23.safety Inspections

Document ID No: MSSM-1-SF-001
Power & Water Utility Company for

Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010
MARAFIQ SAFETY MANUAL
23. SAFETY INSPECTIONS

REFERENCE STANDARDS:
OSHA 2098
INTRODUCTION
Inspections are an invaluable way of identifying potential workplace hazards before they cause a
health and safety problem. It is a proactive approach of monitoring the workplace safety for the
prevention of accidents through the maintenance of safe working conditions and removal of any
potential hazards that arise in the workplace.
The purpose of these Marafiq safety manual on Safety Inspections is to:
 Provide an easy–to-follow and unambiguous process for conducting and documenting site safety
inspections.
 Identify unsafe acts/conditions/work practices for rectifying them.
 Promote safety awareness among employees by alerting them of the hazards.
 Demonstration of management safety commitment through identification & elimination of hazards.
23.1 DEFINITIONS
Safety Inspection: a system used for proactive monitoring of safety performance to identify
workplace hazards (unsafe acts/condition/work practices) through formal site visits.
Team Leader: Person, who controls, supervises and guides a group of persons working in his
department, division or section.
Department Manager: Operations, Maintenance and Materials Managers.
Equipment Inspection: Inspections of equipment by Marafiq Safety Section prior to bring on to plant
and use
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23.2 RESPONSIBILITIES
Department Manager should ensure that:
 Safety inspections are scheduled, conducted, and documented in all work areas under his
jurisdiction
 Corrective actions are taken to control risks against the findings of the safety inspections.
 Copies of all documentation covering safety inspections are retained at their worksite for one (1)
year.
 Prior permission shall be obtained from area person in-charge or Central Control Room operator
to enter unmanned or restricted areas/facilities.
23.3 CLASSIFICATION OF SAFETY INSPECTIONS

Safety inspections shall be classified into following:
i. Formal Bi-Monthly Inspections (Once in 15 days)

ii. Formal Monthly Inspections
iii. EMT HSE Walk -
(Abbreviations:-
EMT – Executive Managing Team
HSE – Health Safety & Environment)
23.4 FORMAL BI-MONTHLY INSPECTIONS (ONCE IN 15 DAYS)

Formal bi-monthly inspections are the inspections conducted once in 15 days (twice a month) by
Department Team Leader (superintendent/engineer/supervisor/foreman) accompanied by an
employee from his division/section, against documentation.
Team leader in his area of responsibility should:
 Conduct “Bi-Monthly Inspections” (once in 15 days) with participation of one of his division/section
employees.
 Inspect the work area to identify hazards and non-compliances to MARAFIQ Safety Procedures.
 Record observations and recommended corrective actions in attached safety non-compliance
report form. (refer to attachment 1)
 Take necessary actions against the items which can be corrected by him and his division/section
employees. Record the same in the list.
 Liaise with other departments to accomplish the corrective actions through notification, purchase
requisitions and other management systems.
 Forward a list of unattended items to his manager/superintendent for further action.
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 Forward a copy of the Bi-Monthly safety inspection report to Department Manager/Superintendent

and Loss Prevention Division.
23.5 FORMAL MONTHLY INSPECTIONS

Formal Monthly Inspections are the inspections conducted by a team comprising of Operation /
Department Manager accompanied by representatives of other departments within the same facility
against documentation.
 Operation Manager should form an inspection team comprising members from Maintenance,
Engineering and Loss Prevention (Contractor if applicable) to conduct monthly site safety
inspection under his leadership.
 For workshops & warehouses inspections, the team would be restricted to Department
Manager, team leader & representative from Loss Prevention.
Department Manager in his area of responsibility shall:
 Decide the area and the date of the month on which inspection should be conducted and will
inform the team members in advance.
 Ensure that all the areas within his jurisdiction are inspected at least once in six months.
 Conduct the inspection.
 Record observations and recommended corrective actions in attached safety non-

compliance report form. (refer to attachment 1)
 Forward a copy of the monthly safety inspection report to Safety Section including team
members.
 Liaise with his department staff and other departments for accomplishment of corrective
actions by target date & action party.
 Adopt a follow up procedure to assure that the corrective actions are taken against the
inspection findings.
Note: - Safety Inspection guidelines for inspecting items under different headings are given in
attachment 2 for easy reference.
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23.6 EMT HSE WALK

(Abbreviations:-
EMT – Executive Managing Team

HSE – Health Safety & Environment)
Each EMT member excluding President will conduct two safety inspections in a year - one safety walk
in Jubail and one Safety walk in Yanbu
All EMT team members (together) will conduct two safety inspections in a year - one safety walk in
Jubail and one Safety walk in Yanbu
The visit team will assemble in the relevant facility Conference Room (Area Manager to book the
conference room). It is anticipated that the total visit time will be no more than 3 hours.
The Facility Manager, Superintendent, Shift Engineer and Maintenance Manager or Superintendent
and Loss Prevention representative should be present. If facility manager is unavailable on the
notified dates, ensure that a deputy is available.
Loss Prevention representative will provide an overview of the facility’s safety performance with
respect to the Site Safety Targets & Performance, status of the incident and non-compliances related
corrective actions, commenting as appropriate on areas for improvement.
The Facility Manager will give a brief overview of:

Progress on implementation of the company Safety Action Plan
Status of previous visit raised observations
The current safety concerns within his facility.
The EMT members will split into two teams or more to carry out site inspection on selected areas of
the facility, accompanied by facility’s representatives.
After the site inspections the teams will re-assemble in the Conference Room to discuss the findings
and any action required.
Marafiq safety section representative will collate the observations of EMT team & forward the report to
the Facility Manager.
Facility Manager should liaise with other departments, contractors, etc, for resolving interacting safety
related issues.
Page 4 of 21
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23.7 EQUIPMENT INSPECTIONS

23.7.1 All equipment that are brought on site must be inspected by the user and ensure that they are in safe
working condition
23.7.2 User should forward a written Equipment inspection request and get following listed machines inspected
by Marafiq Safety section prior to bringing on site as per checklist attached: -
 Mobile Crane Inspection– Please refer Title – Lifting Equipment – inspection checklist number
 Forklift Inspection Please refer Title – Lifting Equipment – inspection checklist number –
 General mobile equipment – Attachment-6
 Excavator – Attachment-7
 Vacuum tanker - Attachment-8
Page 5 of 21
Rev. No.: 0
Attachment 1
SAFETY INSPECTION REPORT
From:
Report # J( ) Y( )
Department:
Facility: Location:
Date: Time:
Inspection Team Name Job Title
Inspection Team Leader
Inspection Team Member 1
Inspection Team Member 2.
Inspection Team Member 3.
Status
Preventive / Corrective Action
Item No. Observation ETC Closed /
Action Required Party
open
Note: Please return this form to Safety Section after taking action(s) on above mentioned Safety Non-
Compliance(s)
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Rev. No.: 0
Attachment 2
SAFETY INSPECTION GUIDELINES
Safety Inspection guidelines given below are provided for easy reference to inspect items under
different headings.
Sr. DESCRIPTION OF ITEMS

1. PERMIT TO WORK
A. Permit to Work Certificate PTWC – exists
B. API (Authorized Permit Issuer ) – signed
C. APR (Authorized Permit Receiver ) – signed
D. AGT (Authorized Gas Tester ) – signed where required
E. APC (Authorized Permit Controller ) – signed where required
F. Work details – clearly specified
G. Specified safety requirements –adequate
H. Isolation Certificate – exists
I. Lock out boxes / padlocks / chains etc – available adequately
J. Department Isolation procedure / list - available
K. Isolation points – locked and tagged
L. Isolation – complete and effective
M. Excavation Work Request – Completed
N. Ionizing Radiation Work – Completed
O. Gas Free Certificate – Maintained
P. Notification Form to work on fire protection system – completed
Q. Test/Adjustment on Live Clearance – used
R. Record of Interconnection Point Safety –maintained
2. PERSONAL PROTECTIVE EQUIPMENT

A. Conforms to Standards
B. Provided & used properly
C. Maintained / stored properly
D. Employees trained in use / store /care / maintain of PPE
E. Records of inspection & maintenance – maintained
F. Helmet – worn
G. Safety Shoes – worn
H. Safety goggles – available / worn
I. Face shield – available / worn
J. Ear muffs / protectors – available / worn
K. Hand gloves – available / worn
L. Welding aprons – available / worn
M. Full body harness / lifeline – available / worn
N. Respirator – appropriate / available / worn
O. Breathing apparatus –available / worn
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P. Chemical clothing – available / worn

Q. Fireproof clothing – available / worn
R. Fire blanket - available
3. WORKPLACE
A. Good housekeeping – maintained
B. Access / egress - provided
C. Floors free from slipping hazards
D. Floors free from tripping hazards
E. Steel barriers – provided
F. Warning tape -provided
G. Flashing beacon lamps - provided
H. Illumination – adequate
I. Flameproof lighting - provided
J. Entry – restricted / prohibited
K. Waste bins – provided / segregated / labeled
Drinking water – available
L.
Non drinking water - identified
M. Toilets - adequate / hygienically clean
N. Ventilation - provided
O. Exhaust ventilation / hood - provided
P. Odor control system - working
Q. Locker rooms - provided
R. Openings- pits, holes, skylights, etc covered / guarded / screened
S. Aisles, stairs and passageways– marked /guarded /free from slips,
trip & fire hazards / clearance maintained for people and moving
machines
T. Access, exits, emergency exits and escape routes – marked /
signs posted / free from obstacles / clearly visible / lighting
provided
U. Workstation including chair– ergonomically sound
4.HAND & PORTABLE POWER TOOLS

A. Inspected & safe to use
B. Non sparking tools – available / used
C. Insulated tools - available / used
D. Sharp tools – prohibited
E. Chisels – Not mushroomed
F. Handles - provided
G. Hand held grinder – Guarded & Dead man’s switch provided
H. Storage – proper & safe
I. Guards – provided
J. Safe and defective tools - segregated
K. General condition - Good
L. Ground cable – connected
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1. ELECTRICAL SAFETY
A. Electrical tools/equipment –maintained / inspected /safe to use
B. Ladder used – Non conductive of electricity
C. Cables – free from defects of cuts / damaged insulation
D. Cables - Secured properly
E. Cables - Free from defects
F. Cables - Routed safely
G. Cables - Free from tape joints
H. Cables connectors –safe & free from defects
I. Plugs & sockets –safe & free from defects
J. GFCI (ELCB) – provided
K. Tools – insulated
L. Testers – insulated and safe to use
M. Electrical face shield – provided / used
N. Rubber mats – provided / used
O. Equipment –
i. Marked with identification numbers
ii. Isolated
iii. Locked
iv. Tagged / safety signs posted
v. Grounded
vi. Tested and proved dead
P. Switchboards / panel – closed
Q. Electrical panels – closed & secured
R. Panels – identified and accessible
S. Condition of equipment / fixtures – guarded / safe
T. Explosion proof fixtures in flammable atmosphere – available
U. Second man for live work – accompanied
7.LIFTING OPERATIONS
A. Lifting crane – Tested, certified & safe to use
B. Forklift – Tested, certified & safe to use
C. Lifting tackles – Tested, certified & safe to use
D. Man basket – tested, certified & safe to use
E. Load test certificates – available
F. Lifting study for critical lift – prepared
G. Rigger – appointed
H. Signal man – appointed
I. Operator – licensed
J. Safe and unsafe equipment – segregated
K. Storage – Proper & safe
L. Inventory – maintained
8.MACHINERY GUARDING
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A. Guard – provided
B. Machine – stable & rigid
C. Safe operating instructions – posted
D. Fence - provided where required
E. Locked where required
F. Exhaust – routed outside
G. Emergency stop switch – provided & operational
H. Push sticks for carpentry machines – provided / used
I. Gap between tool rest and grinding wheel – correct
9.SCAFFOLDING
A. Scaffold supervisor –qualified / present while erection/alteration
B. Scaffold erectors – Trained /wear full body harness
C. Scaffolding – inspected & tagged
D. Scaffolding structure –stable & rigid
E. Platform – fully boarded
F. Platform – free from excess material
G. Wooden boards – secured & free from defects
H. Base plates & braces– provided
I. Steel / wooden planking under base plates on soft soil – placed
J. Two guardrails – provided
K. Toe boards – provided
L. Castor wheels – locked
M. Access/Ladder – provided & adequate
N.
10.LADDERS
A. Nonconductive for electrical works –used
B. Conforms to International Standards
C. Standing on a firm base
D. Secured by lashing /clamping to stiles
E. Held by second person if not secured
F. Installed at 75 Deg angle –slope 1:4
G. Extended 1 meter above platform
H. Stiles – in good condition
I. Rungs – in good condition
J. Non slip pads –provided
K. Cages – provided for fixed ladders
L. Locking device for step or A frame ladders – provided
M. Allowed one person at a time on ladder
11.HAZARDOUS CHEMICALS
A. MSDS (Material Safety Data Sheets) available
B. Hazard Communication program – developed /implemented
C. Employee Training Program - developed /implemented
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D. Containers & storage areas – labeled and are in good condition

E. Chemicals – classified
F. Incompatible chemicals – separated
G. Safety signs – posted
H. NFPA Diamond – posted
I. Inventory – maintained
J. Flammables – stored in fireproof cabinets
K. Laboratory fume cupboard – working
L. Eye wash & Showers – provided
M. Wind socks – provided
N. Tanks – Vented
O. Tanks – grounded
P. Tanks – Pressure relief valves provided
Q. Spill containment / dyke- adequate
R. Absorbents & socks – provided
S. Means of exit /egress –provided
Pipe lines & vessels
T.
– color coded / direction marked / contents labeled
U. Disposal program – developed / implemented
11.CONFINED SPACE ENTRY

A. Gas testing – done and recorded in PTWC
B. Gas Free Certificate – Maintained
C. Gas Tester – Authorized
D. Entry and Exit record – maintained
E. Access / egress – provided
F. Standby Attendant – trained / appointed
G. Communication devices – provided
H. Forced Ventilation – provided
I. Exhaust fan / duct- provided
J. Flameproof lighting – provided
K. Gas cylinders – kept outside space
L. Gas hoses / torch –removed if not in use
M. Extra low voltage electrical tools – used
N. Emergency rescue arrangement – available / people trained
O. Fire extinguisher – provided
P. Hazard classification identified
Q. Hot work – controls in place
12.MOBILE VEHICLES / TANKERS

A. Equipment –inspected
B. Grounding – provided
C. Reversing backup alarms – provided
D. Overhead guard – provided where required
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E. Battery charging areas – designated

F. Operators – licensed
G. Fire extinguishers – provided
H. Lights – functional
I. Oil and fuel tank / lines- free from leaks
J. Exhaust silencer – efficient / not noisy
13.PNEUMATIC EQUIPMENT
A. Vessels – Inspected, pressure tested and tagged
B. Connections – appropriate
C. Breathing air compressor / filter - provided
D. Safety valves –provided /operational
E. Vent / pressure relieve valves – provided
F. Pressure regulator valve – functional
G. Drains – clear
H. Flexible hoses – connected with proper couplings and secured
14.WATER SAFETY
A. Lifebuoys– provided
B. Rescue team – available
C. Life jacket – provided / used
D. Rescue rope lines
E. Warning notices – posted
F. Platforms and gangways – barricaded
G. Grab lines – provided
Self Contained Underwater Breathing apparatus SCUBA –
H.
provided-
I. Life boat – inspected / safe to use
15.HOT WORK
A. Gas cylinders – kept upright & secured
B. Gas cutting set – inspected
C. Flashback arrestors – provided
D. Hose check valves at torch end – used
E. Fireproof screens / metal sheets – used
F. Fire blanket – Used
G. Standby Attendant/Fire watch –appointed
H. Fire extinguisher – kept nearby
I. Welding cables – in good condition
J. Welding apron – available / used
K. Welding screen – used
L. Electric holder – insulated
M. Cables / couplings – insulated and in good condition
N. Earth – connected
O. Proper welding respirators – used
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16.EXCAVATION
A. Underground services – Identified
B. Hand digging – performed as specified in PTWC
C. Machine digging – performed if specified in PTWC
D. Shoring / Benching Sloping – provided
E. Trench sheets / steel piling – provided
F. Spoil – kept 1 meter away
G. Cross over bridge – provided
H. Access / ladder – provided
I. Stop blocks for vehicles – provided
J. Dewatering – done / being continued
K. Hard barriers – placed 1 meter away from edges
L. Means of escape – provided
M. Emergency arrangement – available
N. Ventilation – provided
O. Flashing lamps – provided
P. Underground services – protected
17.RADIOGRAPHY
A. Prior notice to concerned - given
B. Radiation caution signs - posted
C. Barrier - erected up to safe distance
D. Flashing warning lamps – provided
E. Contingency plan – made
F. Contractor – licensed
G. Employees – classified
H. Ionizing radiation request - completed
18.EMERGENCY ARRANGEMENT
A. Rescue winch & tripod - ready
B. Stretcher / body harnesses - available
C. Trained rescuer – appointed
D. Emergency eyewash & shower - provided
E. Assembly points - marked
F. Wind socks - installed
G. Emergency evacuation plan – posted
H. Emergency contact telephone number – posted
I. Emergency communication system -available.
19.LIGHTING
A. Lighting - adequate / no eyestrain / glare / reflection
B. Stairs and doors - lit properly
C. Bulbs / tubes– working
D. Walkways – adequately illuminated / clear vision
E. Lighting fixtures – clean / efficiently working
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F. Explosion proof lighting – provided where required
20.PORTABLE FIRE EXTINGUISHERS

A. Inspected & tagged
B. Mounted on walls / brackets /trolleys
C. Appropriate and adequate in number
D. Hydro-tested
E. Gage shows correct pressure
F. Fire extinguisher point – labeled
G. Safety pin – in tact
H. Access –free of obstacles
21.FIXED FIRE PROTECTION SYSTEMS

A. Automatic sprinkler system - working
B. Alarm system - working
C. Alarm break glass w/ hammer - available
D. Smoke / gas detectors – available / working
Fire extinguisher – UL listed / marked with identification number /
E.
inspected / tagged /serviceable / records maintained
F. Carbon Dioxide CO2 system - working
G. FM200 system - working
H. Deluge system - working
I. Foam system - working
J. Fire hoses –
i) Properly mounted
ii) Accessible & free from obstacles
iii) Maintained in good condition
iv) Visibly marked
K. Fire hydrant valve – locked open where required.
L. Fire doors / lids / shutters –
i. Free from obstacles / kept closed
ii. Maintained in good condition
22.CHLORINE SAFETY
A. Cylinders –
a. i) Tested and certified
ii) Free from defects like corrosion, dents, pitting, etc.
B. Protective safety caps - in place
C. Emergency repair kits -available
D. Lime pit - available
E. Ammonia torch - available
F. Lifting beams – tested & certified
G. Lifting crane – Tested & certified
H. Safety signs – provided
I. Container handling instructions - posted
Page 14 of 21
Rev. No.: 0
J. Windsocks - provided
K. Material Safety Data Sheet - available
L. SCBA - available
23. COMPRESSED GAS CYLINDERS

A. Tested & certified and correct color coded
B. Color coded correctly
C. Kept upright
D. Properly secured
E. Protected from heat sources
F. Stored away from stairs, elevators and egress routes
Full & empty cylinders –
G.  legibly marked
 separated
H. Oxygen and acetylene cylinders –separated
I. Cylinder caps – provided / in place
J. Storage area – labeled
K. Safety signs - posted
24.SAFETY SIGNS & INSTRUCTIONS

A. Clean and clearly visible
B. Placed at prominent positions
C. Conform to Marafiq Standards
D. Prohibition & limit signs - provided
E. Emergency signs - provided
F. Fire equipment signs - provided
G. Mandatory signs - provided
H. Caution & Warning signs - provided
I. Specific instructions - posted
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Attachment 3 Equipment Inspection Request
Request to: Date:
Requested by: Name of Company:
Type/model: Equipment location:
Area intended to use: Duration of duration:
Note: Please Complete the Requirements Specified In Equipment Inspection Checklist Form
Issued By Safety Section Prior to the Actual Inspection.
Page 16 of 21
Rev. No.: 0
Attachment 4 MOBILE CRANE INSPECION CHECKIST

Department / Contractor: Date of Inspection:
Crane Details:
Make/Model:
Type:
Serial Number:
CHECK POINTS YES NO
 Crane operator’s license/certificate - valid
Name of Operator: License Number:
Date of certification: Date of Expiry:

 Crane’s current load test certificate from third party inspectorate - exists
Name of Third party inspectorate:
Test certificate No:
 Tires - free from obvious defects
 Electrical items including battery - safe and covered
 Fire extinguisher – provided, inspected & in good condition
 Engine, hydraulic, brake and fuel systems - free from leaks
 Crane hook hoisting and auxiliary cables - in good condition
 Audible reversing alarm - fitted and in working order
 Main hoist operation - smooth with no binding / vibration
 Spark arrestor - exists
 Flashing visible warning light – available and in working order
 Safe Working Load SWL – marked on crane
 Load chart and working range diagram – available in the cabin
 Automatic safe load indicator alarm – working a must
 Hoist limit switches / anti-two blocking device - working

 Wooden / steel blockings to place under outrigger floats Minimum 1 M x 1M - provided
 Lifting hook safety latch – in good condition

 Competency of crane operator–Understanding of crane’s load chart and limitations
Crane: Approved / Not approved

Comments:
Inspected by : Signature :
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Attachment 5 FORKLIFT INSPECTION CHECKLIST
Department / Contractor: Date of Inspection:
Forklift Details:
Make: Type:
Model: Serial Number:
CHECK POINTS YES NO
1. Forklift operator’s license/certificate - valid
Name of Operator: License Number:
2. Forklift’s current load test certificate from third party inspectorate - exists
Name of Third party inspectorate:
Test certificate No:
3. Safe working Load - clearly marked and or known by the driver
4. Flashing warning light - fitted and in working order
5. Lifting mast chain, brakes & hydraulic system - in good condition?
6. Dangerous moving parts - suitably guarded
7. Tires - free from obvious defects
8. Audible reversing alarm - fitted and in working order
9. Electrical (battery) connections - covered and free from obvious defects
10. Fire extinguisher - inspected & in good condition
Forklift: Approved / Not approved

Comments:
Inspected by : Signature :
Page 18 of 21
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Attachment 6
GENERAL MOBILE EQUIPMENT INSPECTION FORM
Type of Equipment / Model / Serial #: Name of Company:
Inspected by: Date of Inspection:
_____________________________ ___________________
Name
CHECK POINTS YES NO N/A

Are the Electric (Battery) connections and wiring in good condition?
Are earthling connections in good conditions (i.e. available, PVC
covered and bolted into connection point)?
Are there any visible fuel or hydraulic leaks?
Are moving parts (e.g. Fan or belts) securely guarded?
Are the tires in good condition?
Is the towing connection in good condition?
Is there a flashing warning light fitted and in working order?
Is there an audible reversing alarm fitted and in working order?
Is the “STOP " button clearly marked?
Is the fire extinguisher inspected & in good condition?
The Equipment IS / IS NOT approved for use at MARAFIQ

Action Required / Comments
Page 19 of 21
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Attachment 7
EXCAVATOR INSPECTION FORM
Type / Model / Serial #: Name of Company:
_____________________________ ___________________
Name
CHECK POINTS YES NO

Is the Safe Working Load (SWL) clearly marked or displayed in the cab?
If fitted, is the lifting hook in good condition?
Are dangerous moving parts suitably guarded?
Are the tires free from obvious defect?
Is the horn in working order?
Is there an audible reversing alarm fitted & in working order?
Are electrical (battery) connections covered & free from obvious defect?
Are there any obvious hydraulic or fuel leaks?
The equipment IS / IS NOT approved for use at MARAFIQ
Page 20 of 21
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Attachment 8
VACUUM TANKER INSPECTION FORM
Type / Model / Serial # : Name of Company:
_____________________________ ___________________
Name
CHECK POINTS YES NO

Is the vehicle generally in good condition? ( Check tires, fuel / hydraulic
leaks)
Is the vehicle fitted with a readable pressure gauge?
Does the vehicle have a means of level detection? Is it clear?
Is there a pressure relief valve fitted to the tank?
Are the hoses in good condition and certified anti-static?
Are the Vacuum pump controls accessible from outside the cab?
Is the Vacuum pump outlet sited away from the exhaust system?
Is there an earth / bonding cable fitted? Is it in good condition?
Are electrical (Battery) connections free from obvious defect?
The Equipment IS / IS NOT approved for use at MARAFIQ
Page 21 of 21

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Document ID No: MSSM-1-SF-001

Power & Water Utility Company for

MARAFIQ SAFETY MANUAL