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HAZARD IDENTIFICATION PLAN

Sulayyil Bulk Plant

SAUDI ARABIAN OIL COMPANY-SAUDI ARAMCO
BI-10-00612-0001

September 16 2009

POTENTIAL
ACTIVITIES LOCATION ACTIONS TO BE DONE
HAZARD
1. WORK PERMITS ALL AREAS SERIOUS OR FATAL 1. A qualified / certified person to obtain work permit from
INJURY an authorized issuer prior to start the job.
2. Discuss with operation clearly of the activities to be
MAJOR EQUIPMENT performed and location where the job is to be carried out.
DAMAGE
3. Conduct a joint inspection & do necessary tests before
obtaining permit.
4. Comply with all instructions specified in the permit.
(Ensure that all precautions are taken)
5. Obtain separate permits for each location & types of
jobs.
6. Communicate with the work crew of the conditions on
work permit.
7. Ref-Aramco GI-2.100 (All requirements to be fulfilled
with).
1.
2. EMERGENCY ALL SAUDI ARAMCO LIFE SAVING 1. Establish an emergency evacuation plan and train
RESPONSE/EVACUAT WORK SITES KNOWLEDGE NOT employees based on the plan.
ION PLANS PUT INTO ACTION 2. Employees not trained shall not be permitted to work in
Aramco.
EMERGENCY
3. Train employees on life saving requirements.
RESPONSE
PROCEDURES NOT 4. Create awareness of emergency response procedure and
FOLLOWED importance of compliance with the procedure.
5. Remind employees on these procedures regularly in Tool
EMPLOYEES NOT Box meetings.
TRAINED 6. Designate an emergency assembly area with the
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concurrence of Aramco operations.

NO EMERGENCY
ASSEMBLY AREAS
3. CRANES & HOISTING ALL AREAS SERIOUS OR FATAL 1. The equipment shall be subjected for inspection of Aramco
EQUIPMENT INJURY and to be certified prior to use them in Aramco facilities.
2. The operator & rigger must be of Aramco certified
SLINGS/RIGGING MAJOR EQUIPMENT personnel. Personnel without Aramco certification are not
EQUIPMENT DAMAGE
allowed to operate equipment.
DEFECTIVE AND/OR 3. Weight of the object to be lifted shall be always below the
INADEQUATE safe workload of the crane, equipment, lifting tackle.
EQUIPMENT 4. Daily check-up and monthly inspection of slings & lifting
tackles shall be done to ensure reliability. Instruction to be
passed on to all concern of this requirement.
UNCERTIFIED 5. Employees shall stay away from the suspended load
EQUIPMENT (employees shall never stay below the load)
6. Never stay in between the load & structures while lifting a
UNCERTIFIED load by crane / hoist equipment.
PERSONNEL
7. Conduct regular inspection (checklist) to ensure that the
LACK OF DAILY /
MONTHLY crane / hoist & rigging equipments are in good condition.
INSPECTION 8. All heavy lifting must be done only in accordance with the
PROGRAMS Aramco approved lift plans.
9. The lifting operation shall only be done under the safe
INADEQUATE LIFT weather condition according to the Aramco standard.
PLANS
1.
4. FIREWATCH AND/OR WHEREVER HOT SERIOUS AND/OR 1. A certified fire watch/standby man to be assigned in hot
MANWATCH WORK IS FATAL INJURIES work areas to monitor the site.
CONDUCTED 2. Control the spark from spreading around.
MAJOR STRUCTURAL/ 3. Gas test is to be done to ensure that the area is free of
ANY CONFINED EQUIPMENT DAMAGE
flammable/explosive gases.
SPACE ENTRY
PLANT UPSET AND/OR 4. Protect the live part of the plant / unit from hot work area.
SHUTDOWN

5. MATERIALS OFF-SITE & ON-SITE SERIOUS INJURIES 1. Provide proper access to all material storages for traffic &
HANDLING FIRES / EMERGENCY personnel.
RESPONSE / TRAFFIC 2. Provide/design emergency exits.
FLOW / EQUIPMENT
DAMAGE
3. Material storage shall be designed away from
UNORGANIZED / passages/traffic.
MAINTAINED 4. Equipment passage area and walkways shall be marked
properly.
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WAREHOUSE 5. Combustible/flammable materials shall be stored separately

in a safe location.
UNCERTIFIED 6. All materials shall be stored itemized and identified properly.
FORKLIFT 7. Create awareness for employees to use proper equipment
OPERATORS
for jobs.
IMPROPERLY 8. All equipment shall be maintained in good condition.
MAINTAINED 9. Operators of forklift/heavy equipment must be certified by
EQUIPMENT Aramco before the assignment to Aramco facility.
10. All equipment to be use in Aramco shall be subjected for
FORKLIFT USED AS Aramco inspections and certification.
CRANE

UNCERTIFIED BOOM
TRUCK OPERATORS

UNCERTIFIED BOOM
TRUCKS
6. SMOKING ALL AREAS FIRE HAZARDS 1. Inform employees on smoking restrictions & monitor
compliance.
SMOKING DONE IN 2. Provide / designate smoking shelter for smokers.
AREAS OTHER THAN 3. Display no smoking signs as needed.
DESIGNATED
SMOKING SHELTERS
7. ELECTRICAL OVERHEAD AND SERIOUS AND/OR 1. All the electric lines interfering with the job shall be rerouted
BELOW GROUND FATAL INJURIES / isolated.
2. Underground works to be fully coordinated with Aramco
ELECTRICAL HAND EQUIPMENT DAMAGE officials and follow the Work Permit requirements.
TOOLS
3. Precautions to be taken against the equipment getting
CORD AND PLUG
BUILDINGS – OFFICE DAMAGE contact with live electric lines.
SITE(S), SHOP 4. All the power cord & electric outlet of power tools &
AREAS, FABRICATION GFCI REQUIREMENTS equipment are to be inspected regularly for damage.
YARDS NOT FOLLOWED Remove the damaged items from service.
5. Provide GFCI for all necessary power lines outlets to
MONTHLY ensure safety of personnel handling the equipment.
INSPECTION 6. All the electric cords & outlets shall be subjected for
PROGRAM inspection on monthly basis in addition to the regular check-
up.

ELECTRICAL REPAIRS 7. Repair of electrical appliances tools / equipment only shall

PERFORMED BY be done by qualified personnel.
UNQUALIFIED 8. Employees qualified for cable splicing only will be assigned
for the same job.
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PERSONNEL 9. Lockout tag-out will be done for all electrical related jobs.

CABLE SPLICERS NOT

CERTIFIED

LOCKOUT / TAGOUT
SYSTEM NOT IN USE

8. HOUSEKEEPING ALL WORK COVERS ALL AREAS 1. All materials / tools shall be stored properly and clear waste
LOCATIONS OF INJURY / ILLNESS materials on a regular basis.
&/OR EQUIPMENT 2. Insulation waste shall be collected handled with extra care
DAMAGE POTENTIAL to avoid spreading around and dispose them as approved.

9. WELDING AND PIPING, SLEEPERS, SERIOUS AND/OR 1. Inspect the hot work area before start of the job for any
CUTTING SKIDS, (WHERE FATAL INJURIES combustible / flammable substances.
WORK PERMIT 2. Conduct gas test to ensure that the work area is free of
PROVIDES) PROPERTY DAMAGE flammable / toxic gases.
FROM FIRE AND/OR
3. Obtain the work permit for the specific job and location.
ALL WORK EXPLOSION
LOCATIONS 4. Remove all the possible combustible and flammable
UNSHELTERED OXY- substances from the hot work area.
ACETYLENE 5. Provide protection for the combustible materials that cannot
STORAGE be removed from the hot work area.
6. Fire blanket protection to be given to control the spark from
OXY-ACETYLENE spreading around. Cover all sewerage pits in hot work area
BOTTLES NOT with the provided rubber mat
SEGREGATED 7. Assign a qualified fire watch/stand by man to monitor the
hot work.
NO FLASH
8. Hot work areas to be barricaded and signboards to be
ARRESTORS AT
GAUGES placed to alert workers nearby.
9. Fire extinguishers of the right types (DCP) and water hose
IMPROPER with continue flow of water shall be kept at the hot work
REGULATOR area.
PRESSURE 10. Employees shall use the right PPE based on the nature of
the job, in addition to the basic required personal protective
NO FIRE equipment.
EXTINGUISHERS
11. Ensure that the gas test is updated as per the requirement
specified on the work permit.
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UNGROUNDED 12. Dispose all the combustible wastes regularly from the work
WELDING MACHINES area.
13. Smoking is strictly prohibited in the site
LACK OF WELDING
SCREENS

WELDING SHELTERS
USING COMBUSTIBLE
MATERIALS

IMPROPER PPE

NO FIRE WATCH

10. PERSONAL ALL WORK INJURIES / ILLNESSES 1. All employees on site shall be provided with basic PPE and
PROTECTIVE LOCATIONS additional PPE according to the nature of the job they
EQUIPMENT (PPE) SUBSTANDARD perform.
EQUIPMENT 2. All PPE issued for employees must be in acceptance with
Aramco standard.
INADEQUATE SUPPLY
OF REPLACEMENT 3. Sufficient numbers of PPE shall be made available at site
EQUIPMENT store for replacement / additional issue.

11. HAND / POWER ALL AREAS POWER TOOLS NOT 1. All single insulated power tools to be grounded properly. All
TOOLS PROPERLY single / double insulated power tools must be kept dry / free
GROUNDED OR of wet to prevent electrical shocks when using them.
DOUBLE INSULATED
2. Power source of all electrically operated tools (maximum
GFCI REQUIREMENTS 125 v) shall be provided with GFCI.
NOT IN EFFECT 3. Potable electrical tools more than 125 v shall not be used in
Aramco job site.

PORTABLE 4. Suitable site and type of disk and blades to be provided to

ELECTRICAL TOOLS match with the type & size of equipment in use.
MORE THAN 127 5. Guards for the rotating equipment / tools shall be installed
VOLTS properly and maintained. (ref.) Aramco const. manual 10.4,
10.5, 10.6 figure # 40 to figure # 45.
ROTATING DISKS AND
6. All employees assigned on job to be provided with all
BLADES DO NOT
MATCH EQUIPMENT required PPE and ensure that they are using them
OR USAGE according to the nature of their job.
7. All tools must be inspected periodically for their reliability
GUARDS NOT and any damaged tools, must be removed from service /
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PROPERLY INSTALLED repaired by a qualified technician and tested properly &

&/OR MAINTAINED certified before put them in service.
8. Periodic inspection for tools & equipment to be done to
PROPER PPE NOT IN ensure their reliability.
USE TOOLS NOT KEPT
IN PROPER WORKING
CONDITION

DAILY / MONTHLY
INSPECTIONS NOT
PERFORMED

12. HEAVY EQUIPMENT ON SITE UNCERTIFIED 1. Operators of heavy equipment to be assigned in Aramco
OPERATORS must be of a valid sag license holder & Aramco certified
personnel.
EQUIPMENT NOT 2. Only Aramco certified equipment to be used in Aramco and
PROPERLY
maintain the equipment in good condition as per Aramco
MAINTAINED
standard.
NO BACK-UP ALARMS 3. All heavy equipment used in Aramco must be fitted with
back-up alarm.
SPOTTERS / FLAGMEN 4. A qualified / trained spot man / flagman shall be deployed in
NOT PROPERLY heavy equipment operating area to guide the equipment.
TRAINED OR
AVAILABLE

13. FIRE PROTECTION & ALL AREAS NO EMERGENCY 1. An emergency response plan, which approved by Aramco
PREVENTION RESPONSE PLANS to be established.
2. All personnel on site to be trained on the emergency
UNTRAINED response plan.
PERSONNEL
3. Adequate numbers of fire extinguishers shall be provided in
all not work areas.
INADEQUATE NUMBER
OF FIRE 4. All the fire fighting equipment to be inspected on a monthly
EXTINGUISHERS basis to ensure their reliability. All such equipment must be
in good working condition.
UNGROUNDED 5. All the internal combustion equipment on site must be
GENERATORS SETS grounded properly to avoid any electrical related fire.
6. Stub buckets to be provided on the site as recommended.
STUB BUCKETS NOT 7. No combustible material shall be used as shelter for hot
IN USE
works.
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COMBUSTIBLE
MATERIAL USED FOR
WELDING SHELTERS

1. ALL SCAFFOLD STRUCTURES SHALL BE ERECTED AS PER

14. SCAFFOLD ALL AREAS a. STRUCTURE ARAMCO STANDARD. Ref. ARAMCO SCAFFOLDING SAFETY HAND
COLLAPSE BOOK AND GI.8.001.
2. ERECTION OF SCAFFOLD, INSPECTION AND APPROVAL BY ONLY
b. FALLS/INJURY
CERTIFIED PERSONNEL ACCORDING TO THE LEVEL OF THEIR
CERTIFICATION.
c. EQUIPMENT /
PROPERTY 3. SUBMIT DESIGN AND OBTAIN APPROVAL FROM ARAMCO FOR
DAMAGE SPECIAL SCAFFOLDS.
4. NO SCAFFOLD PLATFORM SHALL BE OVERLOAD BY MATERIAL
d. IMPROPER STOCK / MORE PERSONNEL.
MATERIALS
5. ALL TOOLS / EQUIPMENT / MATERIALS KEPT ON THE SCAFFOLD
e. IMPROPER FALL PLATFORM SHALL BE SECURED PROPERLY.
PROTECTION 6. PLACE APPROPRIATE SAFETY SIGN BOARD TO ALERT THE
PERSONNEL NEAR BY OF THE ACTIVITIES ON THE SCAFFOLD.
f. IMPROPER
SPACING 7. USE ONLY APPROVED SCAFFOLDING MATERIALS.
8. TO BUILD SCAFFOLDING MAINTAIN VERTICAL AND HORIZONTAL
g. UNQUALIFIED SPACING AS ACCEPTED BY ARAMCO.
SCAFFOLD
CREWS 9. FULL BODY HARNESS SHALL BE USED HOOKED BY SCAFFOLD
CREW AND OTHER PERSONNEL WHILE WORKING ON
SCAFFOLDS.
10. SCAFFOLD CREW & PERSONNEL USING THE SCAFFOLD TO
ENSURE THE STABILITY OF THE SCAFFOLD BEFORE START
USING THEM.
11. ONLY COMPETENT SCAFFOLDER CERTIFIED FOR THE TYPE OF
SCAFFOLD MUST ERECT SCAFFOLD IN ARAMCO FACILITIES.