Chevron Safety Handbook

Pipe Line Company
Safety Handbook
2008
Health, Environment & Safety
Chevron Pipe Line Company
Safety Handbook
Revised February 2008

Emergency Information
Immediate Notification http://cpl.chevron.com/
Procedure emergencyresponse/
Emergency Hotline (877) 863-5196 This number is

Contact Number ONLY for CPL internal calls
Ambulance, Police or 911

Fire Department
CPL Security Issues CPL Security Advisor

281-684-4194
In Case of a Motor Call your supervisor first or the

Vehicle Accident Emergency Hotline
For emergency situations and/or
injuries call 911 immediately
Copyright 2008
This handbook contains confidential and proprietary

information of Chevron Corp. Any use of this manual
without authorization from Chevron and/or its
affiliates is prohibited.
The Safe Practices Handbook was written by the

Chevron Pipe Line Company, Health, Environment,
and Safety Team in Houston. It was published by the
CBRES Information Design and Communications
Team in Houston.
Publication is available on alternative media at:

http://www.chevron.com/pipelinecsm/documents/SafetyHandbook.pdf
Safe Practices Handbook Acknowledgment
This Safe Practices Handbook has been prepared with your

personal safety and well-being in mind. You are expected
to read, understand it and follow these practices as you
perform your daily work assignments.
If you have any questions about the meaning or intent of

any of the practices in this handbook, you may ask your
supervisor or contact the CPL HES staff for more
information.
After you read, understand and agree to follow the

practices listed here, please fill out and sign this form,
detach this “Acknowledgment” and return it to your
supervisor. This document will be retained.
I have read, understood, and agree to abide by the health,

environment and safety practices contained herein.
Name (Print): ___________________________________

Please check as appropriate:
❏ Employee ❏ Contractor
CAI / ID number / Company name: _________________
______________________________________________
Date: __________________________________________
Signature: ______________________________________
Comments: If you have any suggestions for updates or

improvements to this handbook, we’d like to hear them. Please
email your comments to the senior safety specialists or
acknowledge understanding of the handbook via Knowledge
Planet (CPL Safety Handbook).
Preface
It is the intent of Chevron Pipe Line Company (CPL) to read

and use this handbook to comply with our corporate Policy 530,
“Health, Environment and Safety” and to abide by all applicable
government laws and regulations, as well as internationally
accepted industry best practices.
To this end, all levels of the organization are responsible for

taking all practical measures to ensure that the design,
installation, operation, and maintenance of CPL facilities and
equipment, are in accordance with the information contained
here.
That’s why it’s important that you read the handbook in its
entirety and make these safety practices part of your day-to-day
behavior at Chevron Pipe Line Company.
Rebecca B. Roberts
President, CPL
Contents
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.0 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1 Team Leader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.2 Employee. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.3 Contractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.4 Short-Service Employees (SSE). . . . . . . . . . . . . 7
2.1.5 Visitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Incident Investigation and Reporting. . . . . . . . . . . . . 8
2.3 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.1 New Employee Orientation. . . . . . . . . . . . . . . . 8
2.3.2 HES Required Training . . . . . . . . . . . . . . . . . . . 9
2.3.3 Job Safety Analysis (JSA) . . . . . . . . . . . . . . . . . . 9
2.4 Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Food and Beverage . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Smoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Alcohol and Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.8 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.0 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . 14

3.1 Mandatory PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Field Work Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Protective Clothing – General . . . . . . . . . . . . . . . . . . 16
3.4 Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Eyes and Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6 Hearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Respiratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8 Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.10 Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.0 Common Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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4.1 Slip, Trip, and Fall Prevention
(walking hazards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Stairways and Elevated Work Surfaces . . . . . . . . . . 26
4.3 Ladders and Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.1 Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.1.1 Portable
4.3.1.2 Positioning a Ladder Straight
4.3.1.3 Positioning Step
4.3.1.4 Permanently Fixed Ladders
4.3.2 Scaffolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Worker Safe Guards . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Grinding Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.6 Tools Maintenance and Use . . . . . . . . . . . . . . . . . . . . 31
4.7 Equipment/Machinery in Motion . . . . . . . . . . . . . . . 34
4.7.1 Centrifuge Machines . . . . . . . . . . . . . . . . . . . . 34
4.7.2 Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.3 Engines/Turbines . . . . . . . . . . . . . . . . . . . . . . . 35
4.7.4 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.8 Pocket Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.0 Safe Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Safety Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Behavior Based Safety Inspections
or Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Permit to Work (PTW) Systems. . . . . . . . . . . . . . . . . 38
5.5 Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5.1 Handling Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5.2 Tractor Loader/Backhoe Unit Operation. . . . 40
5.5.3 Powered Industrial Truck (PIT or Forklift)
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5.4 Cranes and Hoisting, Cables and Slings. . . . . 43
5.5.4.1 Inspection Criteria
5.5.4.2 Capacity Chart
5.6 Hazardous Materials and Substances. . . . . . . . . . . . 49
5.6.1 General Principles . . . . . . . . . . . . . . . . . . . . . . 49
Safe Practices Handbook – 2008 ii

5.6.2 Safety Color Coding. . . . . . . . . . . . . . . . . . . . . 50
5.6.3 Storing Flammable Liquids . . . . . . . . . . . . . . . 50
5.6.4 Corrosive Chemicals . . . . . . . . . . . . . . . . . . . . 51
5.6.5 Solvents and Cleaning Agents . . . . . . . . . . . . . 51
5.6.6 Using Tools Around Chemicals and Gases . . 52
5.7 Hazards Communication (HAZCOM) . . . . . . . . . . . 53
5.7.1 List of Chemicals . . . . . . . . . . . . . . . . . . . . . . . 53
5.7.2 Material Safety Data Sheet (MSDS) . . . . . . . . 53
5.7.3 Material Labeling . . . . . . . . . . . . . . . . . . . . . . . 54
5.8 Excavation, Trenching and Shoring . . . . . . . . . . . . . 57
5.8.1 Soil type and Site Preparation. . . . . . . . . . . . . 57
5.8.2 Worker Protection . . . . . . . . . . . . . . . . . . . . . . 58
5.8.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.4 Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.9 Gas Testing and Analysis . . . . . . . . . . . . . . . . . . . . . . 59
5.9.1 Plan the Gas Tests. . . . . . . . . . . . . . . . . . . . . . . 59
5.9.2 Calibrating and Maintaining
Gas Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.9.3 Verify Instrument Performance Before
Gas Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.9.4 Review Precautions . . . . . . . . . . . . . . . . . . . . . 60
5.9.5 Conduct Gas Tests . . . . . . . . . . . . . . . . . . . . . . 60
5.9.6 Interpret Gas Test Readings. . . . . . . . . . . . . . . 61
5.10 Confined Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.10.1 Workplace Evaluation . . . . . . . . . . . . . . . . . . . 62
5.10.2 Pre-Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.10.3 Working in a Non-Permit Required
Confined Space. . . . . . . . . . . . . . . . . . . . . . . . . 63
5.10.4 Confined Space Entry Using Forced-Air
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.10.5 Permit-Required Confined Space Entry . . . . 64
5.11 Lockout/Tagout (LOTO) . . . . . . . . . . . . . . . . . . . . . . . 64
5.11.1 Energy Sources . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.11.2 Equipment Specific Procedure (ESP) Sheet . 65
5.11.3 Normal Equipment Isolation . . . . . . . . . . . . . 66
5.11.4 Shift Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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5.12 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.12.2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.12.3 Extension Cords . . . . . . . . . . . . . . . . . . . . . . . 69
5.12.4 Electrical Power Tools . . . . . . . . . . . . . . . . . . 70
5.12.5 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . 71
5.12.6 Sampling and Gauging . . . . . . . . . . . . . . . . . 72
5.12.7 Electrical Fuses and Circuit Breakers . . . . . 72
5.12.8 Explosion-Proof Electrical Equipment . . . . 73
5.12.9 Batteries and Standby Generators . . . . . . . . 73
5.12.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.13 Hot Work Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.13.1 Hot Work Permits . . . . . . . . . . . . . . . . . . . . . 74
5.13.2 Area Preparation . . . . . . . . . . . . . . . . . . . . . . 76
5.13.3 Fire Watch . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.14 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.14.1 General Precautions . . . . . . . . . . . . . . . . . . . 78
5.14.2 Minimizing Electric Shock from
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.14.3 Welding in or Near Tanks or on Pipelines
That Contained or Have Contained
Hydrocarbons . . . . . . . . . . . . . . . . . . . . . . . . 80
5.14.4 Hot Tapping . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.14.5 Compressed Gas Cylinders. . . . . . . . . . . . . . 82
5.14.5.1 Oxygen and Acetylene
5.14.5.2 Compressed Air
5.14.5.3 Natural Gas
6.0 Pipeline Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

6.1 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.1.1 DOT Pipeline Safety Regulations . . . . . . . . . . 90
6.1.2 Work on Existing Pipelines . . . . . . . . . . . . . . . 90
6.1.3 LOTO (5.11) and Blinding Procedure . . . . . . 92
6.1.4 Valves, Piping and Tubing . . . . . . . . . . . . . . . . 93
6.1.4.1 Block Valves
Safe Practices Handbook – 2008 iv

6.1.4.2 Check Valves
6.1.4.3 Pressure Relief (Safety) Valves
6.1.4.4 Valve Actuation
6.1.4.5 Pressure Gauges
6.1.5 Scraper Traps . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.1.6 Engine and Motor Operation . . . . . . . . . . . . . 95
6.2 Tank Gauging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.2.1 Ascending and Descending Tanks . . . . . . . . . 96
6.2.2 Tank Top Safety . . . . . . . . . . . . . . . . . . . . . . . . 96
6.2.3 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.2.4 Static Electricity . . . . . . . . . . . . . . . . . . . . . . . . 97
6.2.5 Sampling and Gauging . . . . . . . . . . . . . . . . . . 97
6.2.6 Tank Dike Maintenance. . . . . . . . . . . . . . . . . . 97
6.3 Tank and Vessel Cleaning . . . . . . . . . . . . . . . . . . . . . . 98
6.3.1 General Precautions . . . . . . . . . . . . . . . . . . . . . 98
6.3.2 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.3.2.1 Light Inside Tanks
6.3.2.2 Personal Protective Equipment
6.3.2.3 Atmospheric Monitoring Equipment
6.3.2.4 Ventilating Fan or Exhauster
6.3.3 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . 99
6.3.3.1 Prepare the Area
6.3.3.2 Cold Repair Work
6.3.3.3 Hot Repair Work
7.0 Transportation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

7.1 Motor Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.1.1 Vehicle Operation. . . . . . . . . . . . . . . . . . . . . . 102
7.1.2 Driver Responsibility . . . . . . . . . . . . . . . . . . . 102
7.1.3 Safe Driving Principles . . . . . . . . . . . . . . . . . 103
7.1.3.1 Inspecting Vehicles
7.1.3.2 Backing
7.1.3.3 Turning
7.1.3.4 Following
7.1.3.5 Parking
7.1.3.6 Loading and Unloading
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7.1.3.7 Use of Cellular Phones While
Driving
7.1.3.8 Transporting Tools and Other
Materials
7.1.4 Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1.5 Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.1.6 Commercial Driver’s License . . . . . . . . . . . . 110
7.1.7 Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2 Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2.1 Marine Travel (Boat Transportation). . . . . . 110
7.2.2 Personal Flotation Devices . . . . . . . . . . . . . . 112
7.2.3 Swing Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.2.4 Personnel Baskets . . . . . . . . . . . . . . . . . . . . . . 115
7.3 Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.3.2 Helicopter Travel . . . . . . . . . . . . . . . . . . . . . . 116
7.3.2.1 Arrival at Departure Points
7.3.2.2 Embarking and Disembarking Aircraft
7.3.2.3 Pilot-in-Command
7.3.2.4 Special Rules for the Sikorsky S-76
7.3.2.5 In Flight
7.3.2.6 Miscellaneous Rules
7.3.3 Fixed Wing Aircraft . . . . . . . . . . . . . . . . . . . . 121
8.0 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

8.1 Musculoskeletal Injuries and Cumulative Trauma
Disorders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.2 Alternative Work Breaks. . . . . . . . . . . . . . . . . . . . . . 122
8.3 Workstation Design. . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.4 Work Habits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.4.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.4.2 Back Injury – Low Back Pain . . . . . . . . . . . . 123
8.5 Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.0 Office Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

9.1 Computer Workstations . . . . . . . . . . . . . . . . . . . . . . 126
Safe Practices Handbook – 2008 vi

9.2 Floors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.3 Aisles and Stairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.4 Office Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.5 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 128
9.6 Material Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9.7 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
10.0 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

10.1 Work Site Fire Emergencies . . . . . . . . . . . . . . . . . . . 130
10.2 Emergency Response Plans . . . . . . . . . . . . . . . . . . . . 131
10.3 Emergency Drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
11.0 First Aid and CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

11.1 First Aid Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 133
11.1.1 First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . 133
11.1.2 Eye Wash and Safety Showers . . . . . . . . . . 133
11.2 Basic First Aid Steps . . . . . . . . . . . . . . . . . . . . . . . . . 134
11.2.1 Artificial Respiration. . . . . . . . . . . . . . . . . . 134
11.2.2 Cardiopulmonary Resuscitation (CPR) . . 135
11.2.3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
11.2.3.1 Arterial
11.2.3.2 Venous
11.2.4 Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
11.2.4.1 Thermal
11.2.4.2 Chemical
11.2.4.3 Electrical
11.2.5 Thermal Stress . . . . . . . . . . . . . . . . . . . . . . . 138
11.2.5.1 Heat Stroke/Heat Prostration
11.2.5.2 Heat Exhaustion
11.2.5.3 Frostbite
11.2.5.4 Hypothermia
11.2.6 Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
11.2.7 Fractures. . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
11.2.8 Foreign Body in an Eye. . . . . . . . . . . . . . . . 141
11.2.9 Choking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
11.2.10 Snake and Insect Bites. . . . . . . . . . . . . . . . . 142
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12.0 Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
12.1 Fire Triangle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
12.2 Fire Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
12.3 Fire Suppression Equipment . . . . . . . . . . . . . . . . . . 145
12.3.1 Fire Protection Equipment. . . . . . . . . . . . . 145
12.3.2 Inspection and Maintenance of Fixed Fire
Extinguishing Systems . . . . . . . . . . . . . . . . 145
12.3.3 Portable Fire Extinguishers . . . . . . . . . . . . 146
12.3.4 Wheeled Fire Extinguishers . . . . . . . . . . . . 147
12.3.5 Fire Water Systems . . . . . . . . . . . . . . . . . . . 147
13.0 Occupational Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

13.1 Work Environment Hazards . . . . . . . . . . . . . . . . . . 149
13.1.1 Chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
13.1.2 Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
13.1.3 Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
13.2 Monitoring Exposures. . . . . . . . . . . . . . . . . . . . . . . . 158
13.3 Bloodborne Pathogens . . . . . . . . . . . . . . . . . . . . . . . 159
14.0 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

14.1 Waste Management. . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.1.1 Hazardous . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.2 Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.2.1 Clean Air Act . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.2.2 Clean Water Act . . . . . . . . . . . . . . . . . . . . . . 161
14.2.3 Resource Conservation and Recovery
Act RCRA . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.2.4 Comprehensive Environmental
Response, Compensation and Liability Act
CERCLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.2.5 Superfund Amendment and Reauthorization
Act (SARA Title III) . . . . . . . . . . . . . . . . . . . 161
14.2.6 Occupational Safety and Health Act
(OSHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
14.2.7 Toxic Substances Control Act (TSCA) . . . . 162
14.2.8 Hazardous Materials Transportation Act . . 163
14.2.9 Safe Drinking Water Act. . . . . . . . . . . . . . . . 163
Safe Practices Handbook – 2008 viii

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
A. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
B. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
C. Safe Work Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . 167
D. Excavations Checklist . . . . . . . . . . . . . . . . . . . . . . . . 168
E. Confined Space Checklist . . . . . . . . . . . . . . . . . . . . . 169
F. LOTO Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
G. Hot Work Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ix Chevron Pipe Line Company

1.0 Introduction
Chevron Pipe Line Company (CPL) is committed to the

principles of Chevron’s Policy 530, for “Health, Environment
and Safety.” We follow the Operational Excellence (OE)
Management System and our conduct is guided by the Tenet
Principles.
This Handbook has been given to you to:

• Provide general guidelines and rules for conducting
company business in a safe manner.
• Verify compliance with various Occupational Safety
and Health Administration (OSHA) and Department
of Transportation (DOT) requirements as well as many
other applicable regulations.
The information contained here applies to all personnel and

visitors, company- or contractor-related, engaged in or on
any CPL activity or in any company owned, operated or
maintained pipelines or facilities.
Remember:
Stop Work Authority

It is your Responsibility
You have the Authority
Zero is Attainable
Your ideas and concerns are important. We always comply
with the Tenets of Operational Excellence shown on the
following page. As an employee or contractor for Chevron,
you are responsible and authorized to stop any work that
does not comply with these tenets, and there will be no
repercussions to you. That is our commitment to you.
Safe Practices Handbook – 2008 1

CPL Tenets and Principles
We believe all incidents are preventable.
✔ Do it safely or not at all

✔ There is always time to do it right
✔ When in doubt, find out
Always:
1. Operate within design or environmental limits.

2. Operate in a safe and controlled condition
3. Ensure safety devices are in place and functioning.
4. Follow safe work practices and procedures.
5. Meet or exceed customers' requirements.
6. Maintain integrity of dedicated systems.
7. Comply with all applicable rules and regulations.
8. Address abnormal conditions.
9. Follow written procedures for high risk or unusual

situations.
10. Involve the right people in decisions that affect
procedures and equipment.
2 Chevron Pipe Line Company

2.0 General Rules
Accidents can and must be prevented.

Safety is a necessary part of an efficient operation.
Compliance shall not be compromised for convenience,
production or expediency.
✓ Shutdown Authorization: In cases of imminent

danger, personnel are authorized and expected to order
work stoppage, shut down facilities, and activate
firefighting and life-safety systems as required to
prevent injuries or catastrophic loss. Employees shall
notify as soon as possible their team leader (and the site
supervisor if appropriate) when such action is taken.
✓ Electronic equipment may be considered a risk (as a
source of ignition) or security threat in certain areas,
therefore the use of:
Cell phones, photographic or film
cameras (digital or not, with
flash, light or without it) or
similar devices, is restricted and
not allowed without a permit.
2.1 Responsibilities
Employees, contractors and/or visitors shall:
• Be familiar with and abide by the:
§ Tenet Principles for CPL
§ rules and practices contained in this handbook
§ posted safety regulations in the workplace
§ written and oral company instructions to perform
their jobs safely
• Comply with all applicable country, federal and state
regulations as applicable

• Consult their team leader before proceeding with a job
if there is any question regarding job safety or
regulatory requirements
2.1.1 Team Leader
• Develop operating rules and procedures consistent
with our Policy 530 regarding Health, Environment
and Safety.
§ Ensure that:
• Emergency procedures (e.g., station bills, pre-fire
plans, emergency response plans, evacuation
routes, etc.) are posted and that personnel are
familiar with them.
• Visitors, contractors, and/or new personnel:
u are briefed on appropriate emergency
procedures on their arrival
u have an HES initial orientation before starting
work
u contractors who will perform work shall
receive a safety handbook returning its
acknowledgement.
§ Provide instruction and guidance to ensure that
employees and contractors follow proper work
procedures; including any additional assistance to
new employees and/or visitors.
§ Communicate with and join employees regarding
behavior based safety, incident reporting and
incident investigation.
§ Inspect tools, equipment, and working conditions to
determine that there are no obvious or hidden safety
hazards, or people performing unsafe acts.
§ Encourage and enforce (if necessary) the rules and
regulations that apply to the operation.

§ Maintain workplace conditions by:
1. Periodically auditing facilities for potential
hazards
2. Eliminating or mitigating hazards that present an
unacceptable level of risk
3. Listening to employee feedback regarding
workplace conditions
2.1.2 Employee
§ Periodically check the equipment, tools and work
area for possible safety hazards and inform the team
leader of any unsafe conditions.
§ Be prepared for emergency situations, locating safety
showers, fire protection equipment, evacuation
route, rally point, respiratory equipment and first aid
equipment before you begin working, and make sure
that the equipment is in good working order.
§ Whenever necessary, participate in behavior based
safety and incident reporting investigation.
2.1.3 Contractor
§ Ensure that personnel assigned to work at Chevron
locations are fit for duty and that they are physically
capable of performing all aspects of their jobs.
§ Conduct operations in a manner that constitutes no
potential hazard to the employees, property, or the
environment.
§ Provide and maintain all required PPE, safety
equipment, and instrumentation necessary to
perform their work effectively, efficiently and safely.
§ Have a designated safety representative at each job
site responsible for all safety-related activities. On
small or low-risk projects, the person in charge of
the job may designate a qualified crewmember to
contractor’s work. In any case, contractor safety

personnel must periodically make visits to
Chevron locations where their personnel are
working.
§ Bring any observed, unsafe conditions to the
attention of a Chevron representative.
§ Provide the designated Chevron Pipe Line
representative with reports of hazards presented by
the contractor’s work or identified during the
contractor’s work.
§ Have written safety programs and procedures, as
required or needed.
§ Conduct appropriate industrial hygiene monitoring
and, if requested, provide copies of the results to
CPL.
2.1.4 Short-Service Employees (SSE):
Note: An SSE is an individual who has been employed by
contractor or subcontractor for less than six months or has
been in a like job by contractor for less than six months.
§ Employee and contract SSE will wear high visibility
orange hard hats. No one-person crew may be staffed
by an SSE. Only one SSE is allowed on a two-to-four
person crew and on crews of five persons or more.
No more than 20 percent may be SSEs.
§ Contractor shall notify team leader and clearly
identify any SSEs on its crews. A qualified mentor
must be assigned to each SSE to monitor the SSE job
performance. Exceptions to the SSE policy may be
made only with Company’s prior approval.
2.1.5 Visitor
§ Sign in when entering, boarding or leaving any
CPL-owned site
§ Follow instructions for the facility you are visiting
§ Adhere to the safety practices contained in this
handbook

§ Wear your security ID at all times
§ Never be alone on premises
2.2 Incident Investigation and
Reporting (II&R)
• Report to your team leader

and/or Chevron representative
immediately:
§ all accidents (e.g., on-the-job
injury/illness, spill, fire, etc.)
§ near-misses
§ all motor vehicle incidents occurring at or affecting
the worksite or its employees, visitors or contractors
• Incidents will be promptly investigated to determine
the root cause. Depending on the nature of the
incident, subject matter experts will assist the
investigation.
• Data collection and investigation will begin as soon
as possible.
2.3 Training
• Personnel must be trained in the proper use of
equipment and safe work practices.
• Documentation of past training must be kept at the
work location.
• Any questions or concerns regarding your training shall
be expressed to your team leader.
2.3.1 New Employee Orientation
§ The team leader is responsible for:
• orientation which will take place the first day on
the job
• enrolling the new employee in the first available
session regarding HES procedures

2.3.2 HES Required Training
Many of the activities summarized here are not allowed
until the employee has taken specific training, such as,
but not limited to:
§ confined spaces entry
§ lockout/tagout (LOTO)
§ heavy equipment operation (e.g., forklift, crane
operation, etc.)
§ first aid response
§ etc.
2.3.3 Job Safety Analysis (JSA)

§ Every employee must be trained and aware of the
potential hazards involved with the operation.
2.4 Housekeeping
• Good housekeeping improves safety and efficiency.
Keep tools, equipment, facilities and your work area
clean and orderly. Before waste accumulates, dispose of
it in compliance with local regulations.
• When not in use, store hand tools in bins or toolboxes
with sharp edges facing inward. Return tools and work
equipment to the place provided for them.
• Maintain tools and work equipment in good condition.
• Store heavy equipment and heavy tools on low shelves.
• Discard any tools that cannot be maintained in good
condition, and request replacements through your team
leader.

• Keep access clear to walkways, exits and firefighting
equipment. Exits shall be kept free of obstructions.
Work areas, walkways, and stairways shall be kept free
of slipping/tripping hazards.
• Keep all company vehicles free of trash, oily rags, and
other debris.
• Clean up spills immediately. Use barricades to secure
the area, if necessary.
2.5 Food and Beverage
• Food or drink shall not be kept or
consumed in areas where possible
contamination is present. Use only
designated areas.
2.6 Smoking
• Smoke in designated “smoking areas” only. When in
doubt, please ask!
• Safety matches are the only type of
matches permitted on a CPL work
site. Carrying strike-anywhere or
lighters on company premises is
prohibited.
• Disposable butane lighters are not permitted at any
field locations. Any lighter carried on company
premises must have enclosed flint, steel, and operating
mechanisms to prevent accidental lighting and
sparking.
2.7 Alcohol and Drugs
• Employees shall notify their
supervisors when they are taking
medication, (prescription or non-
prescription), that might affect
job performance.

• Prescription drugs brought onto
Chevron facilities must be in
the container in which they
were originally dispensed and
must be prescribed for that
employee. The employee's team
leader must be notified of the presence or use of any
prescription drugs that may impair an employee's
judgment or performance.
• The illegal use, possession, distribution, purchase, or
sale of any controlled substance by any person while on
CPL premises, engaged in CPL business, or while
operating equipment is prohibited.
• Personnel assigned to a position which is deemed
“safety-sensitive” are required to maintain a blood
alcohol concentration (BAC) of 0.00 percent at all
times while on duty or driving a company-owned or
rented vehicle.
• CPL reserves the right to conduct or require an
alcohol or controlled substance screening test on any
person who is on premises or operating CPL
equipment, engaging in CPL business, or applying for
employment. Prior consent must be obtained from any
person who is to be screened.
• Mandatory screening will occur when:
§ alcohol or drugs are suspected to be a
contributory cause to an incident
§ an individual’s behavior is such that excessive
alcohol or drug influence is suspected
§ a driver is involved in a motor vehicle crash or the
driver’s vehicle was hit by another vehicle
• DOT Drug Testing Regulations
§ All personnel who perform operations,
maintenance or emergency response functions

required by DOT regulations have been deemed by
the DOT to be “safety sensitive.” All safety sensitive
employees are subject to part 199 of the DOT
drug testing regulations, which includes random
drug testing
§ Random and “for cause” drug testing may be
requested in accordance with DOT regulations, the
CPL Anti-Drug Plan, and Chevron
Corporation drug-abuse prevention policies
2.8 Security
• If the security staff is unavailable to
conduct a search, the supervisor
must have another supervisor
present to witness the search. In all
cases, the supervisor must
inform the department manager
before a search is conducted.
• Without prior announcement, company-authorized
representatives may search any person, vehicle, and
personal items of anyone entering, working at, or
exiting from any controlled company work area.
• When appropriate, items discovered through an
inspection may be taken into custody and turned over
to the appropriate local law enforcement agency. Failure
to comply with any of the above shall result in
disciplinary actions, which may include dismissal.
2.9 Discipline
Disciplinary action, including discharge, will be taken
for disregard or violation of safety instructions or
practices as follows:
• any violations will result in disciplinary action up to
and including termination

• failure to maintain fitness for duty will result in
disciplinary action up to and including termination
• to deviate from safety instructions will be cause for
disciplinary action up to and including termination

3.0 Personal Protective Equipment (PPE)
PPE is an essential element in protecting employees from

work place hazards and on-the-job injuries. All PPE shall
meet standards established by recognized governmental
and/or industry groups.
3.1 Mandatory PPE

• All employees, contractors, and visitors must wear the
following protective equipment when working in areas
other than offices, parking areas or change rooms
unless wearing the PPE causes an additional risk, which
will have to be validated by the team leader:
§ fire-resistant clothing (FRC)
§ hard hats
§ steel-toed footwear
§ safety glasses
Additional protection may be required depending on
the work scope and potential hazards; this equipment
includes, but is not limited to the following:
§ respirators
§ goggles (grinding, chemical, brazing, or cutting)
§ face shields (splash and welding)
§ gloves
§ welders’ jacket
§ pants

§ arm protectors as appropriate
§ life jackets
§ full body harness
PPE shall be furnished by the employer (Chevron or
contractor) as required and at no charge to the
employee or visitor. It is the employee's responsibility
to maintain it in a safe and sanitary condition, as well
as follow the manufacturers' recommended
instructions or applicable procedures for cleaning,
maintenance, use and replacement.
3.2 Field Work Clothing
• Employees should wear natural or non-melting fibers
i.e., cotton or wool under their Fire Resistant
Clothing (FRC).
Kermel, Kevlar (PBI Gold or equivalent), and
Nomex III are all acceptable materials for protection
against flash fires. For other fire resistant clothing
materials check with your safety specialists.
If clothing (including shoes) becomes contaminated
with a potentially hazardous (flammable or toxic)
material it should be:
§ immediately removed to prevent skin irritation
and/or possible ignition
§ changed in a well-ventilated area, and the person
should take a shower if necessary
§ not worn again until it has been properly cleaned
• FRC shall be worn by all persons working in or around
any of CPL-owned or operated facilities and/or
pipelines, which contain hydrocarbons or electrical
equipment, but not limited to:
§ any of the operations units and fenced in areas
§ pump stations and valve locations
§ maintenance areas, truck racks, and tank farms

§ electrical switchgear areas
§ rectifier checks, and valve manifold areas
• Personnel may travel between designated facility
entrances/parking areas and their work locations
without wearing FRC, provided they use the roadways
on the most direct path to their work locations. FRC is
not required in offices and machine shops.
• FRC shall be worn in the appropriate manner to
maximize protection:
§ must cover the entire body from the neck to the
ankles
§ should be worn as an outer garment, unless a
Tyvek suit is required for the operation (you may
also wear layered clothing underneath as needed
for personal warmth)
§ may not be modified, such as, long sleeves rolled
up, zippers left down or shirts/jackets unbuttoned
3.3 Protective Clothing - General
• The wearing of loose or ragged clothing must be
avoided when working around moving machinery
because it can get caught in machinery, moving belts,
etc. Long shirt tails must be tucked in trousers.
Clothing (including shoes) that becomes contaminated
with a potentially hazardous (flammable or toxic)
material should be removed immediately to prevent
skin irritation and possible ignition. Change such
clothing in a well ventilated area and take a shower if
necessary. Do not wear the clothing again until it has
been properly cleaned.
Hair long enough to be potentially hazardous while
working around moving machinery or rotating tools
and equipment shall be secured. Hair styles that make
it impossible to wear a hard hat properly are not

permitted. Except in office jobs, rings and other
jewelry (except watches) should be removed while
at work.
3.4 Head
• Hard hats shall be
worn by all personnel V-Guard
at all work locations
and along the right-
Shock Guard
of-way, except in
offices or when an
employee is riding in
an enclosed vehicle.
Hard hats must be nonmetallic (non-conductive or
‘dielectric’) and meet ANSI Z89.1, Class A and B
requirements.
• Electricians and other employees who could be
exposed to electrical hazards should use dielectric
or nonmetallic accessories (such as liners and
chin straps) only.
• For situations during welding operations where the
welder must work in a head-down position, and where
there are no overhead hazards, the team leader shall
have discretion to allow an exception to the hard hat
requirement. These situations occur mainly in welding
on the underside of pipelines when the welder’s
attempts to keep the hard hat on can create a hazard.
All other welding operations require a hard hat to be
worn in combination with a welding shield.
• Do not alter hard hats in anyway that could reduce its
dielectric or impact qualities. This includes drilling of
any hole, carving, etching, painting, etc. Do not place
objects between the liner and the shell while wearing
the hat.
• Employees should replace liners periodically and
replace the hat when it becomes damaged or brittle. It
is recommended that liners be replaced at least every
six months, and hats at least every two years.

3.5 Eyes and Face
• All safety glasses or face
shields must meet ANSI Z87.1
standards, and its primary
intention is to protect where
a potential eye hazard exists.
• For prescription safety glasses,
the company will pay 100 percent of the cost of frames
and lenses. When an employee requires prescription
lenses, the employee must furnish an up-to-date
prescription (within one year). The employee pays for
the examination and fitting. The company will provide
up to two pairs of safety glasses per year, one clear and
one tinted. The tinted lenses may only be gray, green or
rose depending on the employee’s preference.
• Contact lenses provide no protection to the eye and
should be worn with other eye protection. They should
not be worn in high-dust conditions or in the presence
of irritating vapors or smoke.
• Advise your team leader if you routinely wear any type
of contact lenses. This information may be needed
during a medical emergency. Also advise your team
leader if you wear contact lenses due to surgical
removal of your natural lenses. Carry some form
of medical alert identification at all times. Wear
chemical goggles over implanted contact lenses in
areas where eye protection is required.
• Do not wear “hard” contact lenses when you are
working in a contaminated atmosphere with a supplied
air respirator unless they are gas-permeable lenses
(OSHA 1910.134) (e) (5ii). Air passing over non-gas-
permeable lenses may severely dry the eyes and cause
severe pain. “Soft” contact lenses are permitted.

• Safety glasses are not safety goggles. Use goggles to
protect against hazards that may enter your eye from
the sides. Do not depend on safety glasses for this
protection. There are two primary types of goggles,
impact and chemical.
• Impact-type goggles shall be worn during activities
involving flying or falling objects or particles such as:
§ chipping, cutting, or breaking stone, brick and
concrete
§ using hammers, chisels or other steel hand tools
§ scraping paint or scale from wood or metal
surfaces
§ using a wire brush to clean threads, fittings or
metal and wood surfaces
§ grinding on abrasive wheels (even when a glass or
plastic guard is provided)
§ using compressed air for cleaning purposes to
clean or blow out debris
• Splash-proof chemical goggles and face shields shall be
worn when handling potentially hazardous chemical
liquids and solids or in any other operation where the
eyes may be exposed to potentially hazardous
chemicals.
• Never wear face shields alone as eye protection. Use
face shields in addition to eye protection to protect the
face and neck from flying particles, sprays of chemicals,
splashes of molten metal and from hot solutions.
• Welding, brazing, soldering or cutting operations
require the use of shaded lenses. Use the following
table to select the proper shaded lens for welding:

Minimum
Welding Operation Shade
Number
Shield metal-arc welding, up to 5/32" electrodes.............. 10

Shield metal-arc welding, 3/16 to 1/4" electrodes............. 12
Shield metal-arc welding, over 1/4" electrodes..................14
Gas metal-arc welding (nonferrous)..................................11
Gas metal-arc welding (ferrous)........................................ 12
Gas tungsten-arc welding................................................... 12
Atomic hydrogen welding.................................................. 12
Carbon arc welding............................................................ 14
Torch soldering..................................................................... 2
Torch blazing................................................................. 3 or 4
Light cutting, up to 1"................................................... 3 or 4
Medium cutting, 1 to 6"................................................ 4 or 5
Heavy cutting, over 6"................................................... 5 or 6
Gas welding (light), up to 1/8"..................................... 4 or 5
Gas welding (medium), 1/8 to 1/2".............................. 5 or 6
Gas welding (heavy), over 1/2"..................................... 6 or 8
• Abrasive blasting and sandblasting require a hood

designed specifically for this purpose. The hood should
have appropriate eye and face protection: forced-air
ventilation for the operator, and appropriate air-
purifying respirators for others who may be exposed.

3.6 Hearing
• Hearing protection shall be
worn by all workers exposed to
8-hour, time-weighted average
(TWA) noise levels of 85 dB or
above to prevent hearing loss.
This may require wearing a
combination of hearing
protection devices (for
example, earplugs and ear muffs).
• CPL shall identify high noise areas and post
appropriate warning signs so appropriate actions can
be taken. Employees should report suspected high-
noise areas to their safety specialist.
• The warning signs will be posted at entrances
indicating that hearing protection is required.
• Also, use hearing protection whenever you're exposed
to mobile noise sources such as power tools and
equipment or during venting operations.
3.7 Respiratory
• Respiratory equipment is required
in any situation with at least one of
the following conditions:
§ whenever the job needs to be
performed in an
oxygen-deficient area
§ in an area that contains hazardous concentrations
of toxic contaminants
• Prior to being approved for the use of respiratory
equipment, employees shall:
§ have medical clearance from the company
physician

§ receive the required training (selection, use, care,
maintenance and limitations of the equipment)
§ be fit-tested as appropriate for the respirator
model he/she will be wearing
• The type of respiratory
protection equipment used
will depend on the type of
respiratory hazard, such as
dust, chemical, vapor or paint
respirators for protection
during exposures to specified
concentrations of these contaminants.
• Use self-contained breathing apparatus or supplied air
respirators when the atmosphere is immediately
hazardous to life or health (for example, excessive
concentrations of C02 or H2S). Breathing air shall meet
at least the requirements of the specification for Grade
“D” breathing air.
• All respirators shall be examined prior to use.
Employees shall clean, disinfect, and properly store
respirators after each use, unless this responsibility is
assigned to others. Additionally, respiratory protective
equipment must be inspected monthly and prior to
each use. Maintain a written inspection record with
each piece of equipment.
• Employees and contractors who may be required to
wear respiratory protection, either in their normal
duties or under emergency conditions, shall not be
permitted to have beards, mustaches or sideburns in
the facial area contacted by the mask. A tight face-to-
mask seal is required for the safe use of all types of
respiratory protective equipment.
• Employees who must wear prescription glasses, and
whose normal duties require them to wear full-face-
piece respiratory protection, will be provided with units
designed for use with glasses.

• Employees who wear prescription glasses and who are
required to wear full-face-piece respiratory protection
should remove their glasses only in emergencies if they
can see well enough to function without them; if not,
positive-pressure units designed for use with glasses
will be made available to them.
3.8 Hand
• Employees shall wear appropriate
hand protection when performing
operations that expose the fingers
and hands to cuts, scrapes, bruises,
burns, and chemicals.
Examples of appropriate hand
protection include:
§ insulated or heat-resistant gloves when handling
steam hose, or when performing other duties in
which regular work gloves do not afford burn
protection
§ leather or leather-palmed gloves when handling
wire rope
§ cloth gloves when handling pipe, and rubber
gloves approved for electrical work
§ chemical-resistant gloves when handling acids,
caustics, caustic soda, etc.
§ hydrocarbon resistant gloves when using
hydrocarbon-based solvents, cleaning agents, or
chemicals
The company will supply proper gloves, taking into
account the type of work being performed and the
types of chemicals that may be involved. Use extra
caution when wearing gloves where there is a possibility
of catching them in moving equipment; ask your
supervisor, it may be better not to wear them.

3.9 Foot
• Foot protection is required
whenever risk of falling objects
is present. Field personnel are
required to wear steel-toed
footwear when working in areas
outside of the office setting.
• Acceptable footwear must comply with the following:
§ steel-toed
§ provide ankle coverage
§ have a notched heel that prevents slippage when
climbing ladders
§ oil-resistant soles
• Visitors (non-company personnel) to the field may
not need to comply with CPL steel-toed footwear
policy provided that they are accompanied by a
CPL employee and do not participate in work
activities that could result in a foot injury.
3.10Fall
• Fall protection shall be used in certain situations. These
include, but are not limited to:
§ open-sided floors, floor openings, catwalks, or
platforms elevated six (6) feet or higher where
handrails or barricades are not provided
§ working over water when personal flotation
devices (PFDs) are not used.
• Personal fall arrest systems consist of
anchor points, connectors, and a
full-body harness. They may also
include a shock absorbing lanyard,
deceleration device, lifeline, or
suitable combination of these.

• Employees shall use fall protection devices where they
are installed. Fall protection rescue equipment and
personnel trained in its use will also have to be
available at the job site.

4.0 Common Hazards
On many occasions, accidents occur in places or during

operations and activities that we take for granted. This section
includes a few of those that are more frequent.
4.1 Slip, Trip, and Fall Prevention (Walking

Hazards)
• Watch your step while walking
about the job to avoid tripping,
stumbling, slipping and similar
hazards.
• Be aware that weather conditions
such as ice, water, or mud can
create or aggravate existing hazardous situations.
• Use the walks, stile and stairs provided.
• Remove or repair tripping or slipping hazards as they
are found.
• Avoid jumping from elevated places.
• Do not take shortcuts, such as walking up or down
earthen banks or berms if stiles and walkways have
been installed for your use.
4.2 Stairways and Elevated Work Surfaces
• Employees shall use available
stairways, walkways and handrails.
• Employees shall not climb onto
vessels, tank roofs, etc. without
safeguards (planking, scaffolds,
etc.).
• Working from any surface more than six feet above
adjacent floor or ground requires guard rails or the use
of fall protection.
• Stairways having four or more risers shall have
handrails.

• Where guard rails are installed, toe-boards shall be
provided if a person can pass beneath the open sides or
where falling materials can create a hazard.
• Openings in floors into which a person can accidentally
step or fall shall be covered, continuously attended, or
protected by barricades or standard hand railings.
• Employees shall avoid carrying loads that extend above
eye level or otherwise obstruct vision when on
stairways or elevated work surfaces.
4.3 Ladders and Scaffolds
• Shall be examined for defects before each use. Defective
equipment shall be removed from service and reported
to the appropriate supervisor.
• Wooden ladders shall not be painted. Paint hides cracks
and other damage.
• Always face a ladder when ascending or descending it.
Both hands should be free to grip the ladder firmly.
• Tools should be carried in a belt or should be raised
and lowered by rope. (Make sure no one is standing
below the tools as they're being transported).
• Fiberglass ladders shall be used for electric equipment
installations, repair or maintenance work.
4.3.1 Ladders
4.3.1.1 Portable
• Employees shall only use portable ladders that have
labels showing that the ladders conform to appropriate
ANSI standards.
• Metal ladders shall not be used for electrical equipment
installations, repair or maintenance work where they
may contact electrical conductors. Special
non-conductive ladders (approved wooden, fiberglass,
etc.) may be used.
• A ladder shall not be used in a horizontal position as a
walkway or scaffold.

• Portable ladders shall be equipped with safety feet to
prevent slippage.
• Not more than one person shall be on the ladder.
• Employees shall not lean from a ladder to reach work,
the ladder shall be repositioned.
• Employees shall not stand or sit on the top two steps of
a stepladder.
• When two people are carrying a ladder, grasp it near
both ends. Exercise caution when approaching
doorways and corners.
• A folding step ladder shall not be used in a straight
closed position.
4.3.1.2 Positioning a Ladder Straight
• Set the portable ladder 3 1/2 foot minimum
base at the correct angle. lashed, clamped, or
otherwise secured
A rule of thumb: The to structure
distance from the foot of ladder
the ladder to the object it

will lean against should
be one-fourth the
required height.
1/4 height
In other words, the feet of (working length) of ladder
a 12-foot-long ladder
should be placed about 2-1/8 feet away from the base of
the object (12 ft ladder - 3-1/2 = 8.5 = working length
= 8.5/4 = 2-1/8).
• Straight and extension ladders shall extend 3-1/2
feet beyond the top resting point when used for
climbing onto a platform.
• If this is not possible, a helper should hold the base of
the ladder in position during use. Whenever possible,
securely fasten the ladder at the top to prevent slipping.

• Based on the nominal length of the extension ladder,
each section of a multi-section ladder shall overlap the
adjacent section by at least the number of feet stated
below:
Nominal Length of Overlap

Ladder (Feet) (Feet)
Less than or equal to 36 3
37-48 4
49-60 5
4.3.1.3 Positioning Step

• Set a portable ladder on a firm
base. Fully extend the legs and
lock the cross braces into
place. Have someone help
steady the ladder. Do not use
overlap
the ladder if all its feet are not

firmly contacting the ground.
4.3.1.4 Permanently Fixed
4.3.1.4 Ladders
• May vary from vertical to 75
degrees from horizontal and
shall have a toe clearance of at
least seven inches between the
ladder and the surface behind the ladder.
• Shall be securely fastened at the top, bottom, and
intermediate points, as required.
• Shall not be climbed longer than 20 feet unless it is
equipped with a cage or the employee uses a fall
protection device.
4.3.2 Scaffolds
• Construct scaffolds with provided handrails, midrails,
toe boards, and all other items specified in the
Chevron Safety in Design Manual.

A few safety tips while using a scaffold, do not:
• walk under it while people are on it.
• work off it during a strong wind.
• place it in front of a door without
locking/blocking the door closed or posting a
guard.
• leave tools or materials on it.
4.4 Worker Safeguards
• Do not get inside guardrails or barriers while the
equipment is in operation. Guardrails around operating
equipment are placed there for your protection.
• Follow all appropriate requirements regarding
excavations to prevent someone or something from
falling into one. Provide barricades as required.
• Install temporary guards whenever portions of
handrails have been removed to facilitate the handling
of material. Reinstall permanent handrails immediately
after the need for the opening has ended.
• Make sure machine guards, such as those over belts and
chains, are in place whenever equipment is readied for
operation. Keep long hair, sleeves and shirt tails away
from running equipment.
• High-temperature surfaces (those that will cause burns
if contacted) shall be clearly identified, insulated
and/or guarded.
• Apply lockout/tagout (LOTO) procedures on any
setup or maintenance work.
4.5 Grinding Wheels
• When using or working near a
grinding wheel, wear goggles or
safety glasses and a full-face shield.

• Do not operate the grinder unless it has a safety guard
and is properly adjusted.
• Grinders are considered an ignition source. Obtain a
hot-work permit before operating grinders in a
restricted area (i.e., an electrically-classified area).
• Do not use the side of a grinding wheel to grind unless
the wheel is designed for that purpose.
• Use an appropriate wheel when grinding aluminum,
rather than wheels designed for ferrous metals.
• Inspect safety guards frequently to ensure that proper
distances are maintained.
• The work rest for a grinder shall be no more than
1/4 inch from the wheel and the tongue guard no more
than 1/8 inch from the wheel.
• Do not attempt to adjust the guards while the wheel is
in motion. Make sure it is unplugged (with plug within
reach) before making any adjustments or repairs.
• Inspect the grinding wheel before each use for signs of
possible cracking or other damage. Replace all defective
wheels immediately.
• Grinding wheels should never be used on Asbestos
Containing Materials (ACM) unless retrofitted to an
approved HEPA vacuum system.
4.6 Tools Maintenance and Use
• Inspect all tools before using
them to determine if they are
the proper size and in good
condition. If they are not in
good condition, let your team
leader know. Do not use
defective or damaged tools.

• Keep tool surfaces and handles
clean and free of excess oil to
prevent slipping and glancing.
• Tools shall be used only for the
purpose for which they are
designed. Use the right tool for
the job.
• Keep tools in a safe place and not
in overhead areas or on ladders. Do not carry
screwdrivers or other sharp objects in a pants pocket,
use an approved tool pouch or equivalent to carry
tools.
• Upon completion of a job, clean tools and return them
to the tool box or storage area.
• Make sure wrenches have a good bite before applying
pressure. An employee shall ensure they are in a safe
and stable position before applying pressure to a tool
handle, to avoid losing balance or falling if the tool
should slip.
• Brace yourself and place your body in the proper
position so that you will not fall in case the tool slips.
Also provide sufficient clearance for your hands and
fingers in case the tool slips.
• Keep chisels, axes and similar tools sharp for safety and
efficiency.
• Frequently inspect driving faces of hammers, chisels,
bars, and similar tools for mushroom heads, broken
faces and other defects. Discard defective tools. Use a
tool holder when using driving tools, striking chisels,
punches, rods, stakes, etc., to prevent hand injuries. Eye
protection shall be worn when striking tools are used.

• “Mushroomed” or expanded
heads of impact tools such
as chisels and sledge hammers
shall be dressed (filed off) as
needed.
• Ball peen hammers and sledge
hammers shall be used in
conjunction with striking tools (e.g., chisels, punches,
rods, stakes, etc.). The use of claw hammers is
prohibited.
• A hammer shall not be struck against another hammer.
• Files shall be equipped with handles.
• Wrenches shall be pulled instead of pushed when
possible.
• Adjustable crescent wrenches shall not be used if a box
or open-end wrench of the correct size is available.
• Jaws on adjustable crescent
wrenches shall be tightened
around fitting/nut and the
force applied on the side with the
stationary jaw.
• Local regulations may restrict or
prohibit the use of wrench extensions or “cheaters.”
(e.g., CA-OSHA regulations state: “When a pipe wrench
extension is used, the maximum length of the extension
shall be two times the length of the pipe wrench
handle. The extension shall be constructed of steel pipe
of such a diameter to snugly fit the pipe wrench handle,
and cover the full length of the pipe wrench handle.
The force exerted on the wrench shall not exceed the
manufacturer's rated breaking strength of the wrench.”)
• Tools not bolted, tied or secured in some manner shall
be removed from locations where they could fall on
employees below.
• Handles of sledges, hammers, mauls and the like shall
be securely wedged into the heads. Wooden handles

shall not be painted because paint causes handles to be
slick and hides cracks and other defects. Cracked or
split handles shall be replaced; they shall not be taped.
4.7 Equipment / Machinery in Motion
• The following safety precautions shall be observed
when working around rotating machinery:
§ follow proper LOTO procedures for any type of
equipment
§ do not wipe any moving part while it is in
motion
§ keep rags away from moving machinery; don't let
them protrude from your pockets
§ rotating machinery consists primarily of
compressors, engines, turbines and pumps.
Rotating machinery is dangerous because of the
high speeds and pressures used in its operation.
Repairs shall not be initiated until the fuel supply
is shut off and the starting circuits disconnected,
locked out, and tagged
4.7.1 Centrifuge Machines
§ Centrifuge machines shall be
equipped with guards
§ Centrifuge machines shall be
operated with the tops closed.
§ Pneumatically operated
machines shall be operated at
manufacturer's recommended pressures.
4.7.2 Compressors
§ Before starting repairs, the suction and discharge
valves shall be closed and the pressure bled off.
§ Compressor alarms and shutdowns shall be tested
periodically.

4.7.3 Engines and Turbines
§ Pressurized lines shall be bled off.
§ When turbines are shut down for maintenance or
service, air or gas supply to the auxiliary lube oil pump
shall be shut off to prevent accidental operation (where
applicable).
§ Engines shall be located in well ventilated areas and as
far away as practical from headers, separators, and oil
storage tanks.
§ Air starters shall be used instead of gas starters where
practical; however, if gas starters are used, exhaust
piping shall be securely anchored and vented to a safe
location. Means shall be provided to vent unused gas or
liquid accumulation trapped between the starter and
the starter valve after it is closed. Before activating the
gas starter, the integrity of the vent line shall be
checked.
§ Portable internal combustion engines with engine
mounted fuel tanks shall be shut down and allowed to
cool before refueling. Exceptions shall be approved by
local supervision.
§ When cranking engines using a rope starter, employees
shall not wrap the rope around their hands or wrist.
The starting rope shall be equipped with a pull handle.
4.7.4 Pumps
§ Prior to initiating repairs or maintenance, the pump
shall be shut down, isolated, and the internal pressure
bled down.
§ Main electrical disconnects and valves shall be locked
out and tagged prior to initiating work.
§ A pressure relief valve shall be part of the discharge
manifold on every power-driven pump, with the
exception of centrifugal pumps. It shall be placed ahead
of the first valve on the discharge line. Relief valve

outlets shall be vented to a safe location or discharged
back into the pump suction. When discharge extensions
(vents) are necessary, they shall be securely anchored.
§ If it is necessary to tighten packing glands while pumps
are in operation, use extreme caution.
4.8 Pocket Knives
• Personnel are allowed to carry pocket knives; however,
they are not allowed to use them while working.
USE THE APPROPRIATE TOOLS FOR THE JOB.
POCKET KNIVES ARE NOT APPROPRIATE TOOLS.

5.0 Safe Practices
5.1 Safety Meetings

Pre-job or pre-startup meetings shall be conducted to
review all safety procedures, restrictions, guidelines, permits,
JSA’s and concerns before starting with the activity.
5.2 Safety Signs
• Safety signs are usually posted where dangers are
present. Heed all warning signs (such as those
regarding PPE, “Danger”, “Road Closed”, “Keep Out”,
etc.) and safety guards.
• Never remove, move or change warning signs, safety

guards or equipment without company authorization.
• Warning signs, safety guards or equipment are provided
for your protection - don't ignore them!
5.3 Behavior Based Safety Process, Inspections or

Audits
All personnel are expected to participate in a behavior
based safety process which shall include training to
observe co-workers for “safe” and “at risk” performance
and provide feedback after completion of the observation.

Contractor companies may have their own program.
Any employee or visitor may approach the work area to
perform a safety observation, inspection or audit. The job
will continue as scheduled and everybody is encouraged to
participate if allowed by the operation and requested by the
observer. The team will be expecting feedback from the
observations as soon as practical, in order to improve the
overall safety of the process.
5.4 Permit to Work (PTW) Systems

CPL has instituted permit systems to authorize and
approve, in writing, various types of work activities. The
permit specifies the location and type of work to be
performed and also certifies that hazards have been
evaluated by a qualified person and that all necessary
protective measures have been specified and
implemented.
✓ Please review and follow the Safe Work Permit
checklists in the Appendix section.
Safe Work Permits are required for:
• High-risk operations:
§ hot work
§ confined space entry
§ lockout/tagout
§ excavations
• Non-routine maintenance work:
§ pipeline repair or replacement
§ tank or vessel maintenance and/or repair (except
inspections)
§ hot taps
§ overhauling of equipment (pumps, compressors)
§ site remediation projects
§ any other work that is hazardous or unusual,
such as:

• working from heights where personal fall
protection is required
• overhead activities involving rigging in a
congested area or over piping or equipment in
service
• work activities requiring respiratory protective
equipment
• unbolting, disconnecting, opening or removal of
any line, process piping, equipment or system that
has been in service
• unflanging or removal of heads, isolating blinds,
blind flanges, man ways, process piping or
equipment that has been in service
• working on electrical equipment over 600 V
• removal of process valves and relief valves
• any maintenance work done by contractors
• construction work (includes the installation of
new equipment and the modification of existing
equipment)
5.5 Materials Handling
5.5.1 Handling Pipe
§ Designate a leader if working in a team of two or
more persons. Team will follow his/her directions.
§ Wear gloves and other appropriate PPE when
handling pipe.
§ Make sure stops to hold pipe from rolling are in
place before moving pipe on a rack.
§ Roll pipe away from, rather than toward you, to
reduce the possibility of it rolling on your toes.
§ Use a tether for loads above your head to help
control pipe. The person in charge is responsible to
determine if pipe contains Asbestos Containing
Material (ACM) and ensure proper handling.

Do not hold pipe on the end with your fingers inside, if the
end comes in contact with another object your fingers could
be injured.
5.5.2 Tractor Loader/Backhoe Unit Operation
§ Inspect the backhoe equipment
before operating it. Give special
consideration to:
• Installing step plates or other
devices that provide suitable
footing for the operator when
moving between the backhoe and tractor seats.
• Installing an engine “kill” switch in an explosion-
proof housing near the backhoe controls to
provide a fast means of “killing” the engine in an
emergency.
• Modifying the exhaust system to minimize the
possibility of igniting petroleum vapors or dry
vegetation.
§ The backhoe should be equipped with:
• lights on the front and back of the tractor suitable
for use with the backhoe
• an easily accessible dry-chemical fire extinguisher
on the tractor
• a rollover protection device.
• a noise device that beeps when the vehicle is
backing.
§ Inspect the trailer used to haul the backhoe to make
certain it complies with prevailing motor vehicle codes.
In addition, install the following:
• expanded metal or other suitable material to
provide a non-skid surface on the trailer bed for
tractor wheels
• side rails to aid in preventing the unit from
slipping off the trailer during loading or
unloading

• a hydraulic control, or other device, to control the
rate of tilting during loading or unloading (if
applicable)
• adequate loading ramps, if required
§ Maintain the tractor unit in a safe operating
condition.
§ Be thoroughly familiar with the manufacturer's
instructions regarding maintenance, operation and
safety precautions.
§ Take the following precautions during the operation
of this equipment:
• Only the operator is allowed on the equipment.
• Do not make mechanical adjustments while the
unit is in motion. Do not repair hydraulic hoses
while they are under pressure (e.g., loader bucket
raised, backhoe raised, or engine running).
• Rest loader and backhoe buckets on the ground
and set the brakes when the unit is left
temporarily. If the unit is left unattended for a
longer period, turn off the engine; place the
transmission in “park”, and remove the key from
the ignition.
• Have the operator check for clearance before
moving the unit. Keep co-workers and bystanders
clear of the unit while it is in operation and while
loading or unloading on the trailer.
• Drive at a speed that allows you to maintain
control of the vehicle and ensure the safety of
yourself and others.
5.5.3 Powered Industrial Truck (PIT or Forklift)
Operations
§ No employee who is currently unqualified may
operate a forklift truck. Each forklift truck operator
must re-qualify at least every two years.

§ Before a forklift truck may be operated the first time
during a shift, the forklift operator must complete an
inspection checklist. Keep a copy of the checklist for
three years.
§ To prevent unexpected movement of the vehicle, do not
unload any truck or cargo trailer that is not secured. As
a minimum, set the brake and place chocks under the
wheels of the vehicle.
§ Any employee who is working near a forklift truck
must notify the operator of his/her activities. Each
employee must be careful to avoid entering the path of
a moving forklift truck.
§ Guidelines for safe forklift operation:
• use seat belts
• report any damage or problems that occur to a
forklift during a shift
• don’t jump from an overturning forklift. Stay with
the truck. Hold on firmly. Lean in the opposite
direction of the overturn
• use extreme caution on grades and ramps
• on grades, tilt the load back and raise it only as far
as needed to clear the road surface
• don’t raise or lower the forks while the forklift is
moving
• don’t handle loads that are heavier than the
weight capacity of the forklift
• operate the forklift at a speed that will permit it to
be stopped safely
• slow down and sound the horn at locations where
vision is obstructed
• look toward the travel path and keep a clear view
of it

• don’t allow passengers to ride on forklift trucks
unless a seat is provided
• when dismounting from forklifts, set the parking
brake, lower the forks or mast, and neutralize the
controls
• don’t drive up to anyone standing in front of a
bench or other fixed object
• don’t use a forklift to elevate workers who are
standing on the forks
• elevate a worker on a platform only when the
vehicle is directly below the work area
• whenever a truck is used to elevate personnel,
secure the elevating platform to the mast or forks
of the forklift
• use a restraining means such as rails, chains, or a
full-body harness with a lanyard or deceleration
device for the worker(s) on the platform
• don’t drive to another location with the work
platform elevated or with people on it
5.5.4 Cranes and Hoisting, Cables and Slings
§ Cranes are machines used
to lift, swing, and lower
heavy objects or loads.
Cranes shall be properly
operated and maintained
in accordance with
manufacturer's
guidelines and applicable
regulations.
§ Only qualified (certified and carry the certification
on their person) personnel who are familiar with the
equipment shall operate cranes and hoisting
equipment.
§ Only qualified (certified and carry the certification
on their person) rigger who are familiar rigging shall
rig load for hoisting.

§ Check that the capacity of the equipment can support
the weight of the material to be lifted. Operators must
ensure that safe working capacities are posted on
cranes, and that these capacities are not exceeded.
§ Cranes shall be certified annually.
§ Crane components (booms, cables, rigging, slings,
shackles, fittings, fastenings, foundation mountings,
control cables, etc.) and safety devices, shall be
examined and determined to be functioning properly
by the crane operator each day before starting
operations.
§ All cranes shall have a pre-operation checklist
performed by the operator prior to use. The checklist
can be a manufacturer or vendor check list.
§ The examination shall include, but not be limited to, a
visual examination for:
• cracked welds
• cable defects
• bent braces
• sheave condition
• deformed or broken hooks
• load indicators
• stops
• evidence of overloading
• excessive wear
• sharp bends
• knots
• equipment damage or any other defects
In addition to these “before-use” inspections,
Maintenance-related inspections shall be made on
cranes and their cables and any other lifting devices.
Records of these periodic inspections shall be
maintained.

§ The crane operator shall not operate the crane until
persons involved have been instructed as to the work to
be performed.
§ Employees shall be clear of a load before it is picked up
or landed and must remain clear at all times.
§ Employees shall not stand/pass under suspended loads.
§ Cranes shall not be operated in adverse weather
conditions (lightning storm, high winds, rain, etc.).
§ The operator of a truck-mounted crane shall check
truck positioning and anchoring prior to use. The
wheels shall be chocked to prevent the truck from
moving. If the truck is so equipped, maxi brakes shall
be set.
§ Outriggers shall be properly used and positioned when
available. Outriggers shall not be used in the place of
wheel chocks.
§ Wire rope and wire rope slings shall be lubricated to
protect against wear and corrosion. Slings must be
inspected before each use.
§ Chain and fabric slings shall have an identifier
indicating manufacturer, load rating, and date placed in
service. This identifier shall not be removed. Slings
must be inspected before each use.
§ Lifting accessories (chains, slings, etc) should be stored
away from direct contact with adverse weather and
conditions when not in use. Slings must be inspected
before each use.
§ Boom angle indicators shall be permanently attached to
the boom to show the operating radius. The rated load
capacity/boom angle of the crane shall not be exceeded.
§ The crane operator shall check the load chart, confirm
boom length with chart, and establish load weight and
maximum operating radius or corresponding
minimum boom angle.

§ Practice extreme care when operating or working
around equipment such as portable cranes, power
shovels, and forklifts. Do not ride on equipment except
in seats provided for that purpose.
§ If you are operating equipment and cannot see the load
from your position, you must have the assistance of a
co-worker and use the appropriate crane hand signals.
§ For cranes with a lifting capacity of three tons or
greater, a properly trained signalman shall work with
the crane operator. Standard signals shall be used.
Normally, all signals shall be given by the signalman,
but the operator shall obey any emergency stop signal
given by anyone.
CRANE SIGNALS
HOIST LOWER STOP
EMERGENCY
SWING TRAVEL
STOP
RAISE LOWER
BOOM BOOM
MOVE
SLOWLY
TELESCOPING BOOMS DOC

EVERYTHING
EXTEND BOOM RETRACT BOOM
§ Taglines shall be used when it is necessary to control

the load.
§ During operation, at least three wraps of cable shall be
maintained on the drum at all times.
§ During operation, at least three wraps of cable shall be
maintained on the drum at all times.
§ Never stand at, near, or in line with a rope or cable that
is under strain or within a loop that could tighten.

§ Employees shall wear gloves and appropriate PPE when
handling wire rope slings.
§ Boom stops shall be provided on crane booms to
prevent the possibility of overtopping the boom.
§ Platforms, walkways, steps, handholds, guardrails, and
toe boards shall be provided on cranes where necessary.
§ Crane hooks shall not be used without safety bolts or
latches.
§ The crane boom shall be kept in the cradle when not in
use. The operator shall properly secure the crane and
boom before going off duty or when shutting down
operations.
§ Minimum required clearances from overhead high-
voltage lines shall be maintained in all directions:
Except where electrical
Line Voltage Minimum Required
(Phase to Phase) Clearance (Feet) distribution and transmission
< 50k 10 lines have been de-energized
50k - 75k 11
75k - 125k 13 and visibly grounded on both
125k - 175k 15 sides of the work area, or
175k - 250k 17
250k - 370k 21
where insulating barriers not a
370k - 550k 27 part of or an attachment to the
550k - 1000k 42
crane have been erected to
prevent physical contact with
the lines.
In transit with no load and boom lowered, the following
minimum clearances shall be maintained:
Line Voltage Minimum Required

(Phase to Phase) Clearance (Feet)
< 50k 4
50k - 345k 10
345k - 750k 16
§ When working in areas with power lines:

• the area of the work and paths of equipment
travel shall be surveyed to identify locations of all
overhead power lines

• a person shall be assigned to observe the
operation of the equipment and power lines
• high voltage proximity alarms should be mounted
on the crane boom
5.5.4.1 Inspection Criteria
Lifting equipment presenting any of the following
conditions shall be immediately removed from working area
and replaced as needed.
Acid Damage Examples of Wire Rope Sling Abuse
Heat Damage
Broken Wires
Cuts
Worn Wires
Cuts & Tensile Damage

Corroded
Abrasion Damage
Bird Caging
Face Cuts
Punctures & Snags
Tensile Breaks Kinked and Crushed
Worn and Deformed

Attachments
Illegible or Missing Tag
Taken from the World Wide Web

http://www.lift-all.com/PDF/WebSlings/WebSlingGeneral.pdf

5.5.4.2 Capacity Chart
HOW ANGLES EFFECT SLING STRESS
1. Divide the total load to be lifted by the number of LEG ANGLE LOAD
legs to be used. (This provides the load per leg if the lift (Degrees) FACTOR
wher being made with all the legs lifting vertically.)
2. Determine the angle between the legs of the sling 0 1.000
and the verticle. 5 1.003
3. Then, MULTIPLY the load per leg by the LOAD 10 1.015
FACTOR for the leg angle being used (from the table at 15 1.035
right) to compute the ACTUAL LOAD on each leg for 20 1.064
this lift and angle. 25 1.103
NOTE: THE ACTUAL LOAD MUST NOT EXCEED 30 1.154
THE RATED SLING CAPACITY. 35 1.220
40 1.305
45 1.414
50 1.555
55 1.743
60 2.000
5.6 Hazardous Materials and Substances

5.6.1 General Principles
§ Be certain of the properties of every substance you
handle and take every precaution as directed. Know the
protective equipment you need to wear. Consult your
team leader and the Material Safety Data Sheet (MSDS)
if you're ever in doubt.
§ Employees should be aware of how chemicals and
substances can contact the body and how that contact
can be prevented.
§ Handle all chemicals with caution. Avoid contact with
the skin or eyes, and never put them in or near your
mouth.
§ Be sure to wash carefully after working with petroleum
or chemicals. Many of these materials will not cause
immediate burns but will irritate your skin if they are
contacted repeatedly and not washed off thoroughly.
Don't wear clothing or shoes contaminated with
petroleum or chemicals; take a shower and put on clean
clothing.
§ If you find evidence of chemical spills - such as a visible
fume or vapor cloud or a strong odor or eye irritation -
notify your team leader. If you suspect that you or a

co-worker are reacting to a chemical exposure and
have any symptoms - such as dizziness, headache,
irritated nose, throat or eyes, coughing or nausea -
seek medical help and notify your team leader as
soon as possible.
5.6.2 Safety Color Coding
Color-coding provides a uniform system of identifying
corrosive and toxic chemicals, hazardous equipment or
conditions, and emergency safety equipment.
5.6.3 Storing Flammable Liquids
§ Use only safety-
Automatic Closing
rated metal Flame Vent
Arrestor Cap
containers for
flammable
Spout
liquids as
Small Large Large
required by Storage Container Storage Container Dispensing Container
DOT regulations.
§ Store flammable liquids in designated cabinets and
areas only; away from heat sources, electrical
apparatus and other sources of ignition. Label all
containers.
§ Samples or other liquids with flash points less than
100 degrees Fahrenheit should not be stored inside of
laboratories. Store them in a separate building in
flammable materials storage cabinets provided for
that purpose.
§ Do not carry gasoline or
other flammable liquids in
the trunk of company
vehicles. Flammable liquids
may be transported in the
bed of company trucks if they are in proper
containers that are securely fastened to the bed.
§ Gasoline or other flammable material shall be
transported only in approved DOT (metal) safety
containers.

§ Bonding and grounding procedures shall be
followed during the transfer/collection of flammable
liquids into portable containers to prevent ignition
from static electricity.
§ Plastic buckets do not conduct or dissipate static
electrical charges and therefore shall not be used to
collect flammable liquids, e.g., condensate samples,
oil samples, etc.
5.6.4 Corrosive Chemicals
§ Before using corrosive chemicals, note the location
of emergency showers and eye wash facilities, as well
as other nearby water sources.
§ Take every precaution to avoid direct contact with
corrosive chemicals. These chemicals may cause
severe burns or poisoning. If you do come into
contact with corrosive chemicals, immediately
remove any contaminated clothing and flush the
affected parts with running water. Eyes should be
washed for at least 15 minutes; skin may need to be
washed for 30 minutes to remove all traces of the
chemical. After washing, consult a physician to see if
further medical treatment is needed.
5.6.5 Solvents and Cleaning Agents
§ Gasoline, distillate, condensate or any other similar
flammable materials shall not be used for cleaning
purposes (skin, clothing or machinery). It is a fire
hazard and could cause flesh burns.
§ The following may be approved by local
management for use as cleaning agents if proper PPE
is used:
• diesel fuel
• kerosene
• stoddard solvent or equivalent
• cold water cleaners (solvents or detergent base)

§ Carbon disulfide, carbon tetrachloride, benzene, and
halogenated solvents shall not be used as degreasers or
cleaning agents.
§ Stoddard solvent or equivalent, kerosene, or cutting
agents shall be used for the purpose of shakeouts
(cuts).
§ Cleaning agents shall not be heated or used on hot
surfaces or near flames.
§ Rags that have been used with cleaning agents shall be
placed in designated covered metal containers until
they can be properly cleaned or disposed of.
§ Skin contact with solvent liquids or inhalation of
vapors shall be avoided. Nitrile, neoprene, or other
suitable gloves shall be used to protect hands when
using petroleum based solvents and cleaning agents. If
a cleaning agent or solvent comes in contact with the
skin, the affected area shall be cleaned with soap and
water and a lotion applied to replace the natural body
oils.
§ Areas where cleaning solvents are used shall be well
ventilated.
§ Employees shall review cleaning agent container labels
to determine if contents are acceptable for the intended
use. Acceptable solvents shall be those listed in this
section.
§ Non-petroleum based products should be substituted
where practical in parts washers.
§ Fusible links on parts washers shall not be bypassed,
disabled, or altered.
5.6.6 Using Tools Around Chemicals and Gases
§ Handle tools with caution when working around acid,
caustic substances or other hazardous chemicals.
§ Be careful not to drop tools where they may cause
chemicals to splash.

§ Thoroughly clean all tools after working with
hazardous chemicals. If the tools become heavily
contaminated while working, wash them at once.
§ Avoid using rope slings or lines near corrosive
chemicals. If you must use a rope sling or line in this
environment, carefully check it for wear after you're
done and tag it identifying the hazard before
returning it to the tool storage area.
5.7 Hazardous Communication (HAZCOM)
5.7.1 List of Chemicals
The company maintains an inventory or index of all
chemicals used at each facility. This index, the
Chemical Inventory, is available at each facility and
from your team leader.
5.7.2 Material Safety Data Sheet (MSDS)
§ The MSDS must be made
available to each employee for
review prior to handling
hazardous chemicals.
§ It contains precautions for
handling, requirements for
protective clothing, and a 24-
hour emergency number to
reach the manufacturer who can tell you what to do
in an emergency.
§ Each facility must have its set of MSDS’s for the
chemicals normally used at that location.
§ Contact your local safety specialist before bringing
any new chemicals onto company property.
§ An MSDS must accompany each chemical brought
onto the work site regardless of how long it will be
used there.
§ The MSDS must be obtained from the manufacturer
and reviewed for possible health hazards and
handling concerns.

§ Chemicals that will be used or stored routinely at the
location must be added to the chemical inventory for
that location.
5.7.3 Material Labeling
Any container containing chemicals must be labeled
with the name of the substance and any hazards
associated with it, regardless of the size of the
container. There are three main systems of hazard
warning labels that you are likely to encounter within
the company:
Department of Transportation (DOT)
The following is a partial listing of the more commonly
encountered DOT labels. DOT labels are required when
vehicles are used to transport hazardous:
• Explosive - A substance that will
ignite with a violent reaction and can
cause massive destruction. EXPLOSIVES
• Non-Flammable Gas - A compressed

gas that will not readily burn and is
not poisonous. It is hazardous NON-FLAMMABLE
GAS
because it is under pressure and/or it
can suffocate a person within a
confined space.
• Flammable Gas - A gas that, at
ambient temperature and pressure,
forms a flammable mixture with air FLAMMABLE GAS
at a concentration of 13 percent by
volume or less.
• Poison Gas - Gases such as chlorine
and anhydrous ammonia that are
poisonous to humans or animals POISON
GAS
when inhaled.

• Flammable Liquid - Any liquid
having a flash point below 100°F
(37.8°C), except any mixture having FLAMMABLE
LIQUID
components with flash points of

100°F (37.8°C) or higher, the total of
which make up 99 percent or more of the total
volume of the mixture.
• Flammable Solid - A solid, other
than a blasting agent or explosive,
that is liable to cause fire through FLAMMABLE SOLID
friction, absorption of moisture,

spontaneous chemical change, or
retained heat from manufacturing or processing,
or that can be ignited readily and when ignited
burns so vigorously and persistently as to create a
serious hazard.
• Oxidizer and Oxidizing Agent - A
substance that yields oxygen readily
to stimulate the combustion OXIDIZER
(oxidation) of organic matter.
• Poison - A substance that is

harmful to human health. Toxic.
Poison
• Radioactive - Material that emits

radioactive particles or rays, such as
many of the materials used in well
RADIOACTIVE
logging and/or for industrial
radiography. The type of placard
used relates to the amount of radioactive material
stored in the vehicle or container.
• Corrosive - Causes visible
destruction of irreversible alterations
in living tissue by chemical action at CORROSIVE
the site of contact. Causes a severe

corrosion rate in steel.

The Hazardous Material Identification System
(HMIS®)
HMIS is a registered trademark of the National Paint &
Coating Association. The code numbers, on a scale of 0
for no hazard to 4 for high hazard, for degree of health
hazard, flammability, reactivity, and recommended
personal protective equipment (PPE) are written on the
label at the time the label is placed into service. The
numbers on the following figure were created solely for
illustration purposes.
Substance Identity (same as shown on MSDS) HMIS ®
Identify Product
Blue
Red
Yellow
PERSONAL PROTECTION
4-Extreme, 3-High, 2-Moderate, 1-Slight

RATINGS: 0-No significant hazard
Health Hazards (Immediate & Delayed Target Organ Effects)
ABC Chemical Company

1234 Main Street
Anywhere, ST 00123
The National Fire Protection Association System

(NFPA)
The NFPA System is used in industrial plant and
storage locations to provide information for fire
fighting and emergency response personnel.
The code numbers, on a scale of 0 for no hazard to 4
for high hazard, for degree of health hazard, fire
hazard, reactivity, and special hazard are written on the
label at the time the label is placed into service.
The numbers on the following figure were created
solely for illustration purposes.

Red
Health Hazard: Fire Hazard:
4 Deadly Flash Points
3 Extreme Danger 4 Below 73°F (boiling
2 Hazardous pt. below 100°F)
3
1 Slightly Hazardous 3 Below 73°F (boiling
0 Normal Material pt. at/above 100°F)
and/or at/above
73°F - not
exceeding
100°F
Blue
3 1 Yellow
Specific
Hazard:
Oxidizer OX
ACID Reactivity:
4 May Detonate
3 Shock and heat
Acid Acid may detonate
Alkali ALK 2 Violent chemical
Corrosive COR change
Use No Water W 1 Unstable if heated
Radioactive 0 Stable
White
5.8 Excavation, Trenching and Shoring

✓ Please review and follow the checklist related to this
activity in Appendix D.
• An excavation is any man-made cut, cavity or
depression in the earth’s surface formed by earth
removal.
• Notify the appropriate state, regional and/or local 'one-
call service' at least 48 hours before any excavation
(unless the excavation work itself is an emergency) to
notify other pipeline and utility companies.
• Consult the team leader and check station maps and
line atlas sheets to locate possible hazards such as
underground conduit, electric cables and gas or oil
lines.
5.8.1 Soil Type and Site Preparation
§ The Person-In-Charge (PIC) will inspect the work
area around the proposed excavation site prior to
commencing excavation activities to identify and
alleviate any hazardous conditions and obtain
information to request any state or local permits.
§ Employees who work in and around excavations and
trenches shall be trained in the hazards associated
with this work and the correct work practices.

§ The competent person or PE (registered professional
engineer) shall determine:
• if sloping, benching or shoring is required to
protect against cave-ins
• the need for PPE and specify the means of escape
for employees
• certify any shoring devices to be used on site
5.8.2 Worker Protection
§ When personnel are working in the trench, the distance
from the work area to an escape ramp must not be
greater than 25 feet laterally. For example, ladders or
ramps shall be placed so that no person will have to
move or be moved more than 25 feet to exit the trench.
§ If employees may be expected to cross over the trench
from one side to the other, a platform with standard
handrails and guards must be installed.
§ Any trench or excavation left open at night or left
unattended for any reason must be surrounded with
some form of barrier identifying the existence of a
hazard, such as a tape barrier that reads, “Danger -
Excavation Work in Progress.”
§ If employees are working in the trench, the atmosphere
inside the trench must be monitored for any hazards to
employees, such as oxygen deficiencies, or flammable
or combustible vapor build-up. The results of the
monitoring must be documented.
5.8.3 Inspection
§ The trench must be inspected before each shift by the
competent person. In addition to that, competent
person inspections are required after any rain or if
there may be suspected movement of the trench walls.
All inspections must be documented.

5.8.4 Permit
All excavations require an Excavation Permit. For all
excavations involving entry, a competent person is
required to conduct soil tests and determine the type of
protective system to be used to protect workers. The
competent person is a person who is capable of
identifying existing and predictable hazards, soil types
in the surroundings and working conditions that are
hazardous to employees, and is authorized to take
prompt corrective measures.
5.9 Gas Testing and Analysis
✓ Review the HES-209 procedure for more information.
5.9.1 Plan the Gas Tests
§ The PIC identifies hazardous substances or
conditions that may be present and require gas
testing such as:
• oxygen deficiency or enrichment
• flammable gas or vapor
• toxic airborne concentrations of benzene
• hydrogen sulfide
• carbon monoxide
• carbon dioxide
§ The gas testing plan includes at a minimum:
• gases to be tested
• frequency of the testing
• acceptable limits
5.9.2 Calibrating and Maintaining Gas Detectors
§ The Qualified Calibrator must calibrate and
maintain the equipment according to the
manufacturer’s guidelines. In general, calibrate
equipment at nearly the same conditions
(temperature, relative humidity, etc.) as test
conditions.

§ Calibration results and routine maintenance must be
documented.
5.9.3 Verify Instrument Performance Before Gas
Testing
§ The Qualified Gas Tester must do a physical check of
the instrument, and verify gas sensor performance,
before using it to measure the atmosphere. This must
be performed on every work shift, or before each use,
if not used on every shift.
Refer to the manufacturer’s instructions as necessary
to ensure understanding.
5.9.4 Review Precautions
§ Review the warnings and cautionary statements in
the manufacturer’s instructions. These vary
depending upon the manufacturer and the type of
sensor being used.
Here are some of the warnings that may apply:
• oxygen deficient atmospheres will cause
erroneous low LEL readings
• oxygen enriched atmospheres will cause
erroneous low LEL readings
• recharge battery only in a non-hazardous
atmosphere
• do not draw liquid into the sampling probe
• only zero the instrument in clean air
5.9.5 Conduct Gas Tests
§ Test the atmospheric hazards specified by the Hot
Work Permit, Confined Space Entry Permit,
Excavation Work Permit, Job Site Safety Plan or other
gas testing plan.
Test the required gases in the following order:
1. oxygen
2. flammable gas
3. toxic vapors

WARNING: If oxygen levels are outside acceptable limits,
flammability and toxic levels may not be accurate. Use
extreme caution. Acceptable levels are listed on the Hot Work
Permit, Confined Space Entry Permit, Excavation Work
Permit, or Gas Testing Plan and Results form.
If tests indicate that oxygen deficiency or enrichment,
flammable gas, or toxic vapors exist, the tests should be
stopped and the space ventilated until subsequent tests
indicate the space is safe.
5.9.6 Interpret Gas Test Readings
§ When an alarm sounds, everyone inside the area must
immediately exit and the reason for the alarm must be
determined. The Qualified Gas Tester is responsible for
ensuring all occupants exit immediately.
§ On most instruments with digital displays, an alarm
sounds when unacceptable flammable and/or toxic
levels are detected. Some instruments have low level
alarms and high level alarms for flammable and/or
toxic concentrations. An alarm also sounds when
unacceptably low and high oxygen levels are detected.
§ On older flammable gas testing instruments with
analog displays (i.e., needles on a continuous scale), the
Qualified Gas Tester must observe the needle
constantly. The final resting place on the scale may not
be as important as the movement to the resting place. If
the needle moves to a high reading and then falls back
near zero, the atmosphere may have high flammable
levels. Leave the area, remove the test probe, purge it
with fresh air, and then re-test. If the needle goes
upscale and then falls near zero again, the area is unsafe
for entry or hot work.
§ Whenever the results of any follow-up tests differ
significantly from the initial tests, more frequent tests
must be taken. If the subsequent readings do not return
to the initial levels, the cause for the change must be
determined.

§ The Qualified Gas Tester or any other person must stop
the job whenever gas testing indicates that a hazardous
condition exists that could endanger workers. Workers
must leave the area until the situation has been
corrected and proper precautions have been taken.
5.10 Confined Spaces
✓ Review and follow the checklist related to this activity in
Appendix E.
5.10.1 Workplace Evaluation
§ A confined space is a space that:
• is large enough and configured such that an
employee can bodily enter and perform assigned
work
• has limited or restricted means of entry or exit
(for example; tanks, vessels, silos, storage bins,
hoppers, vaults, or pits
• is not designed for continuous employee human
occupancy
§ Examples of equipment that may be confined spaces
are:
• external floating roof tanks
• below grade valve boxes or sumps or working
platforms
• vessels, separators, and tanks (entered by a
man-way)
• pig or scraper traps
• pits
• tank cars/trucks
• internal floating roof tanks
• pontoons of floating roofs
• footing excavations and bell bottom pier holes

§ There are three types of confined space: non-permit
confined space, confined space entry using forced air
ventilation and permit required confined space.
§ All confined spaces require a Confined Space Entry
Permit. The PIC and the person conducting the work
determine the type of confined space and which
sections of the permit must be completed. No one shall
enter a permit-required confined space unless a
Confined Space Entry Permit has been completed,
approved and posted.
§ Only trained employees are allowed to perform work
involving any confined space entry. Employees assigned
to permit required confined space operations shall be
trained in safe entry and emergency procedures and be
periodically retrained as an entrant, entry supervisor,
attendant, or rescue team member.
§ Persons conducting non-entry and entry rescue must
be trained according to OSHA requirements.
Attendants must be trained in cardiopulmonary
resuscitation, bloodborne pathogens, and first aid.
5.10.2 Pre-Entry
The atmosphere in the confined space shall be tested
for oxygen deficiency, flammability, and toxicity before
entry and continuously monitored (uninterrupted) as
feasible throughout the confined space operation.
5.10.3 Working in a Non-Permit Required
Confined Space
A Non-Permit Confined Space is a confined space that
does not contain, or, with respect to atmospheric
hazards, does not have the potential to contain any
hazard capable of causing death or serious physical
harm.

5.10.4 Confined Space Entry Using Forced-Air
Ventilation
Confined space entry using forced air ventilation
occurs when forced air (local and/or general) is used to
control unacceptable atmospheric hazards.
5.10.5 Permit-Required Confined Space Entry
A permit required confined space is a confined space
that has one or more of the following characteristics:
• contains or has a potential to contain a hazardous
atmosphere
• contains a material that has the potential to
engulf an entrant
• has an internal configuration that could trap or
cause asphyxiation
• contains a recognized health/safety hazard
5.11 Lockout/Tagout (LOTO)
✓ Review and follow the checklist related to this activity in
Appendix F.
5.11.1 Energy Sources
§ There are several energy
sources, all of them may be
locked and tagged. The list
includes:
• electricity
• hydraulic
• pneumatic
• chemical
• thermal
• gravity
• etc.

5.11.2 Equipment Specific Procedure (ESP) Sheet
§ An ESP Sheet must exist for each piece of equipment
that needs to be isolated and released for regular or
maintenance work.
To complete the ESP Sheet, the PIC (CPL employee)
shall:
1. identify each piece of equipment and/or system to
be maintained, serviced, or repaired, including
equipment number and location
2. identify other equipment that must be shut
down, isolated, locked and tagged out, and energy
dissipated
3. identify all actual and potential sources of energy,
all potential sources of energy reaccumulation
and the hazards of these energy sources for the
equipment
4. identify all energy control devices that will be
needed to secure the piece of equipment and/or
pipeline system to be maintained, serviced or
repaired
5. make a simple sketch of the equipment or system
being isolated, showing blinds, valves, switches,
etc. used for isolation
6. identify the normal shut down procedure(s) to be
used or document the steps to shutdown the
equipment or pipeline system
7. document the steps required to isolate each
energy source and the means for isolating or
dissipating the stored or accumulating energy
8. document the steps required to secure
(lockout/tagout) each energy source
9. document the steps to verify continued
isolation
10. document the steps to restoring equipment or
system to service

11. sign the document
12. submit the ESP Sheet to be reviewed by another
field team member with equal or greater
qualifications for final review
13. the team leader will also review the ESP and
sign it
14. review the ESP Sheet with all the persons who will
be working on the equipment or pipeline system
and obtain their agreement on the procedure. This
would usually be done at the safety/training
meeting in preparation for the job
15. the PIC then signs on the line indicating that
affected employees have been notified
5.11.3 Normal Equipment Isolation
§ Normal equipment isolation is initiated when person(s)
servicing or maintaining equipment or piping system
places their own personal lock and tag on the energy
isolating devices. This covers most situations where the
work is in one location where the one PIC can directly
account for all isolations and work that is going on.
5.11.4 Shift Change
§ The exiting PIC or Principal Authorized employees
ensure the incoming people fully understand the work
to be performed under this Equipment Isolation
procedure by having a procedure review meeting.
§ The entering workers review the permits and sign the
Equipment Specific Procedure Sheet indicating they
have read, understood and visually verified that all
equipment on the Equipment Specific Procedure Sheet
is still locked out and tagged out.
For maintenance activities that will last for more than
one day (tank repair; compressor repair) the entering
workers review the permits and sign the Equipment
Specific Procedure Sheet indicating they have read,
understood and visually verified that all equipment

on the Equipment Specific Procedure Sheet is still
locked out and tagged out.
5.12 Electrical Safety
5.12.1 General
§ Work on electrical equipment
and systems shall be performed
only by qualified persons.
Qualified persons are those who
have training in avoiding the
electrical hazards of working on
or near exposed, energized parts.
§ Work on electrical equipment and systems greater than
600 volts requires the use of special PPE and
procedures.
§ Electrical switchgear shall be labeled to identify the
equipment it controls.
§ Follow all applicable LOTO procedures before working
on electrical equipment to ensure that power cannot be
accidentally restored.
§ When working on a motor or circuit, the supply switch
or circuit breaker must be open and locked and the
switch must be properly tagged (i.e., “Danger - Do Not
Close Switch”) to warn others that someone is working
on the equipment. After completing the tagout, double-
check to be sure that the circuit is de-energized and
that it cannot be re-energized by someone else.
§ After disconnecting the power source and before
touching any connections, ground high-voltage points.
§ Exercise extreme care not to touch electrical equipment
while standing in water, on metal floors, on damp
concrete or other well-grounded surfaces.
§ Hands, footwear, and clothing shall be dry when any
energized electrical equipment is handled.

§ Employees should not wear rings or watches, or carry
keys, lighters, or similar metallic objects while working
on electrical systems, unless the metallic objects are
rendered nonconductive by covering, wrapping, or
other insulating means.
§ Where required, use fiberglass or other non-conductive
material made for electrical work.
§ Employees shall avoid being near switch boxes,
pumping units, or other electrically operated
equipment during an electrical storm.
§ Interlocks shall not be made inoperative by removal,
modification, or destruction.
§ Properly sized overload protection (fuses and/or circuit
breakers) shall be provided to protect the circuit's
maximum current carrying capacity. As an example, a
30-amp fuse shall not be used on a 20-amp circuit.
§ A fuse puller shall be used to remove fuses. Fuse pullers
shall be kept clean and dry to prevent a conductive film
from forming on the surface of a puller. Substitutes for
fuses are prohibited.
§ Electrical connections to ground shall not be made to
a gas pipe, steam pipe, dry pipe sprinkler systems, or
lightning protection system.
§ Water shall not be used on electrical equipment fires.
When possible, electrical equipment shall be
de-energized before attempting to extinguish an
incipient stage fire.
§ The National Electrical Code (NEC) and/or the
American Petroleum Institute (API) RP-500,
Recommended Practices for Classification of Locations
for Electrical Installations at Petroleum Facilities, shall
be followed in the installation and operation of
electrical systems.

5.12.2 Lighting
§ Lighting shall be installed as appropriate for the
location. Portable lights used in potentially hazardous
locations shall be either explosion-proof flashlights or
other types of portable lights approved for potentially
hazardous atmospheres.
§ The outside globe and guard on portable hand lights
shall be maintained and be in place during use.
§ Portable lights and extension cords shall be kept in
good repair. They shall be checked for damaged or
worn insulation and cracked or broken protective
globes.
§ When changing a broken/burned out light bulb, the
circuit shall be de-energized. Any fixture designed for
protective glass globes and metal guards shall have the
globes and guards in place before the light is used.
§ Stationary light fixtures that are low enough that they
could be contacted during normal activities, either
directly or by an item held by hand shall have
protective covers or guards installed.
5.12.3 Extension Cords
§ Lighting shall be installed as appropriate for the
location. Portable lights used in potentially hazardous
locations shall be either explosion-proof flashlights or
other types of portable lights approved for potentially
hazardous atmospheres.
§ Make all other electrical connections permanent
installations by proper construction methods. Use
extension cords for temporary use only.
§ Extension cords shall be the appropriate length. Cords
shall not be connected to extend the length.
§ Use extension cords with the appropriate voltage and
amperage rating for the job.

§ Extension cords shall be of a three-wire grounded type
and free of splices. Depending on the location and
intended use, they also shall be equipped at each end
with either explosion-proof or non-explosion-proof
three-wire, grounded receptacles and plugs (but not
with one of each). Do not use “hybrid,” ungrounded or
external ground wire extension cords.
§ Never repair a damaged cord with electrical tape.
§ Prevent cords from contacting oil, hot surfaces and
chemicals.
§ Extension cords shall not be fastened with staples or
otherwise hung in a fashion that could damage the
outer jacket or insulation.
§ Do not hang cords over nails or other sharp edges, or
place them where vehicles may run over them.
§ Extension cords shall be protected from damage when
in use (e.g., vehicular traffic, falling objects, etc.).
§ Extension cords attached to equipment shall not be
used for raising and lowering the equipment. Rope or
line shall be used instead.
§ Do not use twist-lock cords for portable tools.
5.12.4 Electrical Power Tools
§ Portable electrical tools and equipment shall be UL
listed, double insulated tools or be grounded through a
third wire in the cord. The ground wire connection
shall not be defeated.
§ Electrical tools and equipment with damaged or
inadequate insulation, defective cords, etc. shall be
removed from service until repaired. Taped splices in
cords are not considered properly repaired and shall
not be used.
§ The power supply source shall be disconnected before
repairs or services are performed on power tools.
§ Where there is danger of explosion or fire, pneumatic
(air-operated) power tools should be used.

§ Outlets that are not a part of a permanent building or
structure supplying power to portable electrical tools
that may be used in a wet location or construction site,
shall have ground fault circuit interrupter (GFCI)
protection.
5.12.5 Static Electricity
§ Do not “splash fill” tanks storing hydrocarbon
products. Overhead fill lines should have downspouts
extending to the bottom of the tank.
§ Any filter screen should be placed well forward of the
outlet to allow the induced static electrical charge to
dissipate before it reaches the tank.
§ Transport vehicles shall be bonded through a bare
metal surface to the designated location on the loading
facility.
§ Bond nozzles to the tank if steam or water is used to
clean hydrocarbon (crude products, etc.) storage tanks
and separators. Sandblasting nozzles shall be bonded
electrically to the item being blasted.
§ Before transfer/collection of flammable liquids,
dispensing containers or process equipment shall be
properly grounded and bonded to a receiving
container.
§ The illustration below shows one method of bonding
and grounding a metal dispensing drum and a metal
receiving container.
NO
SMOKING
FLAMMABLE
Grounding rod (buried 8-feet deep)

5.12.6 Sampling and Gauging
§ Metal tanks are grounded through contact with the
earth. When using conductive (metal) tapes or
containers to gauge or sample metal tanks, the tape or
container shall be held in continuous contact with the
tank hatch or tap.
§ Use only natural fiber lines (such as hemp or cotton) to
lower conductive items into either metal or nonmetal
tanks.
§ Do not suspend buckets equipped with plastic or
wooden handle grips from a nipple or valve to collect a
sample or to drain a line; the plastic or wood grip
prevents the bucket from being bonded to the valve,
and static electrical charges cannot be drained away.
§ Use metal cans with metal grips or static discharge
connections for this purpose. Never use plastic.
§ Do not pour hydrocarbon products from one container
to another without bonding both containers, whether
by direct contact of both containers or via a bonding
wire. There's one exception to this rule: If one of the
containers is completely made of a non-conducting
material (such as a glass sample bottle or plastic drum),
then bonding is neither needed nor possible.
5.12.7 Electrical Fuses and Circuit Breakers
§ Do not change lights or fuses when circuits are
energized, unless you are a qualified electrician. Only
authorized personnel shall remove or change high-
voltage fuses.
§ Do not bridge fuses or circumvent the normal
operation of circuit breakers.
§ Do not replace blown fuses with fuses having higher
amperage or lower voltage rating. To maintain proper
circuit protection, replace it with a similar fuse.
§ Always use a fuse puller to remove fuses.

§ When operating circuit breakers, stand to one side and
use a firm, swift, positive action to open or close the
circuit.
§ If a circuit breaker continues to trip out, this is
indicative of an abnormal situation. Locate the cause
of the problem. Under no circumstances shall the
breaker be held manually or by some other physical
means; this could cause an electrical fire.
5.12.8 Explosion-Proof Electrical Equipment
§ Electrical equipment in electrically classified areas shall
meet the National Electrical Code (NEC) and/or the
American Petroleum Institute (API) RP-500,
Recommended Practices for Classification of Locations
for Electrical Installations at Petroleum Facilities, for
such installations.
§ Explosion-proof equipment shall be maintained in
good condition to retain its original integrity and the
ability to perform effectively.
§ Explosion-proof caps, covers, boxes, etc. shall be
secured and seated to maintain the integrity of the
system.
§ To prevent the migration of gases in electrical conduit,
EYS seals shall be poured and maintained in
accordance with the requirements.
5.12.9 Batteries and Standby Generators
§ Batteries are generally used as backup power. They
contain acid and may emit gases when being charged.
In certain mixtures, these gases may constitute an
explosion hazard. Provide adequate ventilation for such
batteries. Sealed batteries are preferred and are
recommended for backup use.
§ Treat batteries carefully. A shorting battery can produce
electrical sparking and considerable heat. Wear
protective chemical goggles and gloves when working
on and around batteries.

§ Standby generators, where installed, are used to provide
emergency power and generally are hooked up in a way
to prevent overloading. The power available from a
standby generator is limited.
§ For generators that start automatically, post a sign on
the generator that reads “Caution, this equipment starts
automatically.”
§ Do not overload a generator. Never add additional
loads without checking a generator's capacity.
§ Maintain at least two feet of clearance around all sides
of generators.
§ Do not store combustible or flammable materials near
generators.
5.12.10 Maintenance
§ The covers and all bolts on electrical equipment shall
be reinstalled and tightened upon the completion of
work.
§ Defective appliances, lines/cords, electrical equipment,
etc. shall be taken out of service, tagged, and reported
to your team leader.
5.13 Hot Work Areas
5.13.1 Hot Work Permits
✓ Review and follow the checklist related to this
activity in Appendix G.
§ A Hot Work Permit shall be issued in specified areas
where any source of ignition is used and the potential
for flammable or combustible materials is present. A
source of ignition includes: welding, cutting, burning
with a torch, grinding, smoking, sandblasting, spray
painting, breaking concrete, use of internal combustion
engines, personal electronic devices (cellular phones,
pagers, computers, etc.), and operation of motor
vehicles.

§ On jobs lasting more than one day, hot work permits
shall be reviewed each day so that any situation change
can be evaluated. A new hot work permit must be
issued any time work is suspended and the area is
vacated (this is done to ensure that conditions have not
changed during a crew's absence). Inform new
personnel of the entire scope of the operation,
especially during a crew change.
§ Before introducing an ignition source, test the
atmosphere with a gas detector. Note that the
atmosphere of a normally “safe” area may change due
to wind direction and vent locations.
§ Before welding/cutting work is authorized and started:
• Designate the person in charge to be responsible
for issuing any hot work permits that may be
required.
• Discuss with the team leader, operating personnel,
welder and any contractors, the nature of the work
to be done and all possible hazards.
§ As long as a known ignition source is present in a hot
work permit area:
• The person in charge or a qualified company
representative must remain on site until the work
is completed. If the scope of the operation is too
spread out or involves too many people for one
company representative to adequately supervise it,
a second company representative also must be on
hand to assist.
• All company representatives and contract
personnel shall continually be alert for changing
conditions in the area that might increase the
possibility of fire. Any changing conditions
noticed in the area shall be thoroughly discussed
with all those concerned.

• If the hot work permit area is a confined space, at
least one employee must stand by on the outside,
ready to give prompt assistance in case of
emergency.
5.13.2 Area Preparation
§ Minimize ignition source exposure time in hot work
areas by welding materials together outside of the area
and bringing them to the installation site to complete
final tie-in welds.
§ Do not weld or cut if there is work in progress where
vessels, lines or fittings containing hydrocarbons are
opened to the atmosphere and are not continuously
gas-tested. A closed valve or check valve should not be
considered a means of positive shut off from the
atmosphere or from connecting vessels or lines. Use
blind plates, skillets, or similar devices for this purpose,
and gas test to make sure the atmosphere is safe.
§ Before moving any heavy loads around or other
equipment containing hydrocarbons:
• Stop all welding, cutting, or other operations that
involve ignition sources.
• Shut in and/or bleed off the affected equipment.
§ Do not operate valves while welding/cutting equipment
and other known ignition sources are in operation
around hydrocarbon-producing wells and equipment
on stream. As required by the hot work permit, check
pressured vessels to keep pressure below that of the
relief valve set pressure and the rupture disk bursting
pressure.
§ Do not bleed off pressure in line, fitting, vessels, and
other operating equipment to the atmosphere until:
• The person in charge says it is safe to begin the
procedure.
• Known ignition sources in the area have been
eliminated.

• All conditions of the hot work permit have been
met.
5.13.3 Fire Watch
§ Establish a Fire Watch before starting work on jobs
requiring ignition sources in hot work permit areas.
The Fire Watch may be either a company or contract
employee whose only duty will be that of fire watch.
The fire watch will:
• Have a fire extinguisher on the site near the work
to be done, where it will be readily accessible in a
fire situation with adequate backup extinguishers
strategically located.
• When available, have at least one fire hose reel
ready to operate if required.
• Know how to properly operate the fire
extinguisher and other fire equipment.
• Flush or plug and test (with a detector) all drains
in the area when welding is to be done, since gas
vapors may collect in these areas.
• Remove rags, scrap wood, oil spills, rope, canvas,
mud sacks, etc. from areas where slag may fall,
before work commences. If wood cannot be
removed, thoroughly wet it down with water and
continually observe it for fire.
• Continually observe the work in progress for fire
or other hazardous conditions that may arise.
• Observe where hot slag and sparks are falling to
ensure that they are not falling on combustible
materials.
• Cool or guard hot surfaces to keep personnel from
coming in contact with them.
• Establish a hot work shutdown procedure, should
an emergency arise.

• Thoroughly wash down and observe the area for 30
minutes after welding operations are suspended or
completed to be certain no fire hazard is present.
• Fire watch training must include hands-on defensive
firefighting at a minimum, utilizing a portable fire
extinguisher. Training certification shall be
maintained. Fire watch training requirements are
noted in HES Procedure 205, Appendix C.
5.14 Welding
5.14.1 General Precautions
§ Consult the welding procedure
to determine which welding
methods are appropriate for
repairs and new construction jobs.
§ Follow hot-work permit and fire
watch procedures before beginning welding.
Remember, only the PIC can authorize welding to
begin. The welder should point out any concerns to
this person.
§ Never weld where gas detectors read above 10 percent
of the Lower Explosive Limit (LEL).
§ Comply with the safe practices outlined for working
with pressurized cylinders. In addition, observe the
following precautions:
• Inspect equipment to see that it is in proper
operating condition. If a backfire has occurred and
has reached the hose, the hose may have become
unsafe; the entire length should be tested to verify
that the cutting torch has not become clogged. If
hose is clogged discard and replace before
proceeding.
• Do not hang torches from the regulators attached
to the cylinder.
• Do not let hot slag fall on combustible materials,
hoses or on the cylinder.

• Do not let hoses come in contact with hot steam
lines or solvents.
• Release the hose pressure and close the cylinder
valves when work is interrupted for a longer
period (such as mealtime).
• Do not leave a pilot flame burning at the tip of the
torch during interruption of operations.
• Follow limitations on the amount of tape allowed
on welding hoses (four inches of tape per 12
inches of hose).
• Close the valves if left unattended.
§ When working in an elevated position, protect workers
and materials below.
§ Provide a pan or screen to keep hot metal, electrode
stubs, hot metal slag, etc., from falling below.
§ Provide toe boards when working from scaffolding
under which workers may be passing or working.
§ Restrict access to the area below the work site.
§ Instruct the welder's helper to act as a lookout since
goggles or a helmet often obscures the welder’s vision.
The welder's helper will:
• Eliminate tripping hazards and maintain good
housekeeping in the work area.
• Watch for and warn the welder of any fire or other
potentially dangerous situation.
5.14.2 Minimizing Electric Shock from Arc Welding
§ Cables must be of sufficient size to avoid overheating.
The insulation must be in good condition and there
should be no loose connections.
§ Never weld on any line or equipment until it has been
connected to the ground connection of the welding
machine.
§ Never pull or disconnect a ground line while the arc is
in use.

§ Never let the live metal parts of the welding circuit
touch damp skin or clothing.
§ Ventilate confined spaces (in accordance with the safe
entry procedure) and have assistance readily available.
Toxic or non-toxic vapors, gases, and fumes may
accumulate in the work area during welding
operations.
5.14.3 Welding in or Near Tanks or on Pipelines that
that Contained or Have Contained
Hydrocarbons
§ Inspect the line or tank. The team leader or person in
charge and welder will eliminate the possibility of a
flashback in one section being transmitted to another
section. If the line is not being used at the time of the
welding, this can be done by blinding off or isolating
the section to be welded on. Gas test to verify the level
of hydrocarbons present.
§ Determine the minimum wall thickness with an
ultrasonic testing device. Reduce line pressure as much
as practical for spot welding, welding patches, sleeves,
hot-tap connections, etc. Refer to the welding
procedure for more information.
§ Do not weld on a hydrocarbon pipeline unless
adequate flow is present (greater than one cubic foot
per second), the line is full and under positive pressure
with a means of safely relieving pressure build-ups
away from the work site, or the line is “gas free.”
§ Flush lines with water where practical. Turn off any
cathodic protection rectifiers connected to the line at
each side of the tie-in.
§ Install a bond wire before cutting apart the line.
Plugs
§ Check plugs for tightness, and monitor the open end of
the line for gas vapors (with a combustible gas
indicator) just before welding. The area should be
“flashed” with a torch prior to welding.

§ Do not jar or move the line until welding is complete to
avoid loosening the plug.
§ Start welding as soon as the plug is in place and
complete the job without any interruptions.
Dry Ice
§ Follow the precautions below if dry ice (solid carbon
dioxide) is used to seal off small amounts of petroleum
fluids and dilute flammable vapors in the pipeline.
§ Do not use dry ice in a line where there is a likelihood
of a significant accumulation of petroleum fluid or
expansion of vapors. It does not form a true plug.
§ Be prepared to weld when the line freezes. Do not plug
the line and then leave for a prolonged period (such as
mealtime). Always check the ice plug before welding.
§ Avoid pounding or jarring the pipe in the plug area.
Because the pipe is now much more brittle and the
impact strength is reduced at low temperatures, it could
break.
§ Avoid contact of dry ice with your bare skin. Do not
carry it within the passenger section of any vehicle. If it
is necessary to use the trunk section of an automobile,
prop the trunk lid partially open.
§ Ventilate bell holes when using dry ice. Although
carbon dioxide is a non-toxic gas, it is heavier than air
and, in large quantities, could cause suffocation due to
oxygen deficiency.
Vents
§ If necessary, mechanically install a vent in the pipe to
carry off liquids or vapors that may accumulate behind
the plug. Locate the vent a safe distance from the
welding and make it long enough to carry vapors and
liquids to a safe spot (generally 50 to 200 feet away).

Bell Holes
§ Construct bell holes with ample dimensions to permit
easy access and escape and to allow the welder freedom
of movement. Consult trenching access and shoring
procedures and confined space procedures.
§ Test the bell hole with a combustible gas and oxygen
meter, as explained in the confined space entry
procedure.
§ A standby shall be available to help the welder out of
the bell hole should an emergency arise.
§ Maintain a close fire watch over the welder - a welder's
vision is restricted while welding.
§ If there may be danger of gas in low spots, keep the
welding machine in an elevated location upwind from
the bell hole.
5.14.4 Hot Tapping
§ Tapping a pipeline is a specialized operation and shall
not be done without an adequate, overall
comprehensive plan. Some general guidelines include:
• Make bell holes for hot-tap welding large enough
to allow easy access to those who must work in the
hole.
• Thoroughly check any adjacent fittings for leaks
and safe condition.
• Check working conditions before welding.
5.14.5 Compressed Gas Cylinders
§ Cylinders of any compressed gas
may be dangerous because they can
be under several thousand pounds
of pressure. If a cylinder falls or
the valve nipple breaks, the rapidly
escaping gas may convert the
cylinder into a projectile.

§ Cylinders shall never be used for any purpose other
than to contain gas for which the cylinder was
designed.
§ Empty cylinders shall be marked or labeled "EMPTY."
Valves shall be tightly closed and the valve protection
caps replaced.
Handling
§ When it is necessary to move compressed gas cylinders,
a cart or other mechanical device especially designed
for that purpose shall be used. Cylinders may also be
rolled on the bottom edge, but never dragged.
§ Cylinder valves shall be kept closed with the valve
protection cap in place during handling.
§ Cylinders to be transported shall be loaded and secured
in an upright position, unless specifically designed for
horizontal service.
§ When transporting cylinders in a vehicle, secure the
cylinders to the vehicle so they cannot move or fall
while the vehicle is moving. Keep cylinders of different
types of gases separated as much as possible to avoid
grabbing the wrong one off the vehicle and to reduce
the possibility of an accident or reaction should two
cylinders be leaking slightly.
§ Cylinders shall never be dropped or allowed to strike
each other violently.
§ Do not use ropes or chains to lift a cylinder and do not
lift it by its cap. Cylinders handled by hoisting
equipment shall be carried in a cradle or similar device
and care taken to prevent their being dropped. Valve
protection caps shall never be used for lifting the
cylinder.
Use
§ Never use cylinders that have been defaced or had
suppliers’ identification information (labels, tags,

decals, etc.) removed. The color of a cylinder cannot be
relied upon to indicate a particular gas.
§ Do not attempt to mix two gases in one cylinder or
transfer gas from one cylinder to another.
§ Use regulators, gauges, hoses, etc. only for the particular
gas(es) for which they are specified. Do not “mix and
match” these appliances with cylinders containing gases
that have different properties. Use properly fitted and
recommended wrenches with cylinder valve accessories.
§ A cylinder of compressed gas shall never be used
without a pressure-reducing regulator attached to the
cylinder valve.
§ The cylinder valve shall always be closed before
attempting to stop leaks.
§ Routinely soap-test manifolds, gauges, hoses and
fittings to disclose leaks. Do not attempt to repair
valves or plugs on a leaking gas cylinder; such cylinders
shall not be used. Notify the supplier for assistance.
§ Keep cylinder valves closed and protector caps in place
at all times, except when the cylinder is in use. Open
cylinder valves slowly with the hose end of the valve
pointing away from personnel. Never “force'” a
cylinder valve open; if it doesn't open in a normal
fashion, set it aside and notify the supplier.
§ Never leave cylinder valves open when they are not
being used. When you finish a job or take a break, close
the cylinder valves and release the regulator adjusting
screw to relieve the pressure on the hose. Coil the hoses
near or on top of the cylinders, but do not wrap them
around the cylinder.
§ Never use cylinders for purposes they were not
designed for, such as rollers or supports.

§ Sparks, molten metal, electrical currents, excessive heat,
or flames shall not be permitted to come in contact
with the cylinder or attachments. This includes propane
or acetylene torches and space heaters.
§ Oil or grease shall never be used as a lubricant on
valves or attachments to oxygen cylinders, since oil and
oxygen under pressure can be a fire hazard. Also,
oxygen regulators shall not be handled with oily or
greasy hands or gloves.
§ Threads on a regulator or union shall correspond to
those on the cylinder valve outlet. Connections shall
not be forced.
Examination
§ Compressed gas cylinders shall bear all markings and
be hydrostatically tested as required by U.S.
Department of Transportation (DOT) regulations.
§ Cylinders shall be examined for signs of corrosion or
other damage.
§ Leaky or damaged cylinders shall be reported and taken
out of service immediately. They shall be removed to a
safe location and observed until safely depressurized.
They shall be marked or labeled “DAMAGED.”
Storage
§ Store cylinders in shaded, well-ventilated areas away
from flammable substances (oil, gasoline, waste, etc.).
Post “No Smoking” and “Caution - Flammable Gas”
signs on all cylinders. Secure them with chains or rope,
in an upright position, with valves closed and caps in
place. Separate empty cylinders from full cylinders and
label them when empty.
§ Oxygen cylinders shall not be stored within 20 feet of
fuel gas cylinders or combustible/flammable materials
(especially oil or grease), unless protected by a
noncombustible barrier at least 5 feet high having a fire
resistant rating of at least one-half hour.

§ Compressed gas cylinders shall not be accepted from
the supplier unless they are properly labeled and have
protective valve caps in place.
5.14.5.1 Oxygen and Acetylene
• Do not store oxygen and acetylene together. Keep them
separated by 20 feet or by a five-foot-high fire wall.
• Always use and store acetylene cylinders in an upright
position (valve end up) to prevent the acetone (a
stabilizing agent) from draining into the valves or
fittings. Without acetone present to stabilize the
acetylene, it can explode.
• Never use acetylene at a hose pressure in excess of 15
pounds per square inch (gauge). Above 15 psig,
acetylene is extremely unstable, and can explode.
• Do not allow oxygen to come in contact with oil or
grease; it can cause an explosion and fire. Never
lubricate or allow oil or grease to get on oxygen
connections; use only those types of fittings that do not
require lubrication.
• Never use oxygen as a substitute for compressed air.
• Be aware that oxygen connections for hoses and
regulators have right-hand threads. Acetylene and
cutting gas connections have left-hand threads.
5.14.5.2 Compressed Air
• Compressed air may be dangerous if not used correctly.
Never point an open air hose at another person. Never
use it to blow dirt from clothing. Compressed air can
penetrate the blood stream without breaking the skin.
The resulting air bubbles are extremely painful, and
may cause death.
• Wear goggles if the use of compressed air stirs up dust
and flying particles.
• Direct pressure equipment such as grease guns and
spray paint guns away from the body and other
personnel in the area.

5.14.5.3 Natural Gas
• Never use natural gas to power pneumatic tools.
• Natural gas as a pressure source shall only be used in
equipment designed for its use, including, but not
limited to, gas starters, gas operated pumps, valve
actuators, centrifuges, and instrument systems.
• The use of compressed air or oxygen in a gas system is
prohibited. The use of natural gas in a compressed air
or inert gas system is also prohibited. Nitrogen shall be
the only gas used as an alternate source in both natural
gas and compressed air systems.
• Use natural gas only as fuel for internal combustion
machines or to power pumps, pneumatic controls or
starters. Use only in areas free of other combustion
sources. Any other use of natural gas requires prior
approval by the team leader.
• Do not vent or exhaust natural gas to confined areas,
enclosures or other areas where gas can be trapped.
• Never use rubber hose for supply or exhaust lines for
natural gas powered equipment.
• Natural gas, from safety devices and vent stacks, shall
not be allowed to vent into a building or beneath a
floor or platform. Discharge vents to atmosphere shall
be firmly secured.
• Where located on a building, vent piping shall be above
the eave to prevent vent gas entry into the building.
Drain or weep holes in the vent line shall not be located
inside a building.
• Before venting gas lines, instrumentation lines,
scrubbers, drip pots, etc., the person performing the
work shall determine that the area is free of ignition
sources.
• Natural gas used inside enclosures for instrumentation,
e.g., back pressure valves and level controllers, etc. shall
be vented outside.

• In cleaning and/or maintaining any natural gas fuel
system on field or plant equipment such as treaters, line
heaters, furnaces, etc., care shall be taken to remove any
possible source of ignition. When working in/on a
hot/cold fire box, fuel lines to the pilot and main
burners shall be disconnected or blinded to prevent
accidental gas flow into the fire box. Automatic fuel
shutoff valves shall not be depended upon to isolate the
gas system.
• Before inserting a torch to light a pilot or burner in a
heater or treater, all manual valves shall be closed for a
reasonable length of time (minimum 5 minutes) to
purge the fire box of potentially explosive mixtures.
Fuel systems for fired equipment shall never be turned
on without a pilot light or torch in the fire box.
Precautions shall be taken so employees are not in line
(path) with a possible flame flashback. Employees
should wear appropriate face shields when manually
lighting fired equipment.
• When lighting or firing a steam generator, employees
shall remain away from the air intake (vortex) so as not
to be in the path of a possible flame flashback.
• The vent lines from atmospheric storage tanks/vessels
shall be checked for reduced flow or flow stoppage
when excessive gas pressure is noted in the storage
tanks/vessels. The vent system shall be cleaned if it
becomes plugged.
• Where necessary, gas vent lines shall be equipped with
flame arrestors, pressure-vacuum relief valves, or an
equivalent device to prevent flame flashback from the
end of the vent line to the tank/vessel.
• Flame arrestors shall be installed and maintained
according to manufacturer's specifications.
• Thief hatch covers shall be kept closed except during
the collection of samples or the gauging of
tanks/vessels.

• Flapping thief hatch covers shall be reported to the
immediate supervisor so that action can be taken to
reduce the gas pressure in the tanks/vessels. The gaskets
on the tank/vessel hatch covers shall be maintained in
good condition to prevent gas from escaping.
• Gas vent lines shall be installed to prevent fluid from
accumulating and being trapped in the lines.
• When an ice plug develops in a gas manifold or a gas
line, the upstream and downstream pressures shall be
equalized and reduced to the lowest pressure possible.
Sufficient time shall be allowed for the ice plug to melt.
If possible, free water should be drained and properly
disposed of.
• Natural gas used at some locations may be purchased
from an oil-producing lease and may not have been
odorized for domestic use. Extra precautions should be
taken at these locations, as natural gas itself does not
have a detectable odor. Delivery lines and equipment
lines should be checked periodically for leaks.

6.0 Pipeline Operations
6.1 General Rules

6.1.1 DOT Pipeline Safety Regulations
§ The Federal Department of Transportation or an
affiliated state agency (such as the Texas Railroad
Commission or the California State Fire Marshall)
primarily regulates CPL’s operations. The regulations
covering pipeline operations are contained in 49 CFR,
parts 190-199. The regulations are performance
oriented; they tell pipeline companies what must be
accomplished rather than how to accomplish it.
§ These regulations require pipeline companies to
prepare operating and maintenance manuals detailing
how they will complete all operations, maintenance and
emergency response functions necessary for the safe
operation of their pipeline. Requirements contained in
these manuals have the same legal standing as law.
§ These manuals are reviewed for accuracy and
completeness during inspections by the DOT. Records
also are checked to ensure all required maintenance
inspections are being performed and documented. If
any deficiencies are found in the manuals or record
keeping, civil penalties may be issued.
§ The primary procedures required for compliance with
these regulations are contained in various manuals
including the operations manuals, emergency response
plans, Maintenance and Inspection Manual and the
HES Procedures Manual. For more information
contact your DOT specialist.
6.1.2 Work on Existing Pipelines
§ Before repair work is performed on pipelines or
associated equipment, all affected employees shall be
informed.

§ Pipelines shall be assumed to be under pressure
regardless of precautions taken. When possible,
pipelines shall be physically traced to determine the
sources of pressure that need to be blinded. A check
valve shall never be depended upon to prevent
backflow in a pipeline. Valves shall be locked/tagged
out, both upstream and downstream of the work area.
§ The pipeline pressure shall be bled down. Before
initiating hot work or using spark producing
equipment, the pipeline shall be purged with inert gas,
flushed with water, or ice/mud plugs set. The
atmosphere in the area shall be continuously
monitored for hydrocarbon vapors.
§ When practical, work shall not be performed on
equipment under pressure. When the equipment must
remain pressurized, approval shall be obtained from
your team leader and other precautions shall be taken
to avoid the hazards posed by the pressurized
equipment.
§ When a bolted connection is to be removed, bolts shall
be loosened just enough to allow any trapped pressure
within the pipe to be relieved.
§ Pipelines under cathodic protection shall have the
rectifier switched off or a shunting cable attached to
both sides before the line is separated.
§ If a section of pipe is to be removed temporarily, but
not immediately replaced, the pipeline shall be blinded.
§ All gas lines and gas system equipment, including
existing systems from which pressure has been relieved,
shall be thoroughly purged with gas to remove air
before operations begin. Until air is completely
removed, low-pressure levels and low-gas velocities
shall be maintained. Removal of foreign material by
blowing-down (purging) shall not be performed until
air is purged from the system. This is to prevent

ignition of an air-gas mixture. Ignition sources shall be
eliminated during purging, blowing-down, and
cleaning operations.
§ In some hot work, it is not possible to evacuate the line
and it is necessary to perform a “hot tap”. Hot taps
shall be performed only by qualified persons. To
prevent finger injuries, flange spreaders should be used
when gaskets, blinds, and orifice plates are installed.
6.1.3 LOTO and Blinding Procedure
§ Blinding is the preferred
method of isolation for all
equipment in hydrocarbon
service. Blinds shall be
installed on or in all piping
connected to tanks/vessels
or equipment scheduled for
maintenance, entry, or hot
work. Blinds shall be near the tank/vessel, preferably
on the first flange from the tank/vessel shell.
In instances where a blind cannot be installed near the
tank/vessel, other methods, of isolation can be used as
long as the method provides equal protection for
employees as would be provided by blinds.
§ In some instances a valve, spool piece, or other device
shall be removed from the line and a blind flange
installed on the line and the tank/vessel.
A blind shall be installed with three major
considerations in mind:
• Will the blind effectively accomplish its purpose in
the location selected?
• Can the blind be safely removed?
• Is there access to the selected location?

6.1.4 Valves, Piping and Tubing
§ Grease and operate valves in accordance with
manufacturer's specifications. Gate, plug, and ball
valves are designed to be fully opened or fully closed;
they are not designed for throttling.
§ Only bolted bonnet steel valves should be installed in
hydrocarbon service, unless Technical Services approves
another type for the particular application or service
involved. (For example, some screw bonnet valves may
be installed in locations where pressure and other
factors may allow their use.)
§ Use stainless steel tubing and tubing fittings on all
tubing installations in hydrocarbon service.
§ Mark valves requiring manual operation in the event of
a fire or other emergency. The sign or markings should
indicate which valves are in water service, which ones
are used for hydrocarbons, etc.
§ Plug all valves in hydrocarbon service that open to the
atmosphere. Use a solid steel plug, or blind off the
valve.
§ Cut clean, smooth pipe threads to ensure good, tight
connections.
• Valves that control bleed operations should be opened
and closed slowly.
• Do not hammer on lines or fittings that are under
pressure.
• When repressuring lines and equipment, open valves
slowly. Everyone along a line or in front of the
equipment should stand clear until normal operating
pressures are reached.
6.1.4.1 Block Valves
• The pressure of a flowing well shall not be controlled
by a block valve in the flowline at the tank battery
header or between the header and the separator.

• In switching from one pressure vessel to another, the
valves to the pressure vessel being activated shall be
opened first and flow established before the valves on
the pressure vessel being deactivated are closed.
• Chains that operate overhead valves shall be properly
secured from walkways when not in use. Block valves
shall be operated slowly.
6.1.4.2 Check Valves
• A check valve shall never be relied on to hold line
pressure to protect persons during maintenance
operations.
6.1.4.3 Pressure Relief (Safety) Valves
• Pressure relief valves shall be tested according to
company policy. Pressure relief valves shall be set
based on the lowest pressure-rated vessel in the system.
• Block valves should not be located between the vessel
and the pressure relief valve or between the relief valve
and the discharge vent, unless they are locked and
sealed in the open position.
• Piping from the pressure relief valve outlet shall be at
least the same size as the outlet of the relief valve. If
more than one relief valve discharges into a common
vent line, the line shall be sized so that it can handle the
volume from the vessels should two or more relief
valves release at the same time. Discharge vents to
atmosphere shall be designed in accordance with SOPs
and regulatory requirements.
• Design and installation methods shall be used to
prevent fluid accumulation at the discharge of the
pressure relief valve. Leaking pressure relief valves shall
be replaced as soon as possible.
6.1.4.4 Valve Actuation
• Employees shall not operate (open or close) a valve
unless they know what purpose it serves. Valves that are
part of emergency shutdown systems shall be inspected
at least annually.

6.1.4.5 Pressure Gauges
• Never tighten or loosen pressure gauges while the gauge
is under pressure.
• Equip pressure gauges in product service with safety
plugs or safety backs.
• Gauge pressures should range between 33 percent and
67 percent of the maximum gauge reading for safety
and accuracy. For example, the recommended
operating range of a 5000 lbs. gauge should be 1660 to
3350 psig. A process gauge connection size should
not be less than 1/2” NPT.
• Never install gauges directly into a tap in a vessel or
line. Install them into a valve that has been installed
into the tap. Special gauge valves with bleed ports are
preferred.
6.1.5 Scraper Traps
§ Make sure the trap is equipped with both a pressure
gauge to indicate pressure, and a pressure relief valve
capable of safely relieving pressure in the barrel. Refer
to the Design and Construction Manual.
§ Follow the procedures for opening the scraper trap.
There are several types of scraper trap closures in use
throughout the company. Be sure you understand the
safe operation of the unit you have in place.
6.1.6 Engine and Motor Operation
§ Do not begin repairs on any machinery until the power
source has been turned off and provisions have been
made to prevent revolving or reciprocating parts from
turning over accidentally. This policy does not prevent
minor adjustments being made by authorized
personnel, such as tightening packing glands and
adjusting fuel injectors and valve tappets.
§ Follow the lockout/tagout procedure whenever any
work is being done on a shut-down engine or motor.

§ Before starting an engine or motor, the person in
charge should inspect the engine, checking to see that
all guards are in place, tools and equipment are “in the
clear,” and the engine is ready to start.
6.2 Tank Gauging
6.2.1 Ascending and Descending Tanks
§ Keep one hand free to grasp the
handrail when climbing or
descending tank stairs.
§ Keep both hands free to grasp
rails when climbing or
descending ladders. If necessary,
utilize a hand line for
equipment.
§ Take extra care with footing and
hand holds when climbing a tank under windy or
moist conditions.
6.2.2 Tank Top Safety
§ Under some operating conditions, it may be necessary
to access a roof after dark. Use adequate lighting and a
buddy or notification system.
§ Follow confined space entry procedures when
descending onto floating roofs. Do not walk on tanks
with visible or known roof deterioration, or on tanks
posted with “Keep Off - Unsafe” signs.
§ When possible, stand on the upwind side when
opening the hatches on tanks to avoid breathing vapors
and gases given off by contents of the tank. Follow
precautions for hydrogen sulfide if labeling on the tank
indicates that it contains H2S. Wear a respirator/SCBA
when required (i.e., for benzene exposure, if posted on
heated crude oil tanks or gasoline tanks).

§ Do not leave hatches open unless there is a specific
reason for doing so (such as ventilating a tank). Tag
the open hatch, identifying the reason the hatch is
open. If hatch is required to be left open, contact your
air specialist to ensure compliance with local air district
rules.
§ Do not slam hatches open or shut. Avoid any practice
that could generate sparks or static electricity.
§ Do not leave tapes, plumb bobs, rags, etc., on tank tops.
Any loose equipment left on a tank top may fall onto
someone below.
§ Immediately wipe up all oil or other liquid spills to
prevent slipping.
6.2.3 Gauging
§ Use gauge wells or “target gauges” where available to
avoid descending onto tanks.
§ Follow the above procedures for ascending/descending
tanks and tank tops safely.
§ Do not gauge from the roof of a tank during a
thunderstorm or an electrical storm.
§ For more information contact the measurement
specialist.
6.2.4 Static Electricity
See Section 5.12.5 for static electricity issues associated
with tanks.
6.2.5 Sampling and Gauging
See Section 5.12.6 for electrical issues associated with
tanks sampling and gauging.
6.2.6 Tank Dike Maintenance
§ Lock dike drains closed except when draining
accumulated water from within the dike area. Before
releasing accumulated water, follow local water testing
regulations.

§ Use only walkways and stiles for berm access.
§ In the event of berm damage or collapse, immediately
notify a team leader, your local Spill Prevention
Containment and Contingency Plan/SPCC if
applicable, or your water specialist.
6.3 Tank and Vessel Cleaning
6.3.1 General Precautions
§ Exercise extreme care while working in or around tanks
that contain, or previously contained, petroleum or its
products. These tanks may contain vapors that can
cause asphyxiation or that may be in the flammable
range. Some crude oil and separation tanks also may
contain Normally Occurring Radioactive Material
(NORM).
§ The team leader shall:
• Utilize confined space procedures.
• Ensure that the atmosphere in the tank is safe to
enter and remains safe to work.
• Continuously ventilate tanks prior to, and during,
cleaning operations.
• Make sure all tank cleaning personnel are aware of
all dangers and the procedures necessary to
minimize them.
§ Schedule the job for a time that minimizes any hazards.
For example, tanks near a highway should be ventilated
when the wind is blowing in a direction that will carry
the vapors away from the highway. Dispersion of gas
and vapors is slower in cold weather and during dead
calms, particularly if ground fog prevails. Follow hot-
work permit procedures as applicable.

6.3.2 Equipment
6.3.2.1 Light Inside Tanks
• Use only explosion-proof flashlights inside any tank
that has contained petroleum products, except when
the tank is tested and found to be 10 percent or less of
lower explosive limit (LEL). Then approved, grounded,
vapor-proof, 110-volt hand lights may be used.
6.3.2.2 Personal Protective Equipment
• The PIC must complete the Safe Work Permit including
outlining the personal protective equipment
requirements.
6.3.2.3 Atmospheric Monitoring Equipment
• Test the indicator to see that it is in proper working
condition. Follow the instructions (i.e., those fixed to
the lid of the carrying case) and use the test gas (in the
indicator case) to verify that the gas detector works
properly.
• When transporting the indicator, keep it in its carrying
case. Periodically service the gas indicator and keep it
clean at all times.
6.3.2.4 Ventilating Fan or Exhauster
• Ventilate so that the volume of air in the tanks is
changed three to five times per hour when possible.
For large tanks (approximately 150,000 bbls and
greater), a minimum of one change per hour is
permissible.
6.3.3 Cleaning Procedures
For details on tank and vessel cleaning procedures, see
your team leader regarding cleaning and repairing tanks
procedure. Following are some safety reminders
regarding tank and vessel cleaning.

6.3.3.1 Prepare the Area
• Clear the area around the tank of ignition sources (for
distance of 100 feet or more, if possible). Leave all
matches, lighters, cigarettes, etc., at an area determined
“safe” by the team leader. Signs should designate areas
for smoking.
• Block roads leading to the tank and post signs
indicating “Danger from Escaping Gas” or “Danger -
Flammable or Combustible Vapors,” etc.
• Lay out a fire hose, if available, with combination solid
stream and fog nozzle from the water source to the
tank. Charge the hose before starting to ventilate the
tank.
• Empty the tank as completely as possible.
• Install blinds. Lines in hydrocarbon use must be
blinded or completely disconnected, misaligned and
capped.
• Ventilate the tank.
• Only after the exhausted vapor tests 10 percent or less
LEL should you clean the tank out through the
manhole.
• No worker shall enter any tank or other container,
provided only with manholes in the top, until confined
space entry procedures have been implemented. This
procedure requires that a rescue plan be developed for
each authorized entrant. This plan must outline the
provision for the rescue of all authorized entrants.
• Avoid workers cleaning or hosing from inside the tank.
• While workers are in the tank, periodically test the air
inside the tank.
• Follow guidelines for the required number of workers
for standby and support.

• Test vapors progressively throughout the tank, using
the exploring probe to obtain samples at least five feet
ahead of the tester. Also test near the bottom of the
tank and in places where packets of vapor might
accumulate.
• Keep the escape route open, Move all obstructions away
from the manhole, both inside and outside of the tank.
This is the responsibility of the person in charge of the
job.
6.3.3.2 Cold Repair Work
• No cold repair work shall be done outside or inside any
tank that has contained petroleum products until the
person in charge of the job has determined that the
tank is “safe.”
6.3.3.3 Hot Repair Work
• Under ordinary circumstances, hot/work or open fires
will be permitted 300 feet or more from a tank that is
not vapor-free, except where unusually large quantities
of vapor are likely to be discharged.
• In all cases, the team leader shall:
• Perform the tests or designate someone to do so.
• Determine when prevailing conditions are such
that any vapor discharge from the tank is not
likely to reach the work.
• Give instructions for the work to proceed.
• Designate the “safe” location for other sources of
ignition (such as welding).

7.0 Transportation Safety
7.1 Motor Vehicle

7.1.1 Vehicle Operation
§ Company-owned, leased and/or
rented vehicles are to be used for
company business only. They are
not to be used for regular
commuting except under a team
leader's instruction.
§ Vehicles should be left on company property at night
and on weekends, unless you've received prior
management approval to do otherwise. (Note: The use
of company vehicles for personal business or
commuting is considered a form of taxable income and
must be reported to the Internal Revenue Service.)
§ For insurance reasons, non-employees (including
contractors) are not allowed to drive company vehicles.
§ The driver and all passengers must wear seat belts. All
passengers must ride in the cab or passenger
compartment.
7.1.2 Driver Responsibility
§ As the driver of a company vehicle, you must:
• conduct a walk around inspection of the vehicle
prior to operation
• operate the vehicle in a safe, proper, legal manner
and observe traffic regulations
• use the vehicle only for authorized purposes
• instruct all passengers to wear their seat belts
• provide for the safety of employees helping
load/unload, or otherwise working on or around
the vehicle
• have in your possession a valid driver’s license
appropriate for the vehicle and its use

• ensure the safety of your passengers
§ Drivers may not use cell phones while driving.
§ Drive in accordance with the law. Do not operate
equipment that is defective or that is not in compliance
with the law. Drivers are personally liable and
responsible for the consequences of violating state and
community laws.
§ Employees are strictly forbidden to drive a company
vehicle while under the influence of drugs or alcohol.
§ Certain vehicles require placarding. Proper placarding
is the sole responsibility of the operator.
§ Picking up hitchhikers is prohibited.
7.1.3 Safe Driving Principles
§ Operate company vehicles in a defensive, alert manner.
Try to anticipate what might occur under the existing
conditions and drive to avoid potential hazards.
§ Be considerate of, and courteous to, the traveling public
and pedestrians. Yield the right-of-way to avoid
accidents.
§ Drive at speeds consistent with existing conditions,
such as weather, ranging cattle, etc.
§ Use these principles to reduce driver fatigue and costly
vehicle maintenance:
• aim high when steering
• get the “big picture” when driving
• keep your eyes moving. Avoiding staring.
• leave yourself an available out
• make sure others see you
7.1.3.1 Inspecting Vehicles
• The driver of any company vehicle should regularly
inspect the condition and operation of tires, horn,
windshield wipers, rear-view mirrors, brakes, steering
gear, windshields, headlights, tailights, turn signals and
stop lights.

Also ensure that you have sufficient levels of gasoline,
oil and water.
• Immediately report any missing or defective motor
vehicle equipment.
• Immediately contact your team leader if you have
reason to believe that any motor vehicle is unsafe to
operate.
7.1.3.2 Backing
• When possible, avoid backing. When backing is
required:
• check to be sure path is unobstructed
• walk around your vehicle before you start
• ask for assistance, if necessary, to avoid hazards
• continually check clearances while backing
• stay at the vehicle controls while backing
• back slowly
7.1.3.3 Turning
• When driving trucks with trailers or other long equip-
ment, make sure you allow enough space to make the
turn. Use the street you're turning onto as “extra space”,
swinging wide, if necessary, to complete the turn.
• When turning a truck or long equipment into a narrow
street or alley, try to approach it so you'll be making a
left turn, rather than a right turn.
7.1.3.4 Following
• Maintain a “space cushion” around your vehicle at all
times to help prevent accidents. Leaving ample space
around your vehicle gives you more time to react to
conflicts or other changing conditions. This space
cushion should take into account traffic, icy roads and
other driving conditions.
7.1.3.5 Parking
• Park vehicles where permitted and they do not present
a hazard to other traffic.

• Look for a parking space where backing is not required.
When practical, vehicles shall be parked so they can be
driven forward when next moved.
• Vehicles shall be parked so as not to roll out of control.
Park vehicles with ignition turned off, hand brake set,
and transmission placed in “park” or low gear. Use
extra caution when parking on hills. Turn front wheels
to the curb/bank or place chocks under rear wheels.
• The person in charge may authorize the vehicle to be
parked with the motor running and the hand brake set
when necessary to operate power take-off, electric or
communications equipment for periods of time that
would run down the vehicle battery. In these cases,
select a level parking place if available. In all cases,
chock blocks must be set.
• When operators are out of their vehicles, the engine
shall be shut off and the parking brake set. In extremely
cold areas, the requirement to shut off the engine can
be modified by local management.
7.1.3.6 Loading and Unloading
• Post vehicle load limits in the cab or on the outside of
the vehicle as appropriate.
• Do not overload vehicles with materials or passengers.
• Properly place and secure all vehicle loads.
• Mark all material that extends more than two feet
beyond the cargo bed with a red flag.
• Loads shall not extend directly over a truck cab unless
the cab is protected for the potential hazard.
• Employees shall not be used as counterweights to
correct improperly loaded trucks. The load shall be
rebalanced or lightened.
• Chain binder (boomer) handles shall be secured to
prevent accidental release.

• Load stakes shall be checked to see that they are
securely in place prior to relieving tension on the chain
binders.
• Employees shall not stand directly over the chain
binder handle when tensioning or releasing a chain
binder.
• Employees shall not attempt to stop a shifting, falling,
or tumbling load.
• Employees loading or unloading pipe shall not stand
between the truck bed and the pipe rack.
• A truck from which pipe is to be unloaded shall be in a
direct line with the pipe rack to provide an even roll of
pipe down the skids to the pipe rack.
7.1.3.7 Use of Cellular Phones While Driving
• Cellular phones (even hands-free), radios, PDAs,
pagers, and similar electronic devices are a distraction
while driving.
• Electronic devices such as cellular phones shall not
be used in company cars, rentals, personal cars
on company business or on company property
while the car is in motion. Pull over and stop
when making or receiving calls. Remember to
leave the freeway when stopping. Dial while the
car is legally stopped.
• Do not take notes while the car is in motion.
• Leave them inside the vehicle while re-fueling.
7.1.3.8 Transporting Tools and Other Materials
• Do not leave tools and equipment loose in the cabs or
passenger compartments of cars or trucks. Stow all
equipment in proper tool chests or compartments
whenever available.
• Do not leave loose articles on the seat or dash when the
vehicle is in motion. These may fall to the floor or blow
around, distracting or interfering with the driver. Use
chart carriers or clipboards for papers. Similarly, don't

store anything under the driver's seat that might roll
out and interfere with braking or other actions.
• Portable safety containers shall be removed from
vehicles while being filled with flammable liquids.
• Cargo or heavy tools shall not be transported in the
passenger compartment of vehicles at the same time as
passengers. Vans that carry tools and/or equipment in
the cargo compartment shall be equipped with a
protective barrier between the cargo and passenger
sections.
• Hard hats or other loose objects shall not be stored in
the rear window tray or the front dashboard of vehicles.
• Gasoline or other flammable material shall be
transported only in approved (for example, UL, etc.)
safety containers outside the vehicle passenger
compartment, as required by Department of
Transportation (DOT) regulations. Use only DOT-
approved containers and fasten them securely to
prevent tipping or rolling.
• In addition, explosives, TO JUMP START, REMEMBER
pesticides, flammable and
combustible liquids, and 4. Engine Block* 3.
other hazardous materials Dead Good
Battery Battery
shall not be carried in the
passenger compartment of 1. 2.
trunk of any company *(Connect last clamp away from battery)
vehicle. Such materials shall Batteries are the same voltage.
Both negative posts grounded.
not be stored in vehicle Check fluid, check for freezing.
Cars not touching.
passenger compartments or Ignitions off, accessories off,
gears in “PARK” or “NEUTRAL,”
automobile trunks. Carry brakes on.
Attach clamps in order shown.
properly completed shipping Remove in exact OPPOSITE order.
papers where required.

7.1.4 Breakdowns
§ If your vehicle breaks down, guide it completely off the
main roadway if possible. If it is necessary to tow
equipment, don't stand between a towed vehicle and

the towing vehicle. Place warning devices between the
vehicle and traffic.
7.1.5 Trucks
§ Trucks shall be maintained in proper operating
condition, with particular attention to the condition of
the brakes, signals, lights, horns, windshield wipers,
steering gear, and tires. A vehicle operator who detects
a mechanical defect or potential safety hazard in a
vehicle shall make arrangements for prompt repair or
report the mechanical defect or potential safety hazard
to his/her supervisor or the designated person
responsible for vehicle maintenance.
§ Wheels of trucks and mobile equipment shall be
checked periodically to confirm that lug bolts and axle
flange nuts are in place and tight.
§ Truck beds and cabs shall be kept clean and orderly.
§ Trucks shall be equipped with fire extinguishers, first
aid kits, and disposable drinking cups when potable
water is provided.
§ Employees shall not ride on trucks, forklifts, and other
mobile equipment not equipped for transporting
passengers.
§ The operator shall check clearances when operating a
vehicle. When necessary, the operator shall obtain aid
from a guide.
§ Operators and other employees shall watch for
electrical lines and equipment when working or driving
vehicles equipped with gin poles/“A” frames, masts, or
other protruding objects.
Winch Truck Operation

§ The operator of a winch truck is responsible for the
examination of the winch lines and load guys to the gin
pole/“A” frame. Winch and crane lines shall be visually
examined daily or prior to use or anytime they are
subjected to potential damage.

§ Utility poles shall not be used as anchor points.
§ Employees shall not stand between the truck and a load
when there is a strain on the winch line.
§ Winch lines shall not be used for assistance when
climbing onto truck beds.
§ Winch lines shall be terminated into a tail chain or
other end attachment using an approved termination
fitting (spelter socket, wedge lock, or crimp
connection). An overhand knot in the end of the
winch line is not an approved termination.
§ The tail chain or other end attachments on the winch
line of a gin pole/“A” frame shall not be pulled against
the sheave (pulley) as it might become fouled or
otherwise create a potential hazard.
§ The winch line hook shall be securely fastened to the
truck bed or other fastening point when not in use.
§ Gin pole/“A” frame operators shall check truck
positioning and anchoring prior to use. If the brakes
are not sufficient, the wheels shall be chocked (blocked)
to prevent the truck from moving. Outriggers shall be
used when available.
§ Employees shall not walk or stand under a suspended
load.
§ When heavy equipment is moved with a crane or gin
pole/“A” frame, a tag line shall be attached to the load
to enable the helper to stand in the clear and still
control the load. Trucks should not transport
suspended loads except within the immediate work
area.
§ When loads are handled by gin poles/“A” frames, the
gin poles/“A” frames shall be securely anchored to the
truck bed.

7.1.6 Commercial Driver’s License
§ Special training requirements must be met for
commercial drivers' licenses (chauffeur licenses). Each
employee who needs to carry a commercial driver's
license is responsible for meeting these requirements
and for notifying his/her team leader to schedule
necessary medical tests. This includes a medical
examination every two years, and inclusion in a
random drug screening process (which is more
stringent than the process required for general pipeline
employees).
7.1.7 Accidents
§ Report all accidents involving a company vehicle,
rental vehicle or personal vehicle used for company
business to your team leader. Team leaders shall report
all vehicle accidents as soon as possible to the HES
hotline, and all information should be entered into the
Incident Investigation and Reporting Database.
§ In case of a vehicle accident, the employee driving
should:
• Pull off the road, if possible, to avoid obstructing
traffic.
• Render aid to any injured persons.
• Place warning reflectors on the road as necessary.
• Report the accident to his/her team leader and to
law officers as soon as possible.
• The Incident Investigation and Reporting
Database will be used to document essential
information at the scene of the accident.
7.2 Water
7.2.1 Marine Travel (Boat Transportation)
§ The boat operator have complete authority to make all
decisions concerning the suitability of weather,
condition of the vessel, loading and unloading and

any other factor relating to vessel operation. The boat
operator may elect not to conduct or continue any
voyage. Others shall not question an operator's
decision.
§ Follow the skipper's instructions
regarding loading procedures,
storage of luggage and cargo, seating
arrangements and smoking
restrictions.
§ In the event of an emergency, follow
the skipper's instructions and posted
emergency procedure instructions.
§ If a person falls into the water during a transfer,
immediately notify the skipper by shouting, “Man
overboard!” Assist in the rescue as directed by the
skipper.
§ Crew boats that operate in federally
regulated waterways shall meet U.S.
Coast Guard requirements.
§ Overloading of crew boats is
prohibited.
§ The following shall be observed:
• Employees shall wait on the dock until incoming
crews have disembarked. The boat shall be
boarded in an orderly and safe manner.
• Passengers shall be seated in the cabin. Unless
required, no one is to be outside on the deck when
the boat is in motion.
• Passengers shall observe good housekeeping.
• Boats shall be equipped with fire extinguishers.
The boat operator shall be responsible for
examining fire extinguishers on a monthly basis.
• Flammable or other potentially hazardous
materials, compressed gas cylinders, pipe, or
drilling tools shall not be transported on crew

boats at the same time the boat is transporting
passengers, unless the boat is certified for this
service.
• Passengers and crew shall wear appropriate
hearing protection when necessary.
7.2.2 Personal Floatation Devices (PFDs)
§ United States Coast Guard Type I PFDs
(life jackets) are required on “for hire”
vessels and offshore structures. USCG
Type V PFDs (work vests) are
considered an “open classification.”
§ Approved Type I or Type V PFDs
must be worn when:
• Transferring to or from any
watercraft.
• Working at any over-water location that does not
provide handrail protection.
• Loading or unloading cargo from any boat, barge
or other waterborne structure. (This includes the
crane operator in the cab at an offshore location.)
• Riding in any open or semi-open watercraft.
• Operating any watercraft alone.
• While being transferred with a personnel basket
over water.
• Entering the water to perform work. (Diving
operations are excluded from this rule.)
• Traveling in helicopters over open water or to
offshore locations. If FAA-approved inflatable
PFDs are provided in an aircraft, they may be
worn in place of Type V PFDs. In fixed-wing
aircraft, pilots will advise passengers when PFDs
are needed. Wear the PFD that is used in any
water survival training.
• Conducting USCG fire emergency drills at over-
water locations. (Type I PFDs are required.)

• Deemed necessary by a pilot, boat skipper, team
leader or safety engineer, due to fog, haze, rough
seas, etc.
§ PFDs must be worn fastened, snugly fitted and in
good condition. When required, flotation devices may
be worn over fire resistant clothing. Boat skippers and
captains are responsible for ensuring that all passengers
boarding or leaving their vessels follow all PFD rules.
Boat skippers and captains will refuse boarding to any
passenger not adhering to these rules, and will report
all infractions to the appropriate team leader.
7.2.3 Swing Ropes
§ The swing rope is the most common device for
transferring personnel to and from boats and
structures. Follow the guidelines below when working
with swing ropes:
• Install swing ropes so that they will return or
swing back and hang over the outer edge of the
catwalk.
• At a minimum, the upper 10 feet of a swing rope
connected to the structure shall be stainless steel
wire rope measuring at least 1/4 inch in diameter.
(Single-well and low-profile structures are exempt
from this rule.) The lower part of the rope should
be a comfortable diameter for an average person's
grip, usually 3/4 inch to one inch in diameter. A
three-strand, twisted polypropylene/polyester
blend rope is recommended.
• The rope shall not hit below the landing area of
the catwalk.
• The rope shall have three knots - spaced four, six
and eight feet above the walking surface of the
catwalk.
• The lower section of the swing rope assembly
must be properly maintained. Swing rope
assemblies shall be visually inspected at least four

times per year, and a record of these inspections -
noting the installation and/or inspection date -
shall be maintained at the facility. The lower
section shall be replaced at least every two years.
The rope shall be replaced sooner if it becomes
excessively slick from oil, mud or chemicals; if a
structure has been painted; or if the rope is
otherwise damaged.
• Always follow a skipper's instructions when using
a swing rope to transfer between a boat and
platform. Wear a snugly fitted and securely
fastened PFD.
• When using a swing rope from boat to platform,
have both hands and arms free. Catch the knotted
rope high enough to clear the catwalk on the
structure when the boat is on top of a swell, and
swing to the platform by pushing off from the
boat with your feet. Once you've landed on the
platform, release the rope and be ready to help the
next person using it. Transfer your luggage or
other materials via a material basket and crane, or
by handing them from the boat to personnel on
the platform.
• When using a swing rope from platform to boat,
swing from the catwalk as the boat is beginning to
rise from the bottom of the wave or swell. Time it
so both your feet are on the boat's deck as it is
reaching the top of the swell. Never release the
swing rope until you are safely on the deck. If you
miss the boat, continue to hold the rope; you will
automatically return to the safety of the catwalk,
where you can try again.
• Always keep your feet and legs clear of the
platform landing face where the boat bumps
against the platform.

• A deckhand wearing an approved PFD must be on
the deck at all times whenever a personnel transfer
is being made.
• If, for any reason, you don't think you can
transfer safely using a swing rope, do not attempt
to do so. Never let a boat skipper, deckhand or
anyone else influence your decision or try to rush
you.
• Using a swing rope to transfer between two boats
is prohibited.
7.2.4 Personnel Baskets
§ Personnel baskets are permitted for use at facilities if
management grants approval and governmental
requirements are met.
§ To use a personnel basket, stand on the outside rim of
the basket and firmly grasp the upright basket ropes.
Keep your knees slightly bent or flexed, and prepare
for unexpected moves (particularly in rough seas).
§ Only luggage and hand tools shall be placed inside the
personnel basket.
§ Never stand under a personnel basket.
7.3 Aircraft
7.3.1 General
§ These instructions pertain to private charter flights.
For commercial flights follow Airline Carrier
Instructions.
§ Passengers must report to the designated sign-up area
30 minutes before all flights to receive pre-flight
instructions. If it is a passenger's first flight on the
aircraft, she/he must inform the pilot or dispatcher so
they can perform an appropriate briefing.
• Wait for the pilot's signal before boarding or
deplaning an aircraft.

• Walk, never run, to and from the aircraft.
• When boarding and deplaning, watch footing and
use handholds.
• Ear protection (plugs, muffs or headsets) is
required on company or contract aircraft.
• All passengers must keep their seat belts fastened
for the duration of the flight.
• Federal regulations (FAR 91.11) prohibit carrying
anyone aboard an aircraft who is under the
influence of intoxicating alcohol or drugs.
• All baggage and loose objects must be stored in
baggage compartments or other approved storage
areas. Never block an exit with baggage.
• If any explosives, flammables, compressed gases or
radioactive substances will be transported, you
must notify the pilot so special provisions can be
arranged.
• Never throw anything out of an aircraft.
7.3.2 Helicopter Travel
Prior to initial flights on helicopters, passengers must
view an introductory film.
7.3.2.1 Arrival at Departure Points
• Passengers shall report their name, ID number,
weight (both personal and baggage), and destination
to the Dispatcher as soon as they arrive at the
departure point.
• All hazardous or flammable materials shall be
properly containerized and the required paperwork
completed before such material can be transported
by helicopter.
• Passengers shall remain inside the designated
waiting area until they are notified to board.
• Employees shall not loiter near helidecks during
landings or takeoffs.

• Persons impaired by use of alcohol or drugs shall not
be allowed to board any helicopter.
• Helidecks and landing/takeoff areas shall be kept free of
debris, including, loose objects, baggage, and tools.
• Smoking shall not be permitted within 50 feet of a
helicopter or a fuel installation.
7.3.2.2 Embarking and Disembarking Aircraft
• Upon embarking and disembarking the aircraft,
passengers shall:
• Wait until the pilot has made visual contact and
signaled before approaching the aircraft.
• Always approach or leave from the side of the
helicopter.
• Remain in the pilot's view at all times when
approaching the aircraft.
• Observe the path of the main rotor blades while
they are turning and keep well under them.
• Never walk around or under the tail rotor of any
helicopter or around the front of the aircraft -
there often is a very low clearance between the
ground and the rotor blade.
• Never walk aft of the baggage compartment on
any helicopter. After unloading baggage, leave the
vicinity of the helicopter in a direction away from
the tail rotor and in full view of the pilot.
• Hard hats, safety glasses, light items, including, but
not limited to, caps, hats, jackets, mail, paperwork,
newspapers, and any other items that can be
blown or sucked into the rotors or engine intakes
must be secured or hand-carried in the vicinity of
the helicopter. Long items shall be carried in a
horizontal position below waist level to avoid
contact with rotor blades.
• Never chase after loose objects.

• Follow the pilot's seating and cargo loading
instructions.
• Plastic garbage bags, plastic bags of any type, plastic
wraps, and similar materials are strictly forbidden in
and around heliports, helidecks, and landing and
takeoff areas.
• Always hold pipe, poles, etc. in a horizontal position
when near a helicopter to avoid striking the rotor
blade.
• Passengers arriving offshore shall be clear of the
helideck before departing passengers can be loaded.
(Crew change is conducted below deck.)
Some rotor blades can dip below the 6 foot level
7.3.2.3 Pilot-In-Command
• The pilot in charge of the aircraft shall have complete
authority to make all decisions concerning the
suitability of weather and landing areas, condition of
the aircraft for flight, loading the aircraft, the manner
of flight, and any other factor relating to flight safety.
• A pilot may elect not to conduct or continue any flight.
Others shall not question a pilot's decision not to fly.
No one shall encourage pilots to violate or compromise
any regulation. Passengers shall give the pilot their full
attention and cooperation during the preflight safety
briefing.

7.3.2.4 Special Rules for the Sikorsky S-76
• Because the Sikorsky S-76 has a very low rotor blade
clearance in the front of the aircraft, all passengers shall
approach and depart from the sides only (either side is
okay).
• Persons who must go around the front of the S-76 shall
stay close to the nose and avoid touching the Pitot
tubes as they can be hot enough to cause severe burns.
• There are three rows of passenger seats in an S-76.
Only passengers in the center row can access the
locking pin in the doors that must be lifted before the
doors can be opened, so someone must be seated in the
center of the middle row.
• The emergency exits are jettisoned differently in the S-
76 from other helicopters. Passengers shall pay
particular attention to the pilot during the flight
briefing.
7.3.2.5 In Flight
• Pilots and passengers are prohibited from smoking
onboard all helicopters.
• Passengers shall never throw objects out of helicopters
or in the vicinity of landing and takeoff areas,
helidecks, and heliports.
• Passengers shall not distract the pilot in flight and shall
be especially quiet during takeoffs and landings.
However, the pilot shall be advised of any unusual
occurrence within or outside the helicopter.
• Passengers shall never unfasten seat belts or change
seats while in flight. Passengers must be able to fasten
the seat belts as designed or they will not be permitted
to depart. For safety reasons, do not use seat belt
extenders.

• In the event of an emergency, passengers shall carefully
follow the pilot's instructions and remain with the
helicopter. Passengers shall be familiar with the location
and operation of emergency exits and lifesaving
equipment on board a helicopter.
• Exit-qualified passengers should advise the pilot so they
can plan the seating arrangements. Exit-qualified
passengers must be familiar with the emergency
evacuation instructions and express a willingness to
give their full attention to following these procedures
should it become necessary.
• Hearing protection shall be worn around helicopters
and during flights.
7.3.2.6 Miscellaneous Rules
• Crane operations during helicopter approaches or
departures are prohibited. If possible, the crane
operator shall position the boom 180 degrees away
from the helicopter's approach path, and lock the swing
brake or place the boom in the cradle when a helicopter
is landing or departing the platform. The operator shall
then step out of the cab so the pilot will know the crane
has been shut down.
• The crane operator shall place the crane and load in a
safe position in a prompt but safe manner and vacate
the crane cab, while remaining clearly visible to the
pilot. This indicates the crane is shut down.
• Helicopters shall be electrically grounded before
refueling can begin.
• Employees responsible for refueling helicopters should
undergo a special briefing and be issued an
authorization card.
• Employees shall familiarize themselves with helicopter
safety posters, practices, and briefings each time they
fly.

• Injured persons who may need assistance should be
accompanied by a person other than the pilot or pilots.
• Offshore landing areas shall be properly identified,
painted (marked), lighted, cleared, and have nets or
fencing as per regulations.
• Hard hats shall be secured with chin straps or hand-
carried in the vicinity of helicopters.
• If in doubt, ask - never take chances in and around
helicopters.
7.3.3 Fixed Wing Aircraft
• Always wait for the pilot's signal before approaching or
deplaning a fixed-wing aircraft with the engines
running. Always stay behind the wing until the
propeller is fully stopped.
• When boarding and deplaning, watch footing and use
handholds. Do not rush.
• Smoking is prohibited during take-off and landing.
• Passengers in the front seat should assist the pilot in
watching for air traffic (and boat traffic in water
operations). Never obstruct the pilot's view by reading
a newspaper, etc.
• The pilot will advise passengers when personal flotation
devices (PFDs) are needed. PFDs are located under
each aircraft seat.
• Passengers and/or boat captains waiting for other
aircraft shall stand clear until an aircraft is safely
airborne.
• Passengers awaiting aircraft arrival should be present at
landing to assist in docking.

8.0 Ergonomics
8.1 Musculoskeletal Injuries & Cumulative Trauma

Disorders
• The objective of ergonomics is to adapt the job and
workplace by designing the tasks within the workers'
capabilities and limitations.
• In many cases, evaluation of a workplace to determine
risk to injury will require the experience and education
of a professional, however there are general questions
that can be asked to determine if ergonomic issues need
to be addressed. These, for example, include questions
on topics such as manual material handling, cumulative
trauma disorders, environment, general workplace
hazards, tools, and gloves.
8.2 Alternative Work Breaks
• Task breaks are one of the most effective actions you
can take to prevent the discomforts of prolonged
computer use. Remember to get up and move around
periodically. If you type continuously, a good rule of
thumb is to do other tasks for ten minutes every two
hours.
8.3 Workstation Design
• Repetitive movements, such as keyboarding and using a
mouse, combined with restrictive posture, can cause
injuries commonly known as repetitive strain injuries.
8.4 Work Habits
8.4.1 Lifting
§ Keep your back muscles in shape
through proper exercise. You can avoid
most back injuries simply by taking care
of yourself. Consult your physician for
advice.

§ Before lifting determine the following:
• Always complete a hazard assessment and Job
Safety Analysis prior to changing work tasks.
• Can the object be moved by another means, such
as a mechanical device?
• Is the object so bulky that it would obscure your
vision while lifting it? If so, get another person to
help you carry it.
• Is the object within your strength limits? A
preliminary 'tug' will tell you. If the load is too
heavy, get help.
• Is the footing around the object solid? Slips can
lead to injury.
§ The proper lifting procedure is as following:
• Bend at the knees, with your back nearly vertical
and your feet shoulder-width apart. Your body
should be as close to the object as possible.
• Take a firm hold and straighten the knees, keeping
the back straight and upright.
• Pull the load close to your body and lean back
slightly to keep the center of gravity over your feet.
• Avoid twisting your body when lifting or carrying
loads.
• When handling material with other personnel,
teamwork is very important. Agree on who will act
as leader and give the signals. Loads should not be
released until everyone is ready.
8.4.2 Back Injury - Low Back Pain
§ Most back injuries occur because the worker uses his or
her back muscles for something the muscles cannot
tolerate, he/she is not flexible enough to meet the
required range of motion, he/she had to compensate
for a large mid-section, or excessive use of the back
muscles caused inflammation.

§ To avoid back injury the employee should focus on:
• Exercizing to strengthen the muscles of the back.
• Obtaining training on lifting techniques and
proper use of back muscles.
• Using stretching exercises for hamstrings, gluts,
and lower back prior to beginning work
• Maintaining appropriate body weight.
• Using back resting techniques and endurance
training.
8.5 Exercises
• The following exercises can help you release muscle
tension and reduce the risk of aches and pains:
§ Shoulder Rolls - Gently roll shoulder forward, up
and drop back Do slowly and rhythmically 5 to 10
times.
§ Finger Stretch - Gently open and close hand,
stretching fingers while hand is in the open
position.
§ Trap Stretch - Sit on hand to help stabilize. Tip
head down as if looking in your shirt pocket.
Hold.
§ Pyramid Stretch - Start with hands in pyramid
position. Keeping shoulders relaxed, raise palms
together overhead. Slowly bring arms down,
staying together, until you feel a good stretch on
the underside of your forearms.
§ Side Bending - Lower ear toward shoulder. Repeat
other side.
§ Shoulder Blade Pinch - Rotate arms to back,
pinching shoulder blades together. Palms will
naturally rotate back -- let them.
§ Hug Stretch - Grasp arm at elbow. Pull arm
forward and across body as if you are hugging
somebody.

§ Chin Tuck - Keeping head level, slide chin
back making a double chin. Hold two seconds and
release.
§ Hand Stretch - Make gentle fist. Open hand at first
joint keeping fingers bent. Open hand
straightening fingers all the way.
(Do stretches gently. Don't do any stretch that
causes pain. Hold each stretch 15 to 20 seconds.)

9.0 Office Safety
Many office workers may be lulled into believing that

serious accidents simply do not happen in offices.
Unfortunately, the office environment has potential
hazards just like any other work site. That's why it's
important to observe the following precautions at all
times.
9.1 Computer Workstations
• To help prevent repetitive strain injuries, your
workstation should be adjusted to reduce strain on
your body:
§ Your chair should be easily adjusted, learn and use
all available adjustments.
§ The monitor should be lined up with the user and
the keyboard.
§ The keyboard should be located directly in front
of the monitor and allow the wrists to maintain a
neutral position.
§ Position the mouse directly to either side of the
keyboard and at the same height.
§ Feet should be flat on the floor or on a footrest.
There should be sufficient leg space, this should
not be used as a storage area.
§ If there is a document holder, locate it close to the
computer screen.
§ Your telephone should be within easy reach
without twisting. If you use the telephone often,
don't cradle it between your neck and shoulder.
See if a headset can be adapted to your phone, or
try a receiver shoulder rest. Avoid holding a
handset and typing at the same time.

§ Do not keep drinks by the keyboard area. Spills
inside the keyboard can cause electrical shocks.
Before applying any cleaning fluid to a computer
screen, make sure the computer is off to prevent
the screen from cracking and exploding.
§ If overhead lighting is uneven or insufficient, use
task lighting to shed light on hard copy or high-
use areas of your desk to minimize eye strain.
9.2 Floors
Floor finishes should have anti-slip qualities. Eliminate
tripping hazards by keeping work areas free of clutter.
Repair or replace loose carpet, defective tiles or boards,
plastic floor mats and warped and worn floor mats
under chairs.
9.3 Aisles and Stairs
Keep passages free of obstructions. Place wastebaskets,
telephone and electrical cords and outlets, low tables
and office equipment against walls, in corners, under
desks or in some other suitable place to prevent
tripping. Check stairways and exits regularly to be sure
they are unobstructed and properly lighted.
9.4 Office Equipment
• Repair chairs with poor adjustment features. Equip
desk and file drawers with safety stops. Make sure glass
tops on desks and tables are free of cracks. Equip paper
cutters with guards. Equip fans with guards of a mesh
that does not exceed one-half inch. Equip rolling
ladders and stands with brakes that are engaged when
weight is applied.
• Use extra caution around filing cabinets. They are a
major cause of office injuries. Close file drawers with
the handle only. Open only one file drawer at a time.
Where possible, bolt file cabinets together or otherwise
secure them to prevent toppling over. Warn people in

the area if you open a file drawer so they do not turn
around or straighten up quickly and bump an open
drawer.
9.5 Electrical Connections
Arrange electrical devices to avoid the use of extension
cords. Cover any extension cords with approved guards
or tape to prevent hazards. Do not exceed outlet
capacity.
9.6 Material Storage
Stack boxes, paper and other heavy objects in a manner
that will not create an avalanche-type spill. Store razor
blades, thumb tacks and other sharp objects in boxes or
with the edges otherwise covered when stored in
drawers. Minimize the accumulation of trash and
unused material.
9.7 Fire Protection
• Don't throw matches and cigarettes
into wastebaskets. Provide ashtrays of
adequate size in smoking areas.
Construct waste containers of a
noncombustible material.
• You are responsible for knowing the
location of fire extinguishers, alarms
and exits in your office building.
Ask your team leader what the approved escape
procedure is for your office.
• If you discover a fire:
§ turn on the alarm
§ alert fellow workers
§ if trained to do so, use proper firefighting
equipment

• All offices should have written evacuation plans.
Depending on the location, plans may provide for at
least two gathering locations: one near the site, for
evacuations of only the office building; and one about a
mile from the office, in the event an evacuation of the
area occurs. These plans should be posted for anyone
to read, and all employees should be familiar with the
details of the plan.

10.0 Emergency Procedures
Be familiar with the emergency procedures at your

facility for occurrences such as fires, explosions, injuries
and other major emergencies. Chevron Pipe Line
Company Emergency Response and HES Procedures
manuals can provide you with additional information.
§ Do what you can to protect your co-workers and
company facilities, but do not endanger your
personal safety.
§ Notify team leaders and local management of an
emergency as soon as possible.
§ Any contact with the news media should be made
by a company supervisor or public relations
representative. If you must answer questions, state
only known facts.
10.1 Work Site Fire Emergencies
• Before beginning a project that
may increase the potential of a
fire igniting, such as welding,
cutting, grinding, or electrical
equipment repair, check the
condition and location of fire
hose systems and extinguishers.
• Repair or replace defective equipment before you begin
work. Fireproof the area as much as possible, by
removing flammable or combustible materials from
around hot-work areas.
• If a fire is started, evaluate the situation quickly
before taking action. If swift action can extinguish a
small fire in a safe manner, then take the appropriate
steps. If the fire is already larger than you can handle
safely, call for help, and then take what measures you
can to protect lives and limit property damage.

• When emergency help arrives, identify yourself as an
employee, and offer assistance. Even though the
responsibility for attacking the fire is transferred to the
fire department as they arrive on scene, you are most
familiar with the facility and can aid the department in
isolation and shutdown of pipeline operations.
• All fires that occur, regardless of size, must be reported
to the company within 1 hour of the occurrence. Each
fire must be investigated to determine the causes and
corrective actions to prevent a reoccurrence. If a fire
involves any portion of Chevron Pipe Line Company
facilities regulated by the Department of
Transportation, other reporting requirements also must
be met.
10.2 Emergency Response Plans
• Each employee should respond to any emergency in
accordance with the training and information provided
by Chevron Pipe Line Company and the local
team leader. In addition, each employee should be
familiar with the following emergency response plans:
§ Emergency Response Plan
This book has been developed to help employees
and team leaders locate general response
procedures and telephone numbers for most
locations along the pipeline. This book includes
information on notifying the home office, public
affairs responsibilities, medical facilities and
doctors, fire and police assistance, bomb threat
plans, and so forth. The book is kept up to date by
team leaders and the Emergency Response
Specialists.
§ HAZWOPER
HAZWOPER refers to the Hazardous Waste
Operations and Emergency Response regulation.
Under these requirements, only employees with
proper training may perform work during an
emergency. Emergency response specialists and

your team leader can provide you with current
information about these requirements, they can let
you know if and where you should be trained.
§ Site-Specific Emergency Response Plans
These emergency response plans provide detailed
information for specific sites. They include maps
showing such things as sewer outlets, good
locations for placing booms in the water, maps
outlining practical routes to the site, and so forth.
These are used quite extensively during emergency
response drills, and are revised as conditions and
techniques change. Site-specific emergency
response plans are kept current by the team leader
and the HES group.
10.3 Emergency Drills
Fire drills shall be conducted, where required, at
prescribed intervals. Fire drills shall be documented.
Employees shall be familiar with evacuation
procedures. Employees shall be familiar with and
respond to all alarms.

11.0 First Aid and CPR
First aid is the immediate, temporary care given to a

victim of an accident or sudden illness until a physician
arrives. First aid must be limited to treatment necessary
to prevent further injury or death, to relieve pain, and to
prevent or reduce shock.
This section is not intended to replace that
training, but rather to serve as a reminder for what to do
in case of emergency. The company does not recommend
that you apply first aid (including CPR) unless you have a
current training certificate in the necessary techniques.
Also, all providers of first aid should protect themselves
from contact with bodily fluids of the injured person.
Remember the three First Aid principles:
CHECK, CALL, CARE
11.1First Aid Equipment
11.1.1 First Aid Kits
§ Kits are provided at all work locations. You should
know the location of the first aid kits at your work
location. They should be used as needed. Report
depleted supplies to your team leader. USCG-approved
first aid kits are required for offshore (manned
facilities).
11.1.2 Eye Wash and Safety Showers
§ Where potentially injurious corrosive chemicals are
used, emergency eyewash and body drench stations
(stationary, mobile, portable) should be provided.
Stations shall be clearly marked and readily accessible.
§ When employees may be exposed to corrosive
chemicals, employees shall locate and verify operation
of eyewash and body drench stations prior to beginning
work.

11.2 Basic First Aid Steps
• The basic procedures to follow in a serious or life
threatening first aid incident are:
§ Treat the most serious conditions first, such as
stoppage of heart, severe bleeding, stoppage of
breathing, and shock.
§ Call 911 (if the service is available in your area) or
the local fire department emergency number. Try
to keep the victim comfortable. While waiting for
medical help, an employee shall perform only
those procedures for which he/she has been
trained to help prevent the victim’s condition
from worsening. When there is any doubt about
the victim's condition, or if a head or back injury
is suspected, the victim should not be moved
unless in immediate danger. Move the victim only
if necessary to remove him/her from danger.
§ Do not give liquids to a semi-conscious or
unconscious victim.
§ Remove any dentures from the mouth of an
unconscious victim.
§ Unless you are wearing respiratory equipment, do
not attempt to rescue a victim if poisonous or
suffocating gases are suspected in the area.
§ Use ambulance/medivac, watercraft, or, if
necessary, by available vehicle. When transporting
by available vehicle, attempt to notify the
emergency medical service of your route so they
can meet you en route.
11.2.1 Artificial Respiration
§ If a victim is not conscious and is not breathing but has
a pulse, you may be able to save a life by the prompt
administration of mouth-to-mouth resuscitation.
Immediate action is essential, do not wait for a
physician or try to transport the victim to a medical
facility.

§ If you administer artificial respiration, protect yourself
from contact with the victim’s bodily fluids to prevent
potential transmission of viruses (including Hepatitis B
and HIV). Persons trained in first aid/CPR shall also be
trained in avoiding exposure to bloodborne pathogens.
Universal precautions shall be taken when there is the
possibility of being exposed to certain types of body
fluids from other people.
§ Follow these steps to administer mouth-to-mouth
resuscitation:
• check the area for safety
• tap the victim’s shoulder and shout to see if the
victim responds
• phone emergency medical service for help (dial
911 or follow local procedures)
• position the victim. Look, listen and feel for
breathing for about five seconds.
• open the airway
• look, listen and feel for breathing for about
five seconds
• give two full breaths
• check the carotid pulse
• check for severe bleeding
• begin rescue breathing. Give one breath every five
seconds (count ‘one one-thousand, two one-
thousand, three one-thousand,’ etc.). Administer
approximately 12 breaths.
• recheck carotid pulse
• continue rescue breathing as needed
• if pulse is absent, administer CPR
11.2.2 Cardiopulmonary Resuscitation (CPR)
§ Kneel beside the victim and place the heel of your hand
on the victim’s sternum (located about two inches
above the bottom of the chest plate).

§ Place your other hand on top of the first, lining up the
heels of your hands on top of each other.
§ Push down firmly, but not too hard - don't depress the
victim's chest more than two inches, or you may break
ribs. Ease up and press down again, establishing a
rhythm of 80 to 100 compressions per minute. Do 15
compressions. This pressure causes the heart to
compress and force oxygenated blood to flow to the
central nervous system.
§ Alternate compressions with two breath ventilations.
Repeat compression/breathing cycle three more times.
11.2.3 Bleeding
11.2.3.1 Arterial
Symptoms:
Bright red blood spurting from a wound
Treatment:
Elevate the wound. Apply pressure directly over the
wound with as clean a dressing as possible. Maintain
pressure until professional assistance is available. Do
not remove the dressing even if it becomes saturated;
instead, cover it with additional clean dressings. In
most cases, bleeding can be controlled by this method.
If bleeding continues or is very severe, apply hand
pressure to the pressure point located between the
wound and the heart. There are four main pressure
points to use: one on the inner side of each upper arm
(the brachial artery) and one of the inner side of each
thigh (the femoral artery). Also treat for shock (see
below).
A tourniquet should be used only as a last resort. Never
use a tourniquet if bleeding can be controlled in any
other manner, as it may lead to necessary amputation.
If you must use a tourniquet, use a wide band of
material, not a narrow cord. On the victim's forehead,
mark a 'TK' and the time the tourniquet was applied.

Never release the tourniquet on your own - only a
qualified physician should do so.
11.2.3.2 Venous
Symptoms:
Dark red blood flowing steadily from a wound.
Treatment:
Elevate the wound. Apply pressure directly over the
wound with as clean a dressing as possible. Loosen tight
clothing. Treat for shock.
11.2.4 Burns
Symptoms:
Reddening of the skin, and blistering or charring of
tissue, bone exposure, pain.
11.2.4.1 Thermal
Treatment:
For victims with first or second-degree burns, immerse
the burned area in cold water as soon as possible after
the injury. The temperature of the water should be
comfortably cold for the victim, usually under 70
degrees Fahrenheit. (Heat from the burn will raise the
water temperature. Add ice to the water as needed to
keep it cool.) Do not insist on placing a burn under
cold running water; the pain caused by water pressure
may make matters worse and even induce shock.
Next, cover any blisters with a sterile wrap. If burned
surfaces are raw, cover with a loose, light, dry dressing.
If an extremity is burned, elevate the limb to reduce
swelling.
For victims with severe second or third-degree burns,
or burns over a large portion of their body, cover the
victim with a clean dry sheet or blanket and transport
to a medical facility immediately. If ice is available,
place ice bags over the sheet or sterile dressing. Treat
for shock.

11.2.4.2 Chemical
Treatment:
If burned by a chemical, flush the affected area
immediately and continuously with large amounts of
water for at least 15 minutes. Once the chemical is
completely washed away, treat the affected area as you
would a thermal burn.
Chemical burns to the eye should be flushed for at least
15 minutes with a gentle stream of water from a faucet
or drinking fountain. Next, cover both eyes with a
sterile compress and seek medical attention
immediately.
11.2.4.3 Electrical
Treatment:
Before assisting any victim of an electrical emergency,
first de-energize the electricity source. If the accident
occurs inside, disconnect the power at a fuse box or
circuit breaker. If the accident occurs outside, contact
the power company to de-energize the circuit. Until the
power is safely off, never touch the victim or any wire.
When power is turned off and it is safe for you to touch
the victim, check for responsiveness. If the victim is
unconscious, check for breathing and pulse. Administer
mouth-to-mouth resuscitation and/or CPR as needed.
If the victim is breathing and has a heartbeat, check for
burns. They often are found at the point of contact
with electrical current and where that current exited
the body (such as feet). Cover any burns with loose,
dry, sterile dressing and bandage in place. Treat for
shock.
11.2.5 Thermal Stress
11.2.5.1 Heat Stroke/Heat Prostration (Sunstroke)
Early symptoms usually include a headache, dizziness, a
depressed feeling and dryness of the mouth and skin.
Then the face becomes red, but with no perspiration.

The skin is hot and dry. The pulse is strong and rapid.
Breathing is heavy, even sounding like snoring. Victim
may be unconscious and have a high body temperature.
Move the victim to a cool place and lay the victim on
his/her back. Remove the victim's clothing and place
him/her in a cool bath or wrap in a wet sheet. Be
careful not to induce shivering. Be prepared to reverse
treatment, as heat prostration victims can lapse into
shock.
11.2.5.2 Heat Exhaustion
Early symptoms usually include dizziness and nausea.
Next, the face becomes pale. Skin is sweaty, moist and
cool. The pulse is weak and shallow. The body
temperature is low.
Move the victim to a cool place and have him/her
refrain from activity for 24 hours. Remove enough
clothing to cool the victim, but not to induce chills.
Give fluids and treat for shock.
11.2.5.3 Frostbite
It tends to occur to small, specific areas of the body
exposed to prolonged cold, such as fingers, toes, nose,
ears and cheeks. Symptoms include pale skin and
decreased circulation. If the skin is frozen, it may feel
hard and woody. Pain may or may not be present.
Thaw tissue by placing it in tepid water of
approximately 110 degrees Fahrenheit. Blot area dry
and splint for protection (without constricting the
blood flow). Refrain from using frostbitten area. Never
attempt to thaw frostbitten skin by rubbing it.
Little damage occurs to tissue that remains frozen. It is
the action of freezing and thawing and re-freezing that
causes the most problems.Therefore, do not attempt to
thaw frostbitten areas if there is any possibility of them
re-freezing.

11.2.5.4 Hypothermia
It results when the body's temperature drops below 95
degrees Fahrenheit. Symptoms include emotional
changes such as withdrawal, depression, confusion and
unconsciousness. Physical changes include staggering,
stumbling, falling, sleepiness and loss of fine motor
control (e.g., being unable to zip a zipper).
Prevent further heat loss by moving victim to a warm
area and covering him/her with a light blanket or
jacket. Re-warm the victim slowly. Give warm liquids
by mouth (but never alcohol). Do not immerse the
victim in hot water. Be sure to check for other injuries.
11.2.6 Shock
Shock is the body's normal reaction to loss of blood or
any serious injury. Shock can be fatal. It should be
suspected and treated even if all the symptoms are not
obvious.
Symptoms:
Face is pale, dull and anxious; expression is vacant.
Pupils are dilated; eyes are drooped. Cold perspiration
is present on forehead and palms of hands. Skin is cold
and clammy. Pulse is weak and shallow. The victim may
sigh, yawn or gasp, and may experience chills, nausea
and/or vomiting.
Treatment:
Try to make the victim comfortable. Place the victim on
his/her back with feet elevated. If victim is short of
breath, elevate head and shoulders instead of feet. Try
to maintain a normal body temperature. In cold
weather, cover with a blanket or coat; in warm weather,
provide shade. If victim is conscious and assistance is
more than one to two hours away, give fluids in small
amounts by mouth. Watch for vomiting.

11.2.7 Fractures
Symptoms:
Swelling, protruding bones, pain, tenderness, and/or a
loss of motion in joints adjacent to the injury. If a
fracture is suspected, treat it as one.
Treatment:
First treat any arterial bleeding. Immobilize the limb
and apply splints. A straight stick, rolled magazine or
newspaper, etc., can serve as a splint if it's long enough.
Use a strip of clothing, a tie, a belt, etc., to tie the splint
in place.
Do not affix the tie within six inches of the suspected
break.
To reduce swelling, elevate an injured limb after
splinting, unless it causes pain to the victim. Place ice
packs or cool cloths over the injury. (Do not put ice
directly on the skin surface.)
If you suspect a neck or back injury, do not move the
victim except to remove him/her from danger. If
movement is necessary, exercise extreme care! Slip a
straight board under the victim and keep him/her in
the same position as when the injury occurred.
11.2.8 Foreign Body in an Eye
A foreign body in the eye should be removed
immediately, preferably by a physician. Place a light
compress over the eye to protect it until the victim
receives medical attention.
Do not rub the eye, which may drive the particle deeper
into tissues.
11.2.9 Choking
Symptoms:
Respiratory distress or loss of consciousness while
eating. If the victim is coughing, leave him/her alone
temporarily. If the victim cannot cough or speak, has a
difficult time breathing, uses distress signals or loses
consciousness, render treatment.

Treatment:
Position yourself behind the standing or sitting victim.
Place the thumb side of your fist just below the victim's
rib cage, slightly above the navel. Clutch the fist with
your other hand and press into the victim's abdomen
with a quick, upward thrust. Repeat as many times as
necessary until the object is ejected.
11.2.10 Snake and Insect Bites
§ Poisonous snakes, black widow spiders, wasps, hornets
and other poisonous creatures are common in many
field locations. They frequently are found in valve
boxes, old buildings, piles of stored materials and
similar areas.
§ To avoid bites, wear gloves where poisonous insects are
prevalent, and always check for insects before reaching
toward valves.
§ Most snake bites occur below the knee, on the hand or
on the forearm. Use gauntlet gloves, high-top leather
boots, and extra care when walking in brush and when
moving material on the ground.
§ If your work location has snake bite kits, be familiar
with how to use them.
§ If you are bitten by a snake, stay calm. Notify co-
workers to help you seek immediate medical attention.
§ If you are working alone, contact a team leader or
dispatcher. Notifying them of the bite, your location,
and your vehicle description. Seek medical attention
from the nearest medical facility.
§ Immobilize the affected limb, keeping the bitten part
below the level of the heart. Apply a constricting band
between the bite and your heart, but keep it loose
enough to slip a finger under.
§ Do not cut the bite open and/or suck out the venom.

§ Do not apply ice, cold packs or freon spray.
§ As with all puncture wounds, snake bites carry a high
risk of infection, whether or not venom is injected.
Clean the wound carefully with soap and water.

12.0 Fire Protection
12.1 Fire Triangle

The source of fuel can be oil The source of ignition may be
or other petroleum products;
solid combustibles such as
FUEL IGNITION an electrical circuit arc, hot
surface, welding spark, hand
paper, room furnishings, or tool, discharge of static
plastic; or natural gas.
electricity, flashlight, or camera.
Good housekeeping and FIRE
Proper attention to hot work
proper storage and elimin- TRIANGLE
ation of potential fuel permitting and observation of
sources are key points to electrically classified areas is key
preventing fires. OXYGEN to keeping sources of ignition
away from sources of fuel.
Oxygen is present all around us in the atmosphere, and may be present in some chemical substanc-
es(peroxides, for instance). Oxygen may be controlled by inerting tanks, pipelines, and vessels (or
by filling them with water) before hot work is preformed, and by using carbon dioxide fire exting-
uishers to displace oxygen away from a fire. Fire water forms steam, which also displaces oxygen.
12.2 Fire Classes

Class A:
Fires occur with ordinary not limited ORDINARY
to, wood, tires, coal, cloth, and paper.
The most commonly used
extinguishing agent is water, which
cools and quenches. Special dry
A
chemicals that provide a rapid knock- COMBUSTIBLES
down of the flame and form a fire-

retardant coating that prevents reflash
are also used.
Class B:
Fires occur in the vapor-air mixture FLAMMABLE
over the surface of flammable and
combustible liquids such as, but not
limited to, greases, gasoline, hydraulic
oil, diesel fuel, and lubricating oils.
Materials providing a smothering or
BLIQUIDS
combustion-inhibiting affect, such as
dry chemicals, foam, carbon dioxide,
and water fog are typically used.

Class C:
ELECTRICAL
Fires occur in electrical equipment
where nonconducting extinguishing
agents must be used. Dry chemicals,
carbon dioxide, and halons are
C
suitable. However, carbon dioxide EQUIPMENT
extinguishers are not recommended
for use outdoors because of dilution
by the wind. Foam and water conduct
electricity and shall not be used to
combat an electrical fire.
Class D:
COMBUSTIBLE
Fires occur in metals only, involving
combustible metals: magnesium,
sodium (spills and in depth),
potassium, sodium-potassium alloys, D
uranium and powdered aluminum.
METALS
Class K:
Fires involving cooking oil and grease. These fire
extinguishers are usually located at the kitchen.
12.3 Fire Suppression Equipment
12.3.1 Fire Protection Equipment
Fire extinguishing equipment shall be conspicuously
located and readily accessible. Employees shall be aware
of the location of fire extinguishing equipment.
Employees who are expected to extinguish fires shall be
trained in the use of available, applicable fire
extinguishing equipment.
Unless otherwise trained and authorized, employees
shall not attempt to extinguish any fire other than
incipient stage fires.
12.3.2 Inspection and Maintenance of Fixed Fire
Extinguishing Systems
Water spray, sprinkler, halon, CO2, dry chemical, and
foam systems shall be inspected and tested as required
by the manufacturer's or Chevron's instructions,

whichever specifies the shortest time period between
inspections. For further information, refer to CPL's
HES Procedures Manual, Fire Fighting Equipment
Inspection, HES-302.
12.3.3 Portable Fire Extinguishers
Portable fire extinguishers are Hand-Held Portable Fire Extinguisher
to be used for extinguishing Dry Chemical
Cartridge Type
incipient stage fires only. Cap Puncturing
lever
Incipient stage fires are fires in
early stages of development CO2 cartridge
Carrying handle
that, in the judgment of the
Siphon tube Dry chemical
employee, can be extinguished agent
(cutaway view)
with portable equipment.
Hand-held extinguishers shall be mounted on hangers
or placed in an enclosure (cabinet) at a height required
by applicable regulations to protect the bottom of the
extinguishers from corrosion.
Extinguishers shall have the manufacturer's name plate
and UL label permanently attached. Fire extinguishers
shall be marked with one of the following labels, or
combinations such as ABC.
Because of potential environmental damage,
Chevron is no longer providing new halon fire
extinguishers. Existing halon extinguishers should not
be recharged after use or should be taken out of service
and the halon removed by a qualified vendor when they
are due to have a 12-year hydrostatic test.
A discharged fire extinguisher shall be replaced
immediately with a fully charged unit.
Inspection and maintenance of portable fire
extinguishing equipment:
• A monthly visual inspection and annual
maintenance shall be performed.
• A record of monthly inspections and annual
maintenance shall be attached to each unit.

• Extinguishers showing evidence of corrosion or
physical damage shall be removed from service
and replaced.
• An extinguisher removed from the premises to be
serviced shall be replaced immediately by a spare
extinguisher.
• Extinguishers shall be recharged by qualified
persons after use or as indicated by an inspection.
12.3.4 Wheeled Fire Extinguishers
Wheeled Extinguisher
Cylinder valve Discharge tube
Nitrogen cylinder
Operating valve
Dry chemical
Nozzle
Hose
Gas tube
( cutaway view)
12.3.5 Fire Water Systems

• Fire equipment shall be used for fire protection and
training only. Fire hoses shall not be used as washdown
equipment.
• Hose wrenches and nozzles shall be maintained and
stored near the hose reels.
• Fire water pumps shall be operated at least once a week,
and the operation shall be documented.
• Fire hoses, nozzles, and reels shall be examined at least
once a month for proper operation and condition.
• Hoses shall be dried and returned to the proper
location after being used or tested.

• Hose connections shall be kept greased and protective
caps tightened only enough to protect the threads.
• Fire hydrants and monitors shall be periodically
operated and inspected.

13.0 Occupational Health
13.1Work Environment Hazards

• Some potentially dangerous operations can be detected
by visual observations, however, many operations
require monitoring to determine if a potential hazard is
present. Air monitoring for solvent or benzene vapors,
or area monitoring for noise or naturally occurring
radioactive materials (NORM) levels requires
instrumentation to detect and verify whether or not
conditions or activities are potentially hazardous.
Principle means of employee contact are:
• inhalation (breathing)
• ingestion (swallowing)
• absorption through the skin
• contact with the skin
• a combination of the above routes
• The safe use of potentially dangerous substances or
chemicals is the responsibility of everyone associated
with the workplace. Engineering controls, work
practices, protective equipment, and procedures are
designed to provide for the safe use of otherwise
potentially hazardous substances or chemicals.
Employees shall always follow safe work procedures and
use appropriate personal protective equipment (PPE).
• Sometimes it is feasible to reduce potential IH hazards
through the application of control techniques such as
modifying work practices, substituting a different
material, increasing ventilation, and requiring the use
of personal protective equipment (PPE) discussed in
Section 3, Personal Protective Equipment.

13.1.1 Chemical
§ Gases - General
Some gases encountered in company work sites may be
harmful when inhaled. The following pages list general
characteristics and effects of some of the more
common ones. Before handling any of these substances,
however, make sure you consult the appropriate MSDS
for more information.
§ Hydrogen Sulfide (H2S)
Hydrogen sulfide (H2S) is a colorless, flammable and
highly toxic gas. In low concentrations, it smells like
rotten eggs. Do not rely on this odor, however, because
your sense of smell is deadened after breathing the gas.
H2S may be encountered in vessels, tanks, lines,
compressors, pumps, flares and sewers. It is produced
in toxic concentrations along with crude oil, water, and
gas in certain producing fields.
Activities in suspected areas that may lead to exposure
include, but are not limited to, gauging tanks, repairing
leaks, working in confined spaces, or cleaning and
repairing tanks and vessels. H2S is flammable and
produces toxic sulfur dioxide when burned.
Exposure may cause unconsciousness and death.
Remove workers exposed to H2S from the
contaminated area immediately, but first protect
yourself with an appropriate supplied-air breathing
device. Have a third person stand by. If the exposed
victim is not breathing, begin artificial respiration and
call for help immediately.
Where H2S is encountered or suspected initially in a
field, measurements shall be made to determine
concentrations and potential exposure levels. Various
types of monitoring equipment are available to
determine the presence of H2S. These include hand
pumps with detector tubes, direct reading portable
monitors, fixed monitor/alarm systems, and personal
monitor/alarm systems. In addition, your local Safety

specialist shall be notified so appropriate protective
measures can be implemented.
Hydrogen Sulfide
Concentration (ppm) Potential Effect
10 to 20 Eye irritation, especially in hypersensitive workers
20 to 100 Inflammation, corneal blistering and opacity of the eye, loss of

the sense of smell, headache, cough, nausea
100 to 300 Respiratory difficulty, pulmonary edema, respiratory depression

and irritation (within 30 minutes to 8 hours)
300 to 600 Central and peripheral nervous system effects; e.g., tremors,
weakness, numbness of extremities, unconsciousness, and
convulsions (within several minutes to 8 hours)
600 to 1000 Rapid unconsciousness (from one breath to several minutes)
resulting in death if emergency aid is not promptly administered
1000 and greater Instantaneous cessation of breathing and death
Note! Effects described at a specific concentration usually occur with increasing severity at higher concentrations.
Some facilities (for example, certain tank batteries),

and work areas require the use of respiratory protection
equipment. Employees who may be exposed to H2S
shall wear respiratory protection equipment as
required, including, but not limited to, gauging tanks
and repairing line leaks. Suitable respiratory protection
includes SCBAs and full-face airline respirators with 5-
minute egress bottles.
Employees shall not work in an H2S area without first
receiving training on potential hazards associated with
H2S, in the use of respiratory protection, emergency
response, and first aid. This training shall be done at
least annually or as each individual job requires.
§ Carbon Monoxide (CO)
This gas is odorless and without warning properties.
Prolonged exposure can cause death. A by-product of
combustion, CO is always present in the exhaust of
internal combustion engines. Be careful to prevent
exposure to carbon monoxide when working in
confined spaces around furnaces, kilns, or wherever
flue gases or engine exhausts are not fully ventilated.

§ Carbon Dioxide (CO2)
Carbon dioxide is a colorless, odorless, non-flammable
gas. Carbon dioxide is present in the breath we exhale
and, in small concentrations, the normal air we breathe.
A small increase in the air's CO2 percentage will
increase the rate of breathing. In high concentrations,
CO2 can paralyze the respiratory system and cause
asphyxiation. Carbon dioxide is widely used in its
liquid or solid (dry ice) form as a chilling agent. It also
is used throughout the company to displace air in
vessels or lines filled with substances that create a fire
or explosion hazard when mixed with oxygen Carbon
dioxide is heavier than air and will remain in vessels
that are opened only at the top. If CO2 escapes into the
atmosphere, it tends to gather in low spots.
§ Inert Gas
Carbon dioxide (CO2) and nitrogen (N2) are used as
“inert gas,” either separately or as a mixture. If you
must enter an area of inert gas, you must wear a
supplied-air-breathing apparatus (SCBA).
§ Ammonia(NH3)
Ammonia is a colorless gas with a sharp, irritating odor.
It is readily soluble in water. Ammonia is very irritating
to the respiratory system and to the skin. Although the
irritating odor usually drives people to fresh air before
serious injury occurs, exposure to the vapor can cause
death, often by constricting the throat or lung muscles.
Use a supplied-air-breathing device when working
around normal concentrations of ammonia; high
concentrations also require the use of a special suit to
protect the rest of your body from burns.
§ Benzene
Benzene is a colorless liquid with a sweet odor. It
evaporates into the air very quickly and dissolves
slightly in water. It is highly flammable and as a
petroleum product, inherent in the numerous
products that we transport.

Prolonged contact with benzene and benzene-
containing compounds causes defatting of the skin.
Acute exposures by inhalation cause narcotic effects,
including headache, giddiness, vertigo, and confusion.
Chronic exposure has been shown to cause leukemia in
animals and is a suspected human carcinogen.
Employees should follow safe work practices and limit
skin contact with hydrocarbon materials by using
appropriate personal protective equipment (PPE).
Respiratory protection may be required for tasks
having exposures to benzene-containing materials.
Consult your local Safety Specialist for additional
information.
§ Chlorine (Cl2)
Chlorine is a clear amber liquid that rapidly evaporates
to a greenish yellow gas when exposed to the
atmosphere. Its action is primarily one of irritation to
the skin, mucous membranes, and respiratory system. It
has an irritating, choking odor. Avoid all contact with
the liquid or the vapor. Wear impervious protective
clothing, gloves and a supplied-air-breathing device if
there's a chance of being exposed to this chemical.
Wear eye protection, too. Excessive concentrations of
chlorine may cause injury to the eyes. If chlorine is
inhaled, limit physical activity until you've received
medical attention.
§ Petroleum Gases
All hydrocarbon vapors are flammable and may form
explosive mixtures with air. Light paraffinic
hydrocarbons - such as propane, butane, etc. - are
intoxicating in light concentrations, and may cause
suffocation in heavy concentrations. Aromatic
hydrocarbons - such as benzene, cumene, toluene,
xylene, etc. - are toxic. Avoid breathing any
hydrocarbon vapors.

Other Potential Exposures
§ NORM (Naturally Occurring Radioactive Materials)
Naturally Occurring Radioactive Materials (NORM)
are natural materials which spontaneously emit
ionizing radiation. NORM may be found in the scale
that forms on equipment such as separators, pumps,
heater treaters, filter housings, pipes, tubing and tanks.
In oil and gas production operations, NORM may be
generally considered to be confined to radium 226 and
radium 228 and selected members of these isotopes'
progeny.
Potential exposures to NORM occur when dismantling
and repairing oil production equipment that has been
in service for extended periods of time. For more
information, please contact your local Safety Specialist.
§ Lead
Lead is a metallic element that may exist in an organic
or inorganic form. It is widely used in its inorganic
form in paints, babbit metal, and soldering materials.
Employee exposure to lead comes from working with
lead coated painted surfaces and during burning,
welding or surface grinding to remove coatings. Sand
blasting and manual demolition of structures also
present exposure concerns.
Employees involved in maintenance, construction,
repair, renovation, demolition, and disposal of lead-
coated materials should be aware and trained in the
hazards associated with lead.
A competent person shall be assigned to oversee
activities involving lead.
§ Mercury
Mercury is a heavy, silver-white, highly toxic metallic
element. It is normally a liquid at room temperature.

Mercury can be found in all types of equipment and
instrumentation including:
• flow controllers
• gravitometers having mercury compensators
• instrument maintenance
• laboratories
• measurement shops
• mercury-filled manometers
• mercury-type orifice meters
• thermometers
• warehouses where mercury and mercury
instruments were stored
Metallic mercury is toxic to the human body even in
very small amounts. It may be absorbed by ingestion,
through the skin, and most commonly by the
inhalation of mercury vapor. Skin contact with
mercury shall be avoided. Inhalation of mercury vapors
shall be avoided.
Food or drink shall not be kept or consumed in an area
where mercury is handled.
After handling mercury, employees shall wash their
hands thoroughly before eating or smoking, and at the
end of each job or tour. Smoking is prohibited while
handling mercury.
Impervious gloves shall be used when handling
mercury. Contaminated clothing shall be immediately
removed and properly disposed of. Mercury shall be
stored in air-tight containers. Contaminated rags,
paper, gloves, etc. shall be disposed of properly. They
shall not be discarded in, or be collected and stored
inside of, a work room or the passenger area of boats
and vehicles.
Mercury, mercury-containing instruments, tools, and
other items that may have come in contact with

mercury shall not be transported in the same
compartment as passengers or the operator of a vehicle
or boat.
The workplace where mercury is used shall be well
ventilated. Work involving mercury shall always be
positioned between the worker and an exhaust
ventilation system.
Floors, counters, and other surfaces shall be kept free of
dust and grease.
Mercury spills shall be reported immediately to your
team leader.
Mercury shall not be allowed to come into contact with
ammonia or its vapors. The mixture forms a
compound that is shock sensitive and can cause fires if
it contacts combustible materials.
Mercury shall not be allowed to come into contact with
aluminum equipment because mercury dissolves
aluminum.
§ Acids and Caustics
Acids and caustics are usually handled in a liquid form.
Both cause corrosive burns upon contact with the skin.
Inhalation of acid mist or vapor may cause
pneumonia-like symptoms, including coughing,
congestion, etc.
Avoid skin contact with all acids and caustics. At a
minimum, splash goggles and gloves should be worn
when handling these products.
§ PCBs (Polychlorinated Biphenyls)
PCBs are toxic to humans by all routes of exposure
(that is, inhalation, skin absorption, and ingestion).
PCBs can cause skin disorders and irritation to the
eyes, ears, nose, and throat. In addition, adverse
reproductive and carcinogenic effects may occur.

Some transformers and capacitors may contain
electrical fluids or oil contaminated with PCBs. Contact
your local Safety Specialist for the guidelines to be
followed for proper handling and disposal.
A warning label shall be applied in a readily visible
location on PCB containing equipment. In the event of
a PCB spill, personal protective equipment (PPE) shall
be worn to control skin contact. Records of the
equipment containing PCBs shall be maintained.
Contact your local HES representative for further
information.
13.1.2 Physical
Some physical agents, such as noise and heat, may be
detected by the senses; others, such as radiation, cannot
be detected.
Excessive heat can be dangerous. If you must work in
such an environment, dress appropriately and drink
plenty of fluids.
13.1.3 Dusts
Dusts are small particles of solid matter that have been
dispersed into the air. They can enter the body via the
respiratory system. Some dusts have a rapid effect on
the body, others, such as asbestos and silica, may not
result in damaging effects until years later. Protect
yourself against these agents by using proper protective
equipment.
§ Asbestos
Asbestos is a fibrous mineral that has excellent thermal
insulating properties. In the past, it was widely used as
an insulation and building material. However, it has
been found that asbestos can cause several serious
health effects. Asbestos substitutes are now required for
new construction.

Employees should be aware that asbestos may still exist
in Chevron facilities. The practice is to remove
deteriorated (friable) asbestos insulation that presents a
potential exposure hazard to personnel. Additionally,
asbestos insulation that is removed to perform
maintenance functions shall be replaced with substitute
insulation materials.
Employees involved in maintenance, construction,
repair, renovation, demolition, salvage, or disposal
activities, or otherwise handling asbestos-containing
materials, shall be trained in proper removal techniques
and instructions consistent with their activities.
Where asbestos is used in such items as gaskets, packing
glands, and pipe coatings, strict care and precautions
shall be taken to prevent the generation of airborne
fibers that occur through cutting, tearing, grinding, or
otherwise handling the materials in a way that changes
the integrity of the material.
13.2 Monitoring Exposures
Employees may be asked to participate in industrial
hygiene monitoring to verify their work activity is free
from recognized health related hazards. Either
employees or their work area may be monitored.
Employees who are monitored are generally asked to
wear a small instrument while they either perform a
task or work an entire shift. In either case,
Chevron Pipe Line notifies the employee of the
personal exposure results, including an interpretation
of the results and what further action, if any, may be
required.
Employees who are selected to participate in
monitoring shall assist by:
• reporting unusual events, i.e., spills
• reporting malfunction of the monitoring device

• not tampering with the monitoring device by
shutting off or directly exposing the instrument
to contaminants.
Hazards which are routinely monitored include: noise,
benzene, total hydrocarbons, and hydrogen sulfide.
13.3 Bloodborne Pathogens
Persons trained in first aid/CPR shall also be trained in
avoiding exposure to bloodborne pathogens. Universal
precautions shall be taken when there is the possibility
of being exposed to certain types of body fluids from
other people.
First aid kits/body fluid barrier packs are available for
those providing first aid. These packs include, but are
not limited to, CPR mouth barriers, disposable latex
gloves, and face and eye protection.
Chevron shall provide proper means of disposal for
materials that are considered regulated medical
wastes (biohazards). Bags or containers marked with
the biohazard symbol shall be handled by designated
employees only.
• BIOHAZARD
Employees who have occupational
exposure to bloodborne pathogens
shall be offered Hepatitis B
vaccinations. Please contact your Safety
Specialist if you think you may have
had an occupational exposure to
bloodborne pathogens.

14.0 Environment
Personnel shall:
• Exercise all necessary care to protect and preserve the
environment, including flora, fauna and other natural
resources or assets at any location where work is
performed.
• Minimize and mitigate unavoidable impacts to the local
environment.
• Protect fossils and antiquities found at job sites from
damage or disturbance.
• Report the location to your team leader and cease
work at that location pending further instructions.
14.1Waste Management
14.1.1 Hazardous
In general terms, hazardous wastes are materials that
exhibit qualities that are potentially harmful to humans
and/or the environment, and that are the remainder or
by-products of production operations. They include
materials and mixtures of materials that are toxic,
corrosive, flammable, explosive, and carcinogenic.
Some materials require special training to handle,
package and ship. Oily rags and other contaminated
materials, which may not specifically be classified as
hazardous waste may require special handling. Specific
regulations and procedures also must be followed when
handling and disposing of wastes. Failure to do so can
result in criminal penalties.
For more information on the handling, recycling or
disposals of hazardous materials or wastes contact your
team leader or your waste specialist.

14.2 Regulations
14.2.1 Clean Air Act
This act regulates:
• emissions of pollutants into the atmosphere,
including hydrocarbon vapors
• emissions by treatment technology, unless air
quality requires stricter limits
14.2.2 Clean Water Act
This act regulates:
• discharge of wastewater to receiving waters and
publicly owned treatment works
• discharges by treatment technology, unless water
quality requires stricter limits
14.2.3 Resource Conservation and Recovery Act
(RCRA)
This act regulates:
• generation, manifesting, transportation, storage,
treatment and disposal of hazardous solid wastes
• storage of fuels in underground tanks
14.2.4 Comprehensive Environmental Response,
Compensation and Liability Act (CERCLA)
This act regulates:
• cleanup of leaking landfills
• reporting spills of certain chemicals
• responsibility and liability for contaminated
disposal cleanup
14.2.5 Superfund Amendment and Reauthorization
Act (SARA Title III)
This act regulates:
• emergency response plans

• right-to-know issues
• chemical release reporting
14.2.6 Occupational Safety and Health Act (OSHA)
This act regulates:
• employee right-to-know
• responsibility for keeping work area free of
recognized hazards
• specific procedures for job and industry safety
14.2.7 Toxic Substances Control Act (TSCA)
This act regulates:
• commercial use of most chemicals
• use and disposal of asbestos, PCBs, and CFCs
• reporting of all adverse health effects
• use, labeling, and documentation for chemicals
that pose a risk to health or the environment
The Toxic Substances Control Act (TSCA) requires
prompt reporting of any information reasonably
supporting the conclusion that a chemical substance
presents a substantial risk to human health or the
environment.
The law requires you to report any incident that you
believe fits the description of possibly causing
significant damage to human health or the
environment. Information that should be reported to
the company includes the following:
• an illness or death associated with the use of
company products or related to chemicals used at
a work location
• a pattern of illness occurring among employees or
customers

• results of laboratory experiments and tests which
indicate potential adverse health or environmental
effects may occur
• spills or widespread contamination of chemicals
not covered by other reporting regulations
14.2.8 Hazardous Materials Transportation Act
This act regulates:
• hazardous materials transported in commerce
• activities associated with identifying and
classifying hazardous material; marking, labeling,
placarding and packaging the material, and
documentation of the material
• loading, unloading and incidental storage of
hazardous material
• reporting of unintentional releases; injury or death
to a person; and property damage exceeding
$50,000.
14.2.9 Safe Drinking Water Act
This act regulates:
• enforceable quality procedures for drinking water

Appendix
A. Glossary
Job Safety Analysis (JSA)
A Job Safety Analysis (JSA) is a hazard assessment used to
identify potential hazards associated with a job.
Pre-Startup Review
Equipment shall be constructed, installed, and operated in
accordance with company procedures and applicable local,
state and federal codes and regulations. Ensure new and
existing facilities are safe and ready for operations prior to
startup after design changes, facility construction, or
recommissioning of a facility are completed.
Disciplinary action, including discharge, will be taken for
disregard or violation of safety instructions/safe practices.
Job Site Safety Plan (JSSP)
Job Site Safety Plan addresses safety and health hazards,
including requirements for employee protection. A JSSP is
required whenever there is a need for Emergency Response
clean-up operations. This plan applies to all personnel,
company and contractor, working in or on Chevron Pipe
Line Company owned or operated facilities. The plan must
remain on site and is maintained by the company inspector
or project manager.
ASAP
As soon as possible

B. References
Chevron’s Policy 530 – HES
http://governance.chevrontexaco.com/policies/hes/530_hes.htm
Operational Excellence (OE) Management System
http://cpln-www1.ct/corphes/oehome.nsf
Contractor Safety Management (CSM)
http://cpl.chevron.com/cms/index.htm
CPL Tenets Principles
http://cpl.chevron.com/operationalexcellence/index.htm
CPL HES Procedures
http://www-CPL.chevrontexaco.net/manuals/cplhesgp/index.htm
Occupational Safety and Health Administration
http://www.osha.gov/
National Institute for Occupational Safety and Health
http://www.cdc.gov/niosh/
American Conference of Governmental Industrial Hygienists
http://www.acgih.org/

C. Safe Work Checklist
SAFE WORK PERMIT - HES 204

PROFIT CENTER:
FIELD TEAM: DATE:
REVIEWER: FACILITY:
QUESTION YES NO COMMENTS

1 Is the permit posted?
2 Are all affected persons
aware of the work?
3 Does the permit adequately
describe what work is permitted?
4 Does the permit adequately show
the hazards of work permitted?
5 Is the identified PPE adequate
to protect against the hazards?
6 Are gas testing results
recorded,if required? The work
area may have any one of the
following:
Oxygen deficient or enriched
atmosphere
Flammable gas or vapor
Toxic vapors, Carbon monoxide,
Benzene, and Carbon dioxide
7 Have permit extensions been
granted? Initialed and dated?
8 Are all the required signatures
on the permit? Dates and times?
9 Is the work you observed adequ-
ately covered by the permit?
10 Are the permitted restrictions
and conditions being followed?

D. Excavations Checklist
EXCAVATIONS - HES 202

PROFIT CENTER:
FIELD TEAM: DATE:
REVIEWER: FACILITY:

11 Has the Permit been posted?
12 Has the competent person daily
excavation inspection form been
completed?
13 Approved signatures on the
Permit and inspection form?
14 Competent person on site?
15 Attendant (standby) person on

site?
16 Are Permit restrictions being

followed?
17 Are authorized entrants listed

on Permit?
18 Are protective systems

adequate?
19 Excavation in excess of 20 feet
in depth (If so, shall be
designed by a registered
professional designer)?
20 Has the regional one call been
properly notified prior to
excavation activity? Ticket
number?
21 Are there additional hazards
identified, that are not posted
on the Permit?

E. Confined Space Checklist
CONFINED SPACE ENTRY - HES 201

PROFIT CENTER:
FIELD TEAM: DATE:
REVIEWER: FACILITY:

22 Has the Permit been posted?
23 Are Permit Restrictions being
followed?
24 Has periodic testing been
performed?
25 Are signs posted (”Danger-
Permit Required Confined Space,
Do Not Enter”)if Permit
required confined space?
26 Are approved signatures on
the Permit?
27 Has the evaluation been
completed?
28 Attendance posted near the
entry, if Permit required
confined space?
29 Emergency action plan complete,
if Permit required confined
space?
on Permit?
31 Are there additional hazards

identified, that are not posted
on the Permit?

F. LOTO Checklist
LOCKOUT/TAGOUT - HES 203

PROFIT CENTER:
FIELD TEAM: DATE:
REVIEWER: FACILITY:

32 Approved equipment specific
procedure available?
33 Has a deviation been requested
if applicable?
34 All affected employees

notified?
35 Authorized employee conducting
lockout/tagout process?
36 Equipment prepared for

shutdown?
37 Equipment properly shutdown?
38 Was equipment isolated (operate,

can not start)?
39 Lockout/tagout devices
applied?
40 Sketch of equipment or system

being isolated available?
41 Are there additional energy

sources hazards identified
that are not noted on the
procedure?

G. Hot Work Permit
HOT WORK PERMIT - HES 205

PROFIT CENTER:
FIELD TEAM: DATE:
REVIEWER: FACILITY:

42 Is the Hot Work Permit posted?
43 Is a Safe Work Permit completed

and posted? (Pre-requisite)
44 Is the Permit marked for Open
Flame or Non-Open Flame?
45 Are the Authorized activities
specified?
46 Have the Initial Atmospheric
monitoring results been
documented and signed by a
qualified Gas tester on the
Hot Work Permit?
47 Has the frequency of testing
been specified? (Results for
subsequent testing should be on
Safe Work Permit).
on Permit?
49 Are the Permit restrictions
being followed?
50 Is required fire suppression
and safety equipment on site
and readily available?
51 If a Fire Watch is required,

have the persons been
identified on the Permit?
52 If required, has the Fire
Watch’s training been verified?
53 Are all the required signatures

on the Permit? Dates and times?
54 Have Permit extensions been
granted? Initialed and dated?
55 Does the Hot Work Permit

specify the type of hot work
to be performed and limit the
location of this hot work?

Pipe Line Company
P. O. Box 430
Bellaire, TX 77402-0430

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Pipe Line Company

Revised February 2008

Emergency Hotline (877) 863-5196 This number is

Ambulance, Police or 911

CPL Security Issues CPL Security Advisor

In Case of a Motor Call your supervisor first or the

This handbook contains confidential and proprietary

The Safe Practices Handbook was written by the

Publication is available on alternative media at:

Safe Practices Handbook Acknowledgment

This Safe Practices Handbook has been prepared with your

If you have any questions about the meaning or intent of

After you read, understand and agree to follow the

I have read, understood, and agree to abide by the health,

Name (Print): ___________________________________

CAI / ID number / Company name: _________________

Comments: If you have any suggestions for updates or

It is the intent of Chevron Pipe Line Company (CPL) to read

To this end, all levels of the organization are responsible for

2.0 General Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.0 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . 14

4.0 Common Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

i Chevron Pipe Line Company

Safe Practices Handbook – 2008 ii

iii Chevron Pipe Line Company

6.0 Pipeline Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Safe Practices Handbook – 2008 iv

7.0 Transportation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

v Chevron Pipe Line Company

8.0 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

9.0 Office Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Safe Practices Handbook – 2008 vi

10.0 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

11.0 First Aid and CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

vii Chevron Pipe Line Company

13.0 Occupational Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

14.0 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Safe Practices Handbook – 2008 viii

ix Chevron Pipe Line Company

Chevron Pipe Line Company (CPL) is committed to the

This Handbook has been given to you to:

The information contained here applies to all personnel and

Stop Work Authority

Chevron Pipe Line Company

Safe Practices Handbook – 2008 1

We believe all incidents are preventable.

✔ Do it safely or not at all

1. Operate within design or environmental limits.

3. Ensure safety devices are in place and functioning.

4. Follow safe work practices and procedures.

5. Meet or exceed customers' requirements.

6. Maintain integrity of dedicated systems.

7. Comply with all applicable rules and regulations.

8. Address abnormal conditions.

9. Follow written procedures for high risk or unusual

2 Chevron Pipe Line Company

Accidents can and must be prevented.

✓ Shutdown Authorization: In cases of imminent

4 Chevron Pipe Line Company

Safe Practices Handbook – 2008 5

6 Chevron Pipe Line Company

Safe Practices Handbook – 2008 7

• Report to your team leader