained. If necessary, HSEMA/HSECO also decides
to take the help of external trained auditors to assist
Internal auditing.
HSEMA/
HSECO

5.4 Select trained auditors and ensure that the auditors are
Independent of the areas / activity being audited.
HSEMA/
HSECO

5.5 Identify the area / activity for audit, based on
Occupational Health, Safety and Environment
importance and prepare Internal audit schedule in format
No. HSEAM/F/27 by referring Annual audit plan in
Format No. HSEAM/F/26. The scope of audit is
mentioned in the Internal Audit Schedule.
HSEMA/
HSECO

5.6 Auditor studies the area documents and previous NCR,
specific instructions given by HSEMA / HSECO / Safety
Officer, and conducts the audit as per schedule.
On request of Audi tee / Auditor, HSEMA/HSECO may
Change date of audit and name of auditors.
Auditors
5.7 Auditors use checklist and take interviews
/measurements/ direct observation as appropriate to the
Audile function.
Auditors
5.8 Audit summary reports are prepared in Format No.
HSEAM/F/28and Non-Conformances are recorded in
The Non-Conformance report (NCR) Format
No.HSEAM/F/23.
The acceptance of reports by auditor along with the
Proposed corrective action and time required to resolve
the non-conformities are recorded on NCR.
Auditors
& Audi
tees
Format Nos.
1)HSEAM/F/28;
2)HSEAM/F/23.

5.9 HOD (Audi tee) ensures, the Corrective & Preventive
actions are taken and are effective, and contacts auditors
to verify their effectiveness & record
HOD CAPA planned
5.10 The document changes / revisions arising out of
corrective actions implemented for closure of NCR, are
carried out by concerned HOD, as per procedure for
document control Procedure No.HSEAM/445/01
HOD
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.5.4
O.Cl. No : 4.5.4

Title
HSE Audits
Page No : 3 of 3

S.
NO.
IBILITY
REF.
DOCUMENT
5.11 HSEMA/ HSECO shall prepare a consolidated
report on the internal audit findings and submit to
management review meeting as per Procedure No.
HSEAM/460/01
HSEMA/
HSECO
Consolidated
Audit Summary
report

6. REFERENCES :
6.1. Annual Audit Plan: Format No. HSEAM/F/26
6.2. List of Qualified Auditors: Format No. HSEAM/F/29
6.3. Internal Audit schedule: Format No. HSEAM/F/27
6.4. Non-Conformance Report :Format No.HSEAM/F/23
6.5. Internal HSEMS Audit Summary Report :
Format No. HSEAM/F/28

7. RECORDS :
7.1. Non-Conformance Report :Format No.HSEAM/F/23
7.2. Internal HSEMS Audit Report : Format No.HSEAM/F/28
7.3. MOM of management review: Format No. HSEAM/F/32

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.6.0
O.Cl. No : 4.6.0

Title
Management Review
Page No : 1 of 3

1. PREFACE: The procedure for management review of HSE management system
shall be designed to ensure its continued suitability, adequacy, and effectiveness and
shall include method of assessing opportunities & improvement and the need for
changes in the system.
2. PURPOSE
To review HSE Management System, at regular interval to ensure, its continuing
suitability, adequacy and effectiveness, to meet the requirements HSEMS and
initiate suitable changes, in the system.
3. SCOPE
All activities related to Occupational Health, Safety and Environment Management
Systems at Thermax Limited, Chinchwad, and Pune

4. RESPONSIBILITY
HSECO, HSEMA, Safety Officer and HODs.
S.
NO.
ACTIVITY / TASK RESP-
ONSIBILI
TY
REF.
DOCUMENT
5.1
Inputs ( Non conformances , deviations on objectives
and CAPA taken/planned ) shall be provided by all
HODs/ DECOs , periodically, through the MOMs
of monthly departmental reviews, in specified format.
HOD MOM of
Monthly Dept
Review
5.1.1
Inputs shall includes :
a) result of participation and consultation,
b) Relevant communication (s) from external
interested parties including complaints
c) Status of incident investigations, CA, PA
d) Changing circumstances, including developments
in legal and other requirements related to OH&S .
HOD MOM of
Monthly Dept
Review
Format:
HSEAM/F/30
5.2
HSEMA/ HSECO/ Safety Officer shall compile all
relevant Information on performance of HSE
management system, for last 3 months and , evaluate
the effectiveness of implementation of system and shall
prepare agenda for management Review, based on :
Past Major Injury Incident/ incidents, NCRs and
Performance data of HSE , their analysis and CAPAs
taken/ planned ; and , Proposals to meet set objectives
& / taking up higher / new objectives.
HSEMA Agenda for
Management
Review
5.3
HSEMA/ HSECO/Safety Officer shall convey the
agenda to Management Committee Members, a week
before the date of review, once in every three months.
HSEMA Agenda for
Management
Review
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.6.0
O.Cl. No : 4.6.0

Title
Management Review
Page No : 2 of 3

S.
NO.
NSIBILI
TY
REF.
DOCUMENT
5.4 HSEMS performance shall be reviewed as per agenda,
by the Apex Management Committee members.
HSEMA List of apex
committee
members
5.5 The Agenda for the review meeting takes into account
the following:
a) Progress on Plan of Action decided in last
meeting
b) Review of Audit Reports and Corrective and
Preventive Action
c) A Review of HSE performance of organization
d) Review of objectives, targets and HSE
Management programs undertaken.
e) Review of Major Injury Incident, Incidents,
Near Miss-Major Injury Incident, Emergency
situations , in past 3 months and CAPAs ;
f) Non compliances on Legal & other
requirements, complaints from statutory body,
public and other agencies and their
resolutions.
g) The out put of review shall include decisions
and actions for Continual improvements on :
i) HSE performance
Ii HSE policy & objectives
iii) Resources
iv) Other elements of System
HSEMA Agenda for
Management
Review as per
Format No
HSEAM/F/32
Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.6.0
O.Cl. No : 4.6.0

Title
Management Review
Page No : 3 of 3

S.
NO.
NSIBILI
TY
REF.
DOCUMENT
5.6 The minutes of the apex Management Review Meeting
shall be recorded and circulated to all members of the
HSE Apex Committee, by HSECO, for communication
and consultation of all members of system.
HSEMA MOM of MRM:
Format No.
HSEAM/F/32
5.7 Concerned HOD & DECO of every dept/ plant shall
verify compliance of applicable points of MOM of Apex
Management Review and record the Corrective &
preventive actions planned / taken and status in minutes
of Dept Review meeting , in the format HSEAM/F/30.
HOD MOM of Dept
Review: format
HSEAM/F/30
5.8 HOD shall send a copy of minutes of dept.review (MOM)
to HSEMA, HSECO & concerned individuals, in his
department.
HOD MOM of Dept
Review: format
HSEAM/F/30.

6. REFERENCES
6.1 Format of Minutes for Apex management review meeting : HSEAM/F/32
6.2 Format for Minutes of departmental HSE Committee : HSEAM/F/30

7. RECORD:
7.1 MOM of Apex Management Review Meeting: Format No. HSEAM/F/32

6.3 . Monthly Compliance Status of MOM by Dept Heads. : Format No.
HSEAM/F/30

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.6
O.Cl. No : 4.4.6

Title
List Of Common Formats
Page No : 1 of 2

s.no TITLE FORMAT
NO.
REV
NO.
DATE OF
IMPLEME
NTATION
1 Register of Environmental Aspects & Impacts
HSEAM/F/01 01
2 Register of Significant Environmental Aspects &
Impacts
HSEAM/F/02 01
3 Register of Risk Assessment
HSEAM/F/03 01
4 Register of Unacceptable Risks & Control
Measures
HSEAM/F/04 01
5 Register of Legal & Other Requirements
HSEAM/F/05 01
6 Departmental Objectives, Targets & EMPs
HSEAM/F/06 01
7 Objectives , Targets & Management Programs
HSEAM/F/07 01
8 HSE Management Programme
HSEAM/F/08 01
9 Progress Review of HSE Management
Program
HSEAM/F/10 01
10 Competency , training needs, plan & status
HSEAM/F/11 01
11 Register of External Communication
HSEAM/F/12 01
12 Register of Internal Communication &
Participation
HSEAM/F/13 01
13 Operational Control Procedure
HSEAM/F/14 01

Prepar
ed &
Issued By
Reviewed
By
Approved
By

Date 20.08.2013 Date 30.08.2013 Date 06.09.2013

Rev. No : 00 Date : 20.08.2013
E. Cl. No : 4.4.6
O.Cl. No : 4.4.6

Title
List Of Common Formats
Page No : 2 of 2

Sr.
No
.
TITLE FORMAT NO. REV
NO.
DATE OF
IMPLEMENT-
ATION
14
Work Instruction/ Tool Box talk
HSEAM/F/15 01
15
Document Control Master
HSEAM/F/17 01
16
Document Change Note
HSEAM/F/18 01
17
Emergency Mock drill / Incident Report
HSEAM/F/19 02 20.05.2013
status column
added.
18
Monitoring & Measurement Plan
HSEAM/F/20 01
19
Monthly Compliance Status of Legal & other
Requirements
HSEAM/F/21 01
20
Report of Investigation of Injury incident/
Incident / Near-Miss
HSEAM/F/22 01
21
Non Conformance report
HSEAM/F/23 01
22
Internal audit summary report
HSEAM/F/24 01
23
HSE Common Records
HSEAM/F/25 01
24
Annual Audit Plan
HSEAM/F/26 01
25
Internal Audit Schedule
HSEAM/F/27 01
26
List of Qualified Auditors
HSEAM/F/29 01
27
MOM of Monthly Departmental HSE Committee
Meeting
HSEAM/F/30 01
28
Identification of Unsafe Conditions & Acts
HSEAM/F/31 01
29
Minutes Of Management Review Meeting
HSEAM/F/32 01

30
Work Permits for hazardous Operations
HSEAM/F/33 06

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