Fabrication Site Construction Safety Recommended Practice - Hazardous Activities

REPORT NOVEMBER
577 2018
Fabrication site construction

safety recommended practice
– Hazardous activities
responsible together
Acknowledgements
Safety Committee
Fabrication Site – Construction Safety Practices Task Force
Photography used with permission courtesy of

Front cover: ©Heerema Fabrication Group and ©Sembcorp Marine Ltd
Page 9: ©Saipem
Page 15: ©Sembcorp Marine Ltd
Back cover: ©Shamtor/iStockphoto
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Fabrication site construction safety recommended practice – Hazardous activities
IOGP Fabrication site construction

Safety performance for contracted work performed at fabrication sites continues to
be a challenge in the oil and gas industry. While IOGP’s data shows that injuries and
fatalities have reduced significantly over time, they are still too common. The long-
term repercussions from these incidents can be felt by the injured parties as well as
their families for many years to come.
Fabrication site construction contractors are expected to comply with differing, and
sometimes conflicting, requirements from oil and gas companies. This leads to
workforce uncertainty and change, which have the potential to result in higher risk
work environments. The consistent demand for work in fabrication sites from the oil
and gas industry will continue to expose sites to these risks.
A Task Force comprised of IOGP Members was established to recommend

standardized minimum global safety requirements for these sites, and to help drive
global improvements in contractor and subcontractor safety performance. The
result was the publication of IOGP Report 577 Fabrication site construction safety
recommended practice – Hazardous activities for activities carried out in fabrication
sites in which the contractor’s HSE management system is followed.
In addition, IOGP Report 597 Fabrication site construction safety recommended

practice – Enabling activities was published to complement and support the
implementation of IOGP 577.
To assist with implementation, a Resource Library is available on the IOGP website

to support successful implementation of IOGP 577 and IOGP 597 and provides
optional references, example practices, and tools. The Resource Library is optional
as the need for additional support varies country by country, company by company,
and site by site.
With ownership and implementation by IOGP Members, EPCM companies, and

fabrication contractors, the combination of IOGP 577 and IOGP 597 and the
Resource Library provide a standardized set of requirements and expectations
across fabrication sites resulting in cost savings, simplified processes, and most
importantly: a safer work environment!
These reports have been developed for application to IOGP Members’ and
contractors’ fabrication sites. The practices and activities provided may also be
applicable to construction activities in general, including those at IOGP Members
owned sites. Hence, IOGP encourages the applicability of reports 577 and 597 to all
IOGP Member construction activities.
3
Contents
Scope and implementation 6
Application of this guidance 7
1. General 8
2. Confined space entry 10
3. Construction traffic interface 13
4. Dropped objects 16
5. Energy isolation/Lock-out Tag-out 18
6. Housekeeping 20
7. Job Safety Analysis / Permit to Work 21
8. Lifting and hoisting 24
9. Personal Protective Equipment 27
10. Scaffolding 29
11. Simultaneous Operations 31
12. S
ystem testing 32
13. Working at heights 35
14. Working with electricity 37
Glossary 39
4
REPORT NOVEMBER
577 2018
Fabrication site construction

– Hazardous activities
Companion report to IOGP report 597, Fabrication site
construction safety recommended practice – Enabling activities
Revision history
VERSION DATE AMENDMENTS
Minor revision to align with new IOGP Life-Saving Rules.

1.2 November 2018
Recommended practices content is unchanged
Minor revision to align front matter with publication of companion report 597,
1.1 March 2018
and including corrections throughout
1.0 February 2017 First release
5
Scope and implementation
This report is a part of a project to address fabrication site construction safety,

consisting of the following:
• IOGP 577 Fabrication site construction safety recommended practice –
Hazardous activities
• IOGP 597 Fabrication site construction safety recommended practice –
Enabling activities
• Fabrication site construction safety – online Resource Library
IOGP 577 provides standardized minimum recommended practices for addressing

safety risks associated with fatality potential or significant incident hazardous
activities common to the fabrication sites.
The overall aim is that with IOGP Members requiring a consistent set of
recommended practices, fabrication sites can have their own set of requirements,
no matter the IOGP Member customer, which meet or exceed the requirements of
these recommended practices.
The selection of hazardous activities is not intended to be comprehensive, and the

recommended practices are not detailed procedures; but rather provide essentials
for preventing significant incidents and fatalities that the governing management
system is expected to include. There are other hazardous activities at fabrication
sites that IOGP Members should also ensure that fabrication sites address.
The recommended practices are consistent with other IOGP work, such as the
Life-Saving Rules, Report 459.
They are written as statements of ‘must have’ requirements for activities performed
at the fabrication sites to meet the expectations of IOGP Members. They can be
easily turned into questions and, therefore, easily be used for pre-start/readiness
checklist for construction verification and field verification reviews.
Example of turning a statement into question

General recommended practice #4: Everyone working at a site has the
right and responsibility to Stop Work if they see an unsafe situation. Site
Management ensures that this responsibility is communicated to all on site
and understood.
• Does everyone working at a site have the right and responsibility to
Stop Work if they see an unsafe situation?
• Does the Site Management ensure that this responsibility is
communicated to all on site and understood?
6
Application of this guidance
The IOGP Task Force believes implementation of these recommended practices

across the oil and gas industry will reduce fatalities and significant injuries,
and have a positive impact on the lives of workers and their families. Consistent
support and application by operators, EPCM companies and fabrication
contractors is crucial for maximizing the benefits of these practices.
To achieve this vision, the IOGP Members participating in the Task Force
recommend that IOGP Members consider the use of one or more of the following
adoption approaches:
• incorporate recommended practices within company standards
• include recommended practices within contract specifications and
contract agreements (see also: IOGP Report 423, HSE management –
guidelines for working together in a contract environment)
• utilize recommended practices during pre-execution reviews of contractor
capability
• utilize recommended practices for assurance actions during execution.
As the intent is to have a consistent set of requirements at each fabrication site,

no matter the customer, companies should be cautious about adding additional
statements to the recommended practices for the hazardous activities covered in
this document. Where companies find the need to add requirements to a covered
hazardous activity, they are invited to provide feedback for consideration in future
document updates (email: feedback@iogp.org). IOGP documents are reviewed
every three years but may be updated sooner if needed.
Companies implementing these practices are also encouraged to contact IOGP

publishing with feedback and lessons learned to help improve these recommended
practices in future updates.
7
1. General
1) All activities comply with their local applicable legislative requirements.

2) All recommended practices apply to all workers at site including clients and
subcontractors.
3) Site Management ensures all Personal Protective Equipment (e.g. full body
harnesses and safety eyewear) and dropped objects prevention materials
(e.g. tool lanyards) for construction activities are provided at no personal cost
to all workers on a site (including subcontractor personnel).
4) Everyone working at a site has the right and responsibility to intervene
(sometimes called stop work authority) if they see an unsafe situation. Site
Management ensures that this responsibility is communicated to all on site
and understood.
5) Procedures or policies are in place for all the activities listed in this document
and other hazardous activities that the site executes. Deviations to procedures
are reviewed and approved by management prior to proceeding with activities.
6) Risk assessments are conducted for all work activities, scaled to the need
(from a formal risk assessment for complex tasks to personal Job Safety
Analysis for typical tasks as a minimum).
7) Plans for fire and other emergency situations, containment, escape, and
emergency access and egress are available and communicated.
8) Site Management provides induction, training, and at-work oversight to ensure
people working at the site are competent for their work. Site Management
assures the competence of the people working at the site, including oversight
of subcontractors to ensure competence. Specialist training, such as on the
hazards associated with inert gasses, are specifically addressed.
9) Site Management provides a system to develop short service workers. Short
service workers are in the development program for a timeframe agreed with
the client, unless they can show documentation of an assessment that shows
why they graduate early. The short service worker system needs to include
mentoring and field identification of the worker. If it is not possible to meet
the requirements for short service worker, then an appropriate mitigation plan
needs to be in place.
10) There are assurance and verification processes for compliance with the site’s
system for safe work.
11) There are medical facilities, and/or agreements with local providers, suitable
for immediate response to reasonably foreseeable incidents.
8
12) Site Management provides facilities (e.g. shelter, eating areas, toilets, break
areas and First Aid) typical to cater for the wellbeing of the workforce. Potable
drinking water, toilet and hand washing facilities are made available to the
workers in the work area.
13) Where gas and utility service manifolds (air, nitrogen, flammable gas) are
used, each is specifically identified with unique connection/fitting. The
manifolds are labelled indicating service.
14) Incident management, investigation, reporting and incident learning processes
are agreed with the client.
15) Site Management provides engineering specifications for fit-up tools and
fabrication aids, design and use; specification and testing requirement for all
‘fabricated in-house’ tools, cables, hoses, etc. and fabrication aids design and
use. The Safe Working Load is visible on fabricated supports.
9
2. Confined space entry
Confined spaces are enclosed or partially enclosed spaces that are not
designed or constructed for continuous human occupancy, have limited or
restricted means for entry or exit, and where there is risk of injury or illness
from hazardous substances or conditions. Confined spaces include, but are not
limited to, underground vaults, tanks, storage bins, manholes, pits, silos, process
vessels, pipes and tubulars. Constant vigilance is required during construction
to recognize and manage new confined spaces which may be created, including
entering tubulars/piping for testing or inspection.
1) Carrying out work activities in confined spaces is avoided wherever possible.
2) There is a documented confined space entry procedure that describes work and
permit authorization processes.
3) Pre-entry planning considers and ensures where applicable the following:
• the risks and necessary measures for when atmospheric oxygen content
differs from normal (20.9%)
• that ventilation and air extraction system are in place and used when
natural ventilation is not adequate
• gas/atmospheric testing and its frequency
• that communications are in place and tested between workers and
watchman/attendant
• that Personal Protective Equipment evaluation and its use is relevant for
the work being done
• that an escape/rescue plan is in place
• that emergency response plan and equipment is in place at the workplace
• that the emergency team is trained, equipped and available for rescue and
First Aid
• that the required firefighting equipment is available
• the equipment and tools to be used are checked prior to use
• the low voltage and/or ground fault protected equipment and lighting
inside the confined space
• that spray painting in confined space addresses additional measures as
described below
–– Engineering controls such as ventilation to prevent worker exposure
to hazardous atmospheres
–– Personal protection as described in PPE section for vapor and
chemical exposure
–– Grounding or bonding for Arcing/sparking potential from equipment
–– Hazardous atmosphere or intrinsically safe rating for energized
equipment/systems/wiring
10
• the identification and verification of isolation needs

• the location of breathing air sources
• the location of inert or hazardous gas sources (bottles or packs)
• the location of generators or equipment with engine exhaust.
4) Gas monitoring/atmospheric testing is carried out and recorded by Authorized
Gas Tester prior to the commencement of, and during, the work. Gas
monitoring/atmospheric testing is in place during work activities in accordance
with the Job Safety Analysis and at least after every break, after lunch and at the
beginning of a new work shift, or if the atmosphere inside the confined space is
expected to change during work activities (e.g. during welding operations).
5) Clear communication is maintained between the entrant and the watchman
(attendant), e.g. voice, radio, pre-arranged signals and whistles.
6) All entries into confined spaces are controlled with a confined space entry
permit through the Permit to Work system. Each permit applies to a single
confined space.
7) All the potential hazards (e.g. hazardous atmosphere, fire, falls, snags,
congestion, release of hazardous energy, migration of hazardous products,
fatigue, temperature) and acceptable entry criteria have been identified and
recorded on the pre-entry plan, Job Safety Analysis and permit; and the controls
to safely enter and exit confined spaces are in place.
8) Simultaneous operations relating to confined space entry are identified and
addressed.
9) There is a means of controlling all potential entry points, including labelling,
signage and barricading, a tag system to account for all entrants that is
managed at the access point of the confined space.
10) Isolation requirements are verified through Permit to Work and Lock-out Tag-
out procedures.
11) Pre-entry meetings, attended by all personnel involved in confined space entries,
are held in order to review the Job Safety Analysis and the confined space
entry permit to ensure that all measures are implemented, isolation points in
place and gas detection done prior to authorizing the work to start and entry.
11
12) All personnel with roles and responsibilities in the planning, approval,
execution, and monitoring of entry into confined spaces are trained in a
language they understand, including (but not limited to):
• Entry supervisors
• Authorized entrants
• Watchmen (attendant)
• Permit coordinators
• Permit approvers
• Authorized Gas Tester
• Emergency/Rescue team.
13) Confined space is attended by a trained and competent watchman (attendant)
with no other duties, typically one per entry point. One watchman on two or
more confined spaces is possible if all confined space entry points they are
responsible for are visible from one standing point of the watchman, and the
watchman is able to perform their responsibilities for all confined spaces they
are responsible for.
14) Utility lines (e.g. oxygen and gas hoses) are disconnected or removed when not
in use – this is verified by entry Supervisor in charge and double checked by the
watchman (attendant).
15) Permit to Work is closed after completion or suspension of the confined space
work, and a means of preventing re-entry is established.
Relevant IOGP Life-Saving Rules, Report 459
Obtain authorisation before entering a confined space
Work with a valid permit when required
Control flammables and ignition sources
12
3. Construction traffic interface
The interface between pedestrian traffic and construction traffic, which could
be any self-propelling vehicle or equipment, such as trucks, vans, coaches,
mini-buses, earth movers, tractors, diggers, fork-lift trucks, mobile elevating
platforms or remotely operated vehicles. As much as possible, ensure separation
of pedestrians and vehicular traffic.
1) There is a site-specific construction traffic interface plan.
2) The plan ensures risks associated with workplace transport are identified and
control measures are adopted to ensure the safety of pedestrians or persons
at work. The plan considers the following:
• the layout of the site, the activities carried out, the types of vehicles/
mobile equipment used, the competency of operators, and the control
measures for subcontractors and delivery drivers
• the steps to be taken to prevent vehicle incidents, including detail of
site traffic routes for the safe movement of vehicles/equipment and
pedestrians, fatigue management, and drivers to check that the vehicle
being driven is free from hazards before moving the vehicle (a good
practice is to perform a 360 walk around)
• risk awareness training for all personnel on hazards associated with
construction traffic interface with emphasis on blind spots and the
appropriate use of spotters
• that only authorized/approved persons operate a vehicle/truck/motorized
equipment
3) The plan contains the following ways to protect vehicle Spotter/Banksmen/
Flagmen/Signallers:
• through the use of technology (sensors, cameras etc) eliminate the need
for Spotters if possible
• remove Spotters from direct ground support near vehicles and equipment
by utilizing radio communications or providing a central protected location
for their use
• provide ample separation distance between Spotters and vehicles and
equipment as indicated by blind spots
• train Spotters and vehicle/equipment operators in spotting procedures
including use of standard hand signals and blind spot areas and hazards.
4) Reflective and high visibility apparel is used when exposed to operating vehicles.
5) All external drivers are briefed and monitored on the site’s requirements and
enforcement of rules.
13
6) Pre-mobilization and periodic site vehicle/equipment inspections are

conducted. Defective vehicles/equipment are tagged and removed from
operation. There is a process in place to manage service and preventative
maintenance.
7) The interaction between pedestrians and vehicles/equipment is minimized by:
• dedicated and delineated walkways/paths, clear and marked crosswalks,
efficient intersections, and segregated parking
• signage and barriers that separate pedestrians from vehicle paths
utilizing universal signage or the applicable language of workforce
• barriers or rails to prevent pedestrians crossing traffic routes at
particularly dangerous points
• clearly define pedestrian crossing points, at crossing points where
volumes of traffic are particularly heavy, consider providing suitable
bridges or subways. Consider also potential overhead hazards.
8) Workplace traffic routes:
• eliminate or minimize interaction between pedestrians and vehicles/
equipment
• maximize the use of one-way traffic
• clearly post and enforce speed restrictions
• designate parking areas
• do not pass close to anything that is likely to collapse or be left in a
dangerous state if hit, or to any edge, unless these are fenced or protected
• include planned and maintained access routes for emergency response
vehicles
• minimize the need for vehicles to reverse in loading and unloading areas
9) Sites:
• utilize lighting for night or low visibility vehicle movement
• utilize audio reversing alarms on vehicles and equipment while reversing;
consider back-up cameras for reversing
• establish boundaries to limit non-essential construction vehicles (cars,
scooters, motorcycles, bicycles)
• have safe practices for refueling
• prohibit vehicle blind spots as areas for pedestrians during work or rest
periods
• prohibit the use of hand-held devices (such as mobile phones, tablets,
satellite navigation and order tracking systems) while in control of a
moving vehicle/equipment.
14
Follow safe driving rules
Keep yourself and others out of the line of fire
Please refer also to IOGP Report 365, Land transportation safety recommended
practice, and guidance note 365-17, Mobile Construction Equipment
15
4. Dropped objects
Dropped objects can be associated with tools, materials, debris or other objects
in general which fall from height, or take flight due to high wind conditions, and
end up causing damage or at worse, a fatality.
1) The site has a plan for the prevention of dropped objects. The plan can include
scenarios such as ways to minimize exposure to dropped objects by promoting
ground assembly when possible, preparation for high wind conditions, personal
tool inventory, minimization of any work activities in and around established
exclusion zones, and performing dropped object surveys for the removal of
potential dropped objects prior to transportation of equipment or modules.
2) An identified person is assigned as responsible for the site’s dropped object
prevention plan.
3) Potential dropped objects are identified (including personal items and fixed
equipment), mitigating controls are established, and coaching/training is
included and conducted as part of the pre-job Job Safety Analysis/toolbox
talks.
4) Barricades and signs/tags are in place to restrict access to areas under and
around elevated surfaces on which work is being performed in order to prevent
entry into a potential dropped object area.
5) If work is necessary that puts workers in a potential dropped object area,
workers below are shielded from dropped objects using catch nets, temporary
roofing, floor fabric or other means adequate to retain objects with the
potential to fall.
6) Personnel use mechanized means (e.g. pulley systems or ropes) or tool bags
and tool belts to move tools and materials to or from an elevated work area to
eliminate hand carrying tools and equipment up and down stairs and ladders.
7) All tools, loose materials and equipment that have potential to drop to lower
areas during work are secured using lanyards, material bags, tool bags/boxes,
etc.
8) Personnel working in elevated work areas maintain the highest possible
housekeeping standard at all times to reduce the risk of potential dropped
objects.
9) Regular inspections and periodic ‘Hazard Hunts’ are performed at the site to
ensure that precautions are taken to prevent objects from falling from height
(e.g. hand tools are tied off, no loose objects, no holes in grating, toe boards
are in place, regular housekeeping, barriers are in place where necessary,
head protection is worn where required, etc.)
16
10) Tools and materials are not thrown or dropped to or from elevated work
surfaces (specially designed trash chutes are acceptable).
11) If a work crew identifies their work could have dropped object potential, they
include this on the Permit to Work/Job Safety Analysis and communicate it to
the affected work parties.
12) Fit-up tools are secured by appropriate means to avoid their fall in case of any
failure.
Protect yourself against a fall when working at height
Plan lifting operations and control the area
17
5. Energy isolation/Lock-out
Tag-out
This section identifies and controls energy sources which must be made safe
before work begins (e.g. electrical, pneumatic, mechanical, thermal, hydraulic,
chemical, gravity, rotational).
1) An energy isolation and de-isolation (energy control) procedure is documented
to ensure that potential energy sources for work activities are pre-planned,
identified, isolation verified and test started to demonstrate zero energy is
performed before work begins. Provisions are in place to address extended
period isolations and re-energizing for test purposes.
2) The acceptable standards of isolation used in the fabrication site are defined
(e.g. locked switches, racked out breakers, air gap in piping, double block and
bleed valves, fans immobilized, etc.).
3) The personnel responsible for identifying, implementing, and verifying required
isolations are listed on a register. Training that describes the procedure and
how to fulfill their roles and responsibilities is provided. Training is provided for
all personnel working under or impacted by the energy control procedure.
4) All energy control devices are as close to the work site as possible, have an
attached tag identifying the person who applied the isolation, the date and
purpose of isolation, and a statement such as “Do Not Start” or “Do Not
Operate”. Tags used without an energy control device are not acceptable for
isolation.
5) Energy isolation is documented by the responsible person and is either
attached to, or part of, the work permit identifying the isolations implemented
prior to commencement of the work activities, which are reversed before
Permit to Work is closed out. The existence of multiple energy sources to
individual pieces of equipment are identified and recorded by the responsible
person.
6) Prior to the commencement of work, a pre-work meeting at the work place
occurs with the work team and the authorized person to confirm that all
isolations are in place.
7) When two or more tasks require isolation at the same point, each job is
identified and locked independently.
8) After isolation, locking and tagging, energy sources are tested or otherwise
checked to verify zero energy prior to the commencement of work activities.
9) Work handover between shifts includes verification of energy isolation to
ensure continuity of protection.
18
10) Prior to authorizing de-isolation the Responsible Person ensures that:

• equipment/systems that were isolated are now safe to energize
• the status of the isolation device(s) enables safe de-isolation
• all work on the Permit to Work has been completed satisfactorily
• any areas or operations that may be affected by the de-isolation are
identified
• any communications considered necessary or appropriate have been
carried out.
11) The procedure includes de-isolation in special conditions such as an
emergency, the key is lost, or the responsible individual has left the workplace.
The worksite identifies a person, or delegate in charge, whose approval is
required to de-isolate in these circumstances.
12) Compliance with the energy isolation and de-isolation (energy control)
procedure and practice is audited as part of the Permit to Work process.
13) When the equipment or module is transported out of the site, there is a
handover energy isolation register that records the status of all energy
isolations in place, including any long term over rides. This register is handed
over to the future operator of the module/equipment.
0
Verify isolation and zero energy before work begins
Obtain authorisation before overriding or disabling safety controls
19
6. Housekeeping
Good housekeeping directly prevents incidents such as slips, trips and falls and
dropped objects. Good housekeeping is also a good indicator of a well-run and
disciplined site that has pride in its work and site.
1) Site management provide resources to support effective housekeeping,
including:
• a plan for the segregation and disposal of scrap, waste and surplus
materials
• a plan for storage of material and supplies that considers the flow of
personnel, equipment, materials, fire hazards, and clear routes for
evacuation, firefighting and rescue.
• hardware such as trash chutes, bins, trash cans, hose manifolds, hanging
trees for hoses and cables, etc.
• arrangements for removing debris at a frequency that keeps the worksite
orderly
• equipment such as cranes, tractors, and trucks to support logistical
movements of accumulated trash containers
• personnel to support housekeeping logistics.
2) Site management sets expectations for the following;
• that stairways, passageways, ladders, scaffold and gangways are free of
material, supplies and obstructions
• that lay-down areas and trash segregation areas allow good
housekeeping practices
• that cords, cables and hoses are protected from damage and kept out
of walkways and working surfaces and where possible elevated on
designated hangers to eliminate tripping hazards
• that flammable materials are segregated when stored and used to
minimize fire hazards.
• that material is kept from being placed in locations where it would be a
dropped object hazard.
3) Site management communicates and frequently reinforces expectations for
housekeeping.
4) Regular walkthroughs and inspections by site management are used to
systematically monitor housekeeping.
5) Individuals perform housekeeping in their work areas as needed throughout
their shift, but at minimum at the end of each shift.
6) Supervisors verify that their work teams perform housekeeping in alignment
with expectations.
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7. Job Safety Analysis /

Permit to Work
A Job Safety Analysis is a formalized procedure whereby persons involved in
a task get together before work starts to assess the work, identify associated
hazards and recommend safe job practices and precautionary measures.
A Permit to Work system is a formal written system used to control certain

types of work which are identified as potentially hazardous. It is also a means of
communication between site/installation management, supervisors and those
who carry out the work.
1) All site work activities are risk assessed. All non-routine or hazardous
activities require some type of Job Safety Analysis: a generic Job Safety
Analysis for lower risk activities, a unique Job Safety Analysis and a Permit to
Work are required for higher risk activities as defined by the Site. Sites agree
with the project team those routine activities they feel will not require Job
Safety Analysis.
2) Prior to performing a task, field personnel have a pre-job meeting and review
the Job Safety Analysis and the work permit. All members of the work team
are required to review and sign the Job Safety Analysis and/or permit.
3) Workers will stop work if the work scope or work conditions change, if an
incident or near miss happens or if there is a site emergency alarm or
evacuation. The Job Safety Analysis and permit are reviewed and revised as
needed, and the permit re-authorized or re-issued before work resumes.
4) Work planned for one area or system is reviewed to identify hazards (such as
energy sources, hazardous atmospheres, working at heights, and confined
spaces) and controls associated with conflicting work scopes in the same or
adjacent areas.
5) Site Management has a verification system in place to ensure personnel at site
follow the requirements of the Permit to Work and Job Safety Analysis.
Job Safety Analysis

6) The Job Safety Analysis process:
• identifies the basic steps included in a task
• identifies the hazards associated with each step, including potential
hazards from other activities in the same area
• identifies controls to eliminate/minimize each identified hazard.
7) A Job Safety Analysis is written in the working language of the work group
when the literacy level of the work group allows, or as a minimum there are
arrangements to verbally review the Job Safety Analysis with the work group in
the language they use.
21
8) A Job Safety Analysis is written by the work team or by individuals as close to

the work as possible, with active participation by First Line supervisors and
members of the work team.
9) First Line supervisors are responsible for monitoring the work to verify
implementation of the controls identified in the Job Safety Analysis.
10) Focus areas on line-of-fire hazards are included in the Job Safety Analysis,
such as:
• dropped objects
• swinging loads
• pressure releases
• tool or equipment movement
• hoisted loads that might swing or fall
• sources of energy: electrical, hydraulic, heat or pressure.
Permit to Work
11) Site Management specifies when a Permit to Work is required. Supervisors
risk assess all work and determine if a work permit is required for specific
work or if a Job Safety Analysis alone is sufficient to control hazards.
12) If multiple Permit to Work systems are in place on a construction site then
a mechanism is required to ensure there are no conflicts (e.g. SIMOPS,
incompatible work processes, commissioning clashes etc.) between these
systems or work carried out. For each work activity, there must be one
permit to work utilized by workers so that the permit requirements are clearly
documented and understood.
13) Roles and responsibilities are defined for personnel who take part in Permit
to Work implementation, including Person In Charge, permit requestors,
permit issuers/coordinators, permit receivers, and permit holders. Training is
provided for those positions and the people holding these positions have been
trained.
14) Permits cannot be changed in the field without re-submittal and full approval.
15) Work plans are developed for the coming activities, identifying areas and
systems affected. Plans are formally communicated to the Permit issuer/
coordinator, as a minimum, before the activity starts.
16) The permit holder confirms that the workplace has been inspected before
work starts, that it conforms to permit listed requirements, that it is safe to
start work, and that the work permit has been signed.
22
17) All permits have a specified duration. There is a process in place to identify
permits which have not been closed within the specified duration.
18) There is a process for handover of permits between shifts.
19) Permit closeout checks confirm that:
• work was completed or suspended satisfactorily
• Isolations and Temporary Defeats were returned to service and assessed
• equipment was returned to a safe condition
• housekeeping is satisfactory
• completion of the work is communicated to the affected personnel.
23
8. Lifting and hoisting
Lifting equipment includes lifting appliances (equipment performing the lifting),

lifting accessories (devices that connect the load to the lifting appliance).
Definitions for Routine and Non-Routine lifts are found in the ‘Glossary’ section
at the end of this document.
1) The recommended practices below (e.g. task planning, SME input, competency
verification, procedure review, barricades) apply equally to lifting equipment
setup, lift execution, and lifting equipment take-down.
2) A lift plan is required that represents every lift, the detail of the lift plan is
scaled based on the level of risk. Generic plans may represent multiple
occurrences of routine lifts. Specific plans are needed for non-routine lifts:
a) For non-routine simple crane and lifting operations the lift plan is
prepared by a person assessed as competent, e.g. a slinger, rigger,
Person in Charge of the Lift
b) For complex/critical/tandem lifting operations the lift plan is prepared and
reviewed by an assured qualified engineer.
c) For heavy lifts the lift plan is reviewed with input from an assured qualified
engineer.
d) Lifting of personnel is carried out in accordance with a specific personnel
lift plan.
e) Blind lifts require additional planning and communication before the work
starts.
3) Site Management is responsible to verify to the Client Team the competency of
the lifting and hoisting Subject Matter Expert (SME) and the qualified engineer.
The lifting and hoisting SME verifies the competency of the Person In Charge
and the lifting crew.
4) All persons involved in planning, performing, lifting and maintaining lifting
equipment are trained and assessed as competent for their role. A person
‘assessed competent’ has been assessed as competent by an industry
recognized authority.
5) Initial and refresher training and periodic assessment to assure competence
are required, typically at 3 yearly intervals.
6) If the lift, operational or weather conditions deviate from the agreed lift plan,
the activities are stopped safely, and either risk is re-assessed, controls
identified and represented in a revised plan, or wait until conditions match the
agreed lift plan.
7) An assessment is required of the lift, lift method, equipment, ground stability
and number of people involved in the lifting operation.
24
8) All personnel involved in the lifting operation have their individual

responsibilities clearly defined and communicated.
9) One person in the lift team is designated as the Person In Charge of the lifting
operation.
10) The Person In Charge reviews the lift plan and ensures that the required
controls are in place and the lift is carried out following the agreed lift plan.
11) The Person In Charge ensures that the lift team has tested and understood the
lift plan as well as visual and/or radio communications prior to the lift.
12) The person directing the lift (= banksman/flagman/dogman/signaler/spotter)
is easily identifiable.
13) All people are kept clear of overhead loads & lifting equipment and areas of
potential impact including the counter weight swing radius
14) Potential for falling objects and the extent of the exclusion zone is evaluated to
include deflected falling objects.
15) Manual load handling is never used to stop a swinging load. If control of the
load is required, tag lines or other means of hands-free practice are used. The
safe use of taglines has been part of the training.
16) Equipment is used for its intended purpose and operating conditions as by
Original Equipment Manufacturer’s (OEM) specification and is designed to a
recognized standard.
17) All safety and monitoring devices installed on lifting equipment are operational
and not by-passed or disabled.
18) Inspection and maintenance activities are carried out by persons assessed and
documented as competent.
19) Lifting devices and equipment undergo documented verification of inspection
and maintenance required before first use and thereafter as stipulated by OEM
guidance or recognized industry practice.
20) Color coding or labelling for lifting accessories can be an effective
administrative control to ensure inspection of rigging.
21) All lifting devices and equipment are visually examined before use.
22) Mechanized lifting equipment and rigging apparatus that does not pass visual,
periodic, or annual inspections are immediately taken out of service, repaired
or destroyed and removed from the site
23) A load does not exceed the dynamic and/or static capacities of any individual
item within the lifting assembly.
25
24) Manlift/mobile access platforms is the preferred method for lifting people.
Lifting of personnel with cranes is prohibited unless the risk has been
demonstrated as being as low as is reasonably practicable (ALARP). Work
baskets are designed, certified and used according to recognized international
standards. Cranes involved in lifting of personnel are certified for man-riding
operations.
25) Lifted personnel are secured with approved harnesses and lanyards unless
written procedures and risk assessment require otherwise.
26) Lifting equipment is only left unattended in a safe condition that follows
the OEM recommendations, site operating procedures and considers the
forecasted environmental conditions.
27) Work zone boundaries are identified to prevent contact with overhead power
lines.
Plan lifting operations and control the area
26
9. Personal Protective Equipment
Personal Protective Equipment is used as a last resort in the hierarchy of controls

after hazard elimination, substitution, engineering and administrative controls.
1) Personal Protective Equipment is specified for all work activities based on the
risk assessment.
Based on typical construction activities the basic Personal Protective

Equipment in the work areas is:
• hard hat
• safety-toed shoes
• safety glasses
• gloves
• hearing protection (ear plugs and/or ear covers)
• long sleeves and trousers or coveralls.
2) Additional Personal Protective Equipment use is based on risk. A risk
assessment is completed to identify Personal Protective Equipment needs based
on the site conditions and the scope of work. Where job conditions change,
Personal Protective Equipment selection is reviewed to ensure it is still valid.
Specialty Personal Protective Equipment (e.g. flame resistant clothing, fall

protection, goggles, face shields, specialty gloves, respiratory protection,
personal floatation devices) is specified by procedure and work activity or work
area.
Areas where specialized Personal Protective Equipment is required (e.g.

high noise, radiation, chemical storage areas, hydrocarbon process areas)
are marked with prominent signage, universal symbols or language of the
workforce to ensure that personnel are aware of the additional hazards and
requirements for Personal Protective Equipment.
3) Personal Protective Equipment is high quality and readily available to workers
at no cost (except for everyday clothing such as long sleeves shirts and pants/
trousers), including regular supply of Personal Protective Equipment and
replacement in case of damage or wear and tear.
• If the Personal Protective Equipment no longer provides the intended level
of protection, it is repaired or replaced immediately again at no cost to the
worker
• All Personal Protective Equipment types are certified by recognized
authorities
• All Personal Protective Equipment are inspected, used, stored, and
maintained in alignment with manufacturer’s requirements and
recommendations and inspection records maintained Proper fit of
Personal Protective Equipment is checked when issued.
27
• Personal Protective Equipment which is no longer usable is destroyed

before being discarded or otherwise disposed of where it cannot be
returned to service.
• Baggy or loose clothing is not allowed.
• Respiratory protection is usedaccording to manufacturer’s
recommendations.
4) Personnel receive Personal Protective Equipment training such that they:
• Are aware of the basic Personal Protective Equipment requirements, and
of situations requiring additional Personal Protective Equipment in their
work area
• Are able to select the appropriate Personal Protective Equipment based
on the potential hazards and risk to be encountered
• Are able to put on and take off the Personal Protective Equipment
• Are able to care for and keep clean the Personal Protective Equipment
• Understand the limitations of the Personal Protective Equipment
5) Site Management has a verification system in place to ensure that personnel
are complying with the established requirements for Personal Protective
Equipment
Obtain authorisation before entering a confined space
28
10. Scaffolding
Scaffolding elevates workers to a height that can be fatal should the worker
fall, or from where dropping tools or materials can cause serious harm to
those below. The building, usage and maintenance of scaffolds is therefore an
important aspect to consider in the safe running a fabrication site.
1) Work at a height of more than 1.8 meters (6 ft.) requires either a fixed
platform with railing, approved scaffolding, or the use of approved personal
fall protection systems secured to an appropriate anchoring point. Where
practical, the preference is to work from a platform (fixed or scaffolding)
with protection in place such that additional fall arrest Personal Protective
Equipment is not required.
2) Scaffolds are built, maintained, modified as specified by recognized
international standards. Site Management is required to provide engineering
specifications for scaffolding design and use, as well as set frequency of
inspections.
3) Large scaffolds (over 38 meters/125 feet high), all hanging and suspended
scaffolds, and scaffolds built for non-standard load are engineered. This
includes elevated working platforms and walkways at height.
4) Scaffolds are built, maintained, modified, inspected and dismantled only by
authorized or approved scaffolders.
5) Staircases are the first option for access. Where ladders are used, they extend
at least 1 meter (3 ft) over any landing or scaffold platform and are inside the
scaffold structure. Access that does not meet the above has fall protection
measures in place, such as cages, friction devices or self-retracting lanyards.
Swing gates or other barrier means are used at the entry points to prevent falls.
6) A highly visible multi-colour tagging system is displayed at each access point
which identifies if a scaffold is safe for use or not (i.e. scaff-tag system)
• Green Tag – scaffold is 100% complete and safe for access
• Yellow Tag – scaffold is in modified status but can be used safely with
additional controls as stated on the tag
• Red Tag – scaffold is incomplete and is not safe to use except by
scaffolders.
7) Each scaffold is inspected by an authorized or approved scaffolder after any
modifications or after any event that may have compromised integrity of the
scaffold such as inclement weather.
8) Scaffolding erection or dismantling activities are suspended during inclement
weather or lightning.
29
9) Scaffold material and components (planks boards, scaffolding tubes,

couplings/fittings and base plates, toeboards) are in good condition and free
from visible defects. Damaged material and components are removed from
service.
10) Access ladder landing platforms are included at every 6 meters (20 feet).
11) Scaffolding is erected on stable and even work surfaces using base plates and/
or sills as necessary
12) Scaffold planking is securely attached and wooden planking has an overlap to
the end supports.
13) Risk assessments consider the need for further dropped object prevention
measures on and under scaffolding, e.g. barricades, use of nets.
14) Load category of the scaffolding is known and is identified on the scaff-tag.
15) It is prohibited to use scaffolding for either hanging or supporting material for
which it is not designed, or using scaffolding as a structure to pull against in
order to move materials.
30
11. Simultaneous Operations
Simultaneous Operations (SIMOPS) is defined as two or more work scopes

during pre-commissioning/commissioning at site occurring simultaneously in
a same or adjacent area which can interfere with one another. See reference
library for an example matrix with restrictions table that is key to success for
management of SIMOPS.
1) Work is planned to minimize or eliminate simultaneous operations.
2) SIMOPS risks are identified and controls are set prior to work.
3) SIMOPS are classified as prohibited, controlled or acceptable.
4) A Permit to Work system led by one single authority is in place to control
SIMOPS. It controls all commissioning activities and their interfaces with other
site work.
5) Competent supervisors, identified in the Permit To Work, with authority on
the involved organizations, are available in the work area to manage SIMOPS
activities.
6) SIMOPS communication sessions are held between affected parties, such as
interface meetings and tool box talks.
7) Plans are completed for the upcoming activities identifying areas and systems
affected. There are then communicated to the Permit to Work Person In
Charge prior to beginning of work.
8) SIMOPS activities are executed based on permit conditions. If conditions
cannot be met, options include the temporary cancelation of the activity,
different timeframes, or specific site controls.
9) SIMOPS activities are communicated and visible using permit boards, signage
or barricades.
31
12. System testing

(e.g. Pressure testing, electrical testing, radiography)
System testing is typically conducted during the pre-commissioning phase of

fabrication activities to verify the integrity or functionality of process and control
systems prior to commissioning or transportation. Tests may be conducted on
individual subsystems prior to integration and/or on the overall integrated system.
Radiography is also covered in this section.
Pressure testing
1) Due to the potential for catastrophic release of energy associated with
pneumatic testing, the procedures, size of the test system and the barrier
management for this type of test are pre-approved by the client.
2) Minimize the number of people in the area either by restricting access or by
performing testing activities during times when the general workforce is not
present, such as at night.
3) Provide a work procedure on the system preparation and test that include:
• Permit to Work requirements
• safety meetings/toolbox talks
• risk assessment expectations and controls (e.g. Job Safety Analysis,
equipment/ required Personal Protective Equipment, training, safe
operational procedures, valve verification, blind isolation sheets, etc.)
• an approved test plan with required inspections and verification of hazard
controls (i.e. pressure testing, energy isolation, permit systems, fluid
containment, etc.)
4) System testing controls to consider simultaneous activities.
5) All personnel involved in system testing are trained and competent for their
role including understanding the hazards involved, the control steps and the
Personal Protective Equipment required.
6) Pre-test Verification checkpoints:
• Ensure that a pre-meeting is performed to review the scope of test, risks
involved, equipment and tools required and mitigation actions are taken.
• Ensure that all testing equipment is rated for expected service
• Inspect all piping, valves, and/or electrical controls prior to the test
to verify condition and proper orientation (open/close, energized/de-
energized, isolated/not isolated)
• Check that all temporary hoses, couplings, and gauges are of the correct
type, securely fastened, free from damage, suitable for the maximum
pressure and temperature of the test, and functioning
• Ensure escape route(s) are established and not obstructed by test
equipment or other material in the area.
32
• Ensure Safety Data Sheets are available

• Verify that the Permit to Work is approved and system ready before testing
begins.
7) Systems or areas subject to testing are marked with unique and recognizable
signs, tags or labeling in local language which cannot be mixed up with other
markings or signs.
8) The area is inspected, barricading is placed and no-entry signage is displayed
at a safe distance around the testing zone with consideration of hazards such
as rupture issues, projectiles, or energized equipment. Take into consideration
best engineering practices and procedures.
9) Authorized people’s risk exposure from line of fire of potential leaks, or from
being too close to the testing equipment, is minimized (e.g. by using cameras
or extension mirrors).
10) There is an effective means of communication (two-way radio, hand signals,
etc.) and/or alarm system that allows any crew member to quickly alert
others of system failures or emergencies. Emergency response equipment is
available and trained and competent emergency responders are on standby.
11) Post-test verification checkpoints:
• Establish means to ensure system is isolated, de-pressurized, and/or de-
energized prior to removing blind flanges or accessing electrical control
panels.
• Develop corrective action plan(s) for addressing system failures and
identify needs for retesting.
• Establish means of safely capturing, disposing, and/or discharging
and test fluids or gases in compliance with good industry practice and
applicable laws, regulations and permits.
12) Only once the test has been completed and the area verified safe are barriers
and signage removed.
Radiography
13) The site has a radiography operations plan that includes the following:
• Identifies a Person In Charge such as a licensed Radiation Safety Officer.
They are responsible for ensuring the management, safe use and security
of sources, and for compliance of radiation work.
• Field work is performed by a radiography crew that consists of a minimum
of two people
• Training (general awareness and specific training for radiation workers).
33
• Radiation source handling, including procurement, receiving, storage,

inventory, inspection, emergency response and notification, and disposal
procedures.
• Specific radiation warning signs and labels identifying the location of
radiation sources and areas
• Use of personal dosimetry monitoring, area surveys, and leak testing, and
documentation to ensure that equipment is operable, calibrated.
14) Site Management is responsible to verify to the Client Team the competence,
qualification and training of the radiography crew. Only the radiography
workers are permitted to perform activities and work involving radiography.
They have in their possession at all times a copy of their radiography ID card.
15) The Site establishes barricades and other protective measures to keep general
workers away from exposure levels of 20 microsieverts per hours (2 millirems
per hour). The barricaded area is continuously monitored and documented.
16) A system is in place to monitor exposure that includes personal badge use,
personal dosimeters, records of testing and doses and follow-up requirements
on anomalies.
17) Radioactive sources are not left unattended by the work crew unless the
sources are locked in a shielded storage container (<2 millirems per hour at
the surface).
34
13. Working at heights
Working at heights of more than 1.8 meters (6 ft) requires either a fixed platform
with railing, approved scaffoldings, the use of approved fall prevention equipment,
or fall arrest systems secured to an appropriate anchoring point. Where practical,
preference is to work at ground level. If not practicable, the preference is to work
from a platform (fixed or scaffolding) with protection in place such that additional
fall arrest Personal Protective Equipment is not required.
1) A fall protection plan is in place prior to working at height that includes
emergency response procedures and drills to ensure effectiveness.
2) Following hierarchy of controls: When it is not possible to work at ground
level or in a protect area, fall prevention systems, such as harness tethers
restricting movement or temporary railings, are used as first option. Potential
second options (such as controlled-access zones or leading edge procedures)
are approved prior to use by the client and site management, fall arrest
systems would be the next option.
3) Personal Fall Arrest Systems consist of a full body harness and tie-off
equipment such as dual self-retracting lanyard, dual lanyards with a shock
absorber or other approved devices matched to the fall potential the worker
is exposed to. All have compatible/manufacturer approved accessories and
suspension trauma straps.
4) A trained rescue team knowledgeable in suspension trauma (orthostatic
intolerance) and outfitted with fit for purpose emergency rescue equipment is
located at the work site.
5) Pre-work planning identifies the locations of acceptable anchor points to
facilitate ease of use, load requirements, and height requirements.
6) All personnel who have the potential for exposure to falls are trained to:
• recognize potential hazards
• comply with the work practices and established controls to prevent falls
• select and use the appropriate type of fall protection system and anchor
points
• inspect and maintain the fall protection system.
7) Site requires 100% tie off (i.e. at least one lanyard is tied off at all times) when
people are working at heights outside a protected area.
8) There are procedures to use, maintain, and inspect components of fall
protection systems and ladders as per manufacturer’s requirements and
recommendations, including pre-use inspections.
9) Ladders extending more than 6 meters (20 feet) have fall protection measures
such as cages, friction devices or self-retracting line in place to protect
against falls.
35
10) Anchorages used for tie-off meet internationally recognized standards and the
tie-off point is above the work activity level where possible.
11) Open holes that have been made into floors or platforms have pre-approvals
and covers that are secured, can hold twice the expected load and are
labelled-tagged to prevent inadvertent removal of the cover. Where a hole
cannot be completely covered, a hard barricade is in place around the hole.
12) Removing of handrails and/or alteration of work platforms that would create a
fall hazard requires pre-approval. Fall protection is in place prior to alteration.
13) Fall protection systems or their components are removed from service and
destroyed if they do not pass inspections, or if they have been subjected to a fall.
36
14. Working with electricity
Electricity is a part of everyday life, but it can be fatal, seriously injure people or
cause damage to equipment.
1) Site Management designates an Electrical Responsible Person/s for the site,
and is responsible to verify to the Client Team that the Electrical Responsible
Person(s) is trained and assessed as competent.
2) The Electrical Responsible Person(s) defines the knowledge, skills, and
experience required for various types of electrical work such as High Voltage,
Low Voltage, and Commissioning. The Electrical Responsible Person(s) also
specifies local, regional and international recognized standards and permit to
work requirements applicable to electrical work.
3) Working with electricity requires equipment isolation brought to a ‘zero energy
state’ and verified (Lock-Out/Tag-Out). If not practical, it requires specific
approval by Person In Charge or delegate, following the specified controls and
communications established by the Electrical Responsible Person.
4) Signs, tags and label are used to recognize live electrical equipment and
communicate its hazards in local language/s.
5) The tie-in of temporary electrical systems and equipment to permanent
electrical distribution systems is prohibited unless specifically approved by the
Electrical Responsible Person.
6) Conduit, cable, and wiring systems are protected from damage
7) Equipment requiring ground fault circuit interruption is defined.
8) Electrical system, electrical equipment and portable electrical apparatus
(such as welding machines, generators, hand tools, etc.) brought onto the site
is checked for general condition and conformance with industry or government
standards.
9) Electrical system, electrical equipment and portable electrical apparatus
is periodically inspected to verify integrity of the equipment (e.g. defective
parts, faulty insulation, improper grounding, loose connections, ground faults,
unguarded live parts). Inspection is easily verifiable by visual means (e.g. by
using tags, and colored tape).
10) Electrical system and equipment that does not pass visual, periodic, or annual
inspections are identified, taken out of service, repaired, or destroyed.
37
11) Specialty Personal Protective Equipment appropriate to the electrical exposure

level is provided as needed for working with electrical plant and equipment
(e.g. arc flash Personal Protective Equipment, insulated gloves, non-
conductive hard hats, non-conductive footwear, insulated tools and handling
equipment, insulated blankets and insulated mats).
12) Only personnel trained in electrical ‘hot work’ are authorized to work with
exposed energized equipment.
0
Verify isolation and zero energy before work begins
Control flammables and ignition sources
38
Glossary
Includes terms used in IOGP 597
Term Definition Reference

competent The combination of skills, experience and knowledge IOGP Report 510,
of a manager or member of the workforce that has Operating
been confirmed through assessment. Management System
Competence is assessed for an individual in a post Framework (June
that has a clearly defined profile setting out the job 2014)
requirements. Competence is regularly re-assessed
with a frequency determined by the criticality of the
role.
confined space Confined spaces are enclosed or partially enclosed Definition
spaces that are not designed or constructed for consistent with use
continuous human occupancy, have limited or in IOGP Report 459,
restricted means for entry or exit, and where there is Life-Saving Rules v2
risk of injury or illness from hazardous substances or (April 2013)
conditions.
Confined spaces include, but are not limited to,
underground vaults, tanks, storage bins, manholes,
pits, silos, process vessels, pipes and tubulars.
EPCM (Engineering, EPCM is a services-only contract, under which the www.wikipedia.org
Procurement, contractor performs engineering, procurement and (accessed October
Construction construction management services. 2016)
Management)
exclusion zone Barricaded No-go areas where it has been identified
a risk for workers to be in the area due to potential
harm from items such as dropped objects or lifted
materials.
fabrication yard Designated area/site where industrial construction
work is performed.
fabrication contractor Person/Company that provides construction based
services.
Front Line Individuals who directly supervise and coordinate
supervisors the activities of construction/craft workers.
hazard An object, physical effect or condition with IOGP Report 510,
the potential to harm people, the environment Operating
or property. Management
System Framework
(June 2014)
39

hazardous An atmosphere is hazardous when:
atmosphere • it has too much or too little oxygen (atmospheric
oxygen content is 20.9%), or
• it contains flammable, combustible or explosive
agents, or
• it contains contaminants (for example, noxious
substances, fumes, dusts, mists) that could pose
an immediate or long term threat to life, and/or
interfere with a person’s ability to escape unaided
from a confined space.
hot work Any work that creates an ignition source performed
in an area which has potential for hydrocarbons or
flammable materials.
Hot work includes welding, burning, gas cutting,
grinding and brazing.
HSE Health Safety Security and Environment
HSE Charter HSE Charter – a statement of commitment,
which defines HSE objectives, expectations and
responsibilities.
HSE Plan An HSE plan defines what should be in place during IOGP 423-02
the life cycle of the contract and the steps required
to be taken, by whom and by when in order to meet
client and contractor requirements.
Job Safety A formalized procedure whereby persons involved in
Assessment (JSA) a task get together before work starts to assess the
work, identify associated hazards and recommend
safe job practices and precautionary measures.
Leadership A meeting of senior leaders from primary EPCM/ In document
engagement client, fabrication contractor and site HSE team to
discuss and agree on HSE expectations and visible
and felt leadership actions to support for the project.
non-routine lift A lift that is not classified as a Routine Lift. Non-
Routine Lifts are sub-divided into Simple and Complex
Lifts to reflect increasing Risk.
40

Non-routine A lift using equipment specifically installed by a
simple lift competent operator, with known and evaluated
weight, a center of gravity below the lifting point and
the use of a certified lifting point directly above the
load, ample headroom and a single lifting appliance,
and that is unlikely to be affected by changing
environmental conditions.
non-routine A lift that continues a lifting operation but with
complex lift different equipment; uses two or more lifting
appliances within difficult or restricted areas or
near active or energized hydrocarbon-containing
equipment; is near overhead electrical power lines;
uses a mobile crane on uneven ground; continues
a lifting operation with shift changeover or lifting of
personnel; lowers a load into or out of a Confined
Space; or lifts a load the weight of which is over
90% (‘heavy lift’) of the rated capacity of the lifting
appliance.
Permit to Work A Permit to Work system is a formal written system Based on text in
system used to control certain types of work which are IOGP report 189
identified as potentially hazardous. It is also a – Guidelines on
means of communication between site/installation permit to work
management, plant supervisors and operators and (P.T.W.) systems
those who carry out the work.
Essential features of Permit to Work system are:
• c lear identification of who can authorize particular
jobs (and any limits on their authority) and how
is responsible for specifying the necessary
precautions
• t raining and instruction in the issue and use of
permits
• m
onitoring and auditing to ensure that the system
works as intended.
Permit to Work Term refers to the signed document, certificate or Based on text in
form used as part of a Permit to Work system for IOGP report 189
control of work. – Guidelines on
permit to work
(P.T.W.) systems
41

Person in Charge of The project manager, superintendent or area
the Lift Supervisor who has overall responsibility for any
lift by a crane. The Person in Charge of the Lift
plans the lift operation with any personnel to whom
responsibility has been delegated, and monitors the
development of safety features for lift operations and
the lifting operation.
qualified ‘Qualified’ means one who, by possession of a
recognized degree, certificate, or professional
standing, or who by extensive knowledge, training,
and experience, has successfully demonstrated their
ability to solve or resolve problems relating to the
subject matter, the work, or the project.
Repeat back process A process in which you ask the workforce or a
member of the workforce to respond back with what
they heard to verify they understand what was said.
risk The product of the chance that a specific adverse IOGP Report 510,
event will occur and the severity of the consequences Operating
of the event. Management
System Framework
(June 2014)
risk assessment A process that provides a consistent and comparable IOGP Report 510,
evaluation of the relative level of different risks Operating
introduced by company activities. Management
System Framework
(June 2014)
routine lift A lift that is undertaken within the normal operating
parameters of the crane and in which lifting is over
non-sensitive areas, in suitable familiar environmental
conditions, with competent crane operators and loads
of known and evaluated weight, shape and center of
gravity, using standard rigging arrangements.
safe practice A way to perform a task that minimizes risk.
Site Management Site owner/operator management team responsible
for the worksite. Responsible for Site Safety and HSE
performance at the fabrication yards.
42

(shift) handover Mutually agreed transfer in operational care, custody
and control from one responsible party to another
responsible party, typically from one Shift Team to the
subsequent Shift Team.
short service workers Definition of short service worker to be agreed
between client and fabrication yard contractor
Simultaneous Two or more work scopes during pre-commissioning/
Operations (SIMOPS) commissioning at site occurring simultaneously in a
same or adjacent area which can interfere with one
another
Stand-Down A formal shut down of work to focus on correcting an
unsafe situation or incident.
Stop Work authority Formal approval from site leadership which allows any
worker to intervene on an unsafe situation or stop a
person who is about to put themselves in harm’s way.
Subject Matter Expert A Subject Matter Expert (SME) has Proficiency at
(SME) Skill level and is accredited by a relevant independent
authority. The term SME is a functional description
of the role rather than a job title. An SME is a
person with assigned responsibility as an expert
for specifying how HSE risks will be managed
which could include development and approval of
Procedures and other SME deliverables.
subcontractors Persons, company of business that signs a contract
to perform part or all of the obligation of another’s
contract
toolbox talk (TBT) A toolbox talk is a term referring to operational safety.
A TBT might be held with team due to embark on a
high safety risk task, emphasizing the safety aspects
of the job, or it might be held regularly as a series of
topical safety meetings.
watchman Attendant during confined space work
workforce The people engaged in or available for work in the
fabrication yard
Workforce supervisor refers to the person directly responsible for a team In document
of construction workers (typically contractors or
subcontractors) on a specific job site
43
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This report is a part of a project to

address fabrication site construction
safety, consisting of the following:
• I OGP 577 Fabrication site
construction safety recommended
practice – Hazardous activities
• I OGP 597 Fabrication site
construction safety Recommended
practice – Enabling activities
• F
abrication site construction safety
– online Resource Library
IOGP 577 provides standardized
minimum recommended practices for
addressing safety risks associated
with fatality potential or significant
incident hazardous activities common
to the fabrication sites.

Fabrication Site Construction Safety Recommended Practice - Hazardous Activities

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Fabrication Site Construction Safety Recommended Practice - Hazardous Activities

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REPORT NOVEMBER

Fabrication site construction

Fabrication Site – Construction Safety Practices Task Force

Photography used with permission courtesy of

IOGP welcomes feedback on our reports: publications@iogp.org

These Terms and Conditions shall be governed by and construed in accordance

IOGP Fabrication site construction

A Task Force comprised of IOGP Members was established to recommend

In addition, IOGP Report 597 Fabrication site construction safety recommended

To assist with implementation, a Resource Library is available on the IOGP website

With ownership and implementation by IOGP Members, EPCM companies, and

Scope and implementation 6

Application of this guidance 7

2. Confined space entry 10

3. Construction traffic interface 13

5. Energy isolation/Lock-out Tag-out 18

7. Job Safety Analysis / Permit to Work 21

8. Lifting and hoisting 24

9. Personal Protective Equipment 27

11. Simultaneous Operations 31

13. Working at heights 35

14. Working with electricity 37

Fabrication site construction

VERSION DATE AMENDMENTS

Minor revision to align with new IOGP Life-Saving Rules.

1.0 February 2017 First release

Scope and implementation

This report is a part of a project to address fabrication site construction safety,

IOGP 577 provides standardized minimum recommended practices for addressing

The selection of hazardous activities is not intended to be comprehensive, and the

Example of turning a statement into question

Application of this guidance

The IOGP Task Force believes implementation of these recommended practices

As the intent is to have a consistent set of requirements at each fabrication site,

Companies implementing these practices are also encouraged to contact IOGP

1) All activities comply with their local applicable legislative requirements.

2. Confined space entry

• the identification and verification of isolation needs

Relevant IOGP Life-Saving Rules, Report 459

Obtain authorisation before entering a confined space

Work with a valid permit when required

Control flammables and ignition sources

3. Construction traffic interface

6) Pre-mobilization and periodic site vehicle/equipment inspections are

Relevant IOGP Life-Saving Rules, Report 459

Follow safe driving rules

Keep yourself and others out of the line of fire

Relevant IOGP Life-Saving Rules, Report 459

Protect yourself against a fall when working at height

Keep yourself and others out of the line of fire

Plan lifting operations and control the area

10) Prior to authorizing de-isolation the Responsible Person ensures that:

Relevant IOGP Life-Saving Rules, Report 459

Work with a valid permit when required

Obtain authorisation before overriding or disabling safety controls

7. Job Safety Analysis /

A Permit to Work system is a formal written system used to control certain

Job Safety Analysis

8) A Job Safety Analysis is written by the work team or by individuals as close to

Relevant IOGP Life-Saving Rules, Report 459

Work with a valid permit when required

8. Lifting and hoisting

Lifting equipment includes lifting appliances (equipment performing the lifting),

12. System testing