BASIC SAFETY DEFINITIONS

Safety

Freedom from unacceptable risk of harm.

Safety are the measurements that we do to protect our self, others and to avoid the loss
of property.
Fire
Fire is the chain reaction of three things Fuel, Heat and Oxygen. These three things combine
to a certain job proportion it will cause fire.
Hazard
A situation with potential to cause harm or danger is called hazard.
Risk
Risk is the chance of something happening (event/situation) that has the potential to cause
harm to person/company/society.
Attitude: it is a person’s point of view or the way to look at something to act or react to give him
readiness.
Work Permit
Work permit is a written Document authorizing a Person or a group to perform an identified
work subject to specific conditions and precautions. (It specifies job activity, hazards and precaution
to perform job safely).
Confined Space
A place having limited or restricted means for entry or exit, where toxic gasses can collect,
and which is not designated to continually occupy for the employees. For example Tank, Boiler,
vessels, pits, sumps and Excavation 4 feet (1.2meter) deep or deeper.
Incident
Anything which could have cause of accident called incident.
Near Miss:
These are any form of accident which could result in injury or loss but do not.
Accident
Unplanned and undesired occurrences resulting from unsafe acts and conditions which may
cause personal injury, Damage to property or loss of output or all three called accident.
Types of accident:
Fatality, lost time injury, lost work day case, restricted work day case, near miss accident,
medical treatment case, first aid accident.
Tag Line
It is used to control the load for any lifting proposal.
ROW
It is clearing made along with pipeline to have access.
PPE
(PPE) personal protective equipment’s are used to wear to protect workers from the
exposure to occupational hazard. It is considered as the last line of defense.
Environment
A surrounding in which a person lives called environment as water, land and air. It is
everyone’s responsibility to help protect the clean environment.
Emergency
Sudden juncture demanding immediate action called emergency.
Steam blowing
Steam blowing is a procedure to clean oil, grease, rust, metal sparks and other particulates
from pipe line left during erection or maintenance. We use temporary silencer (water spray) to
reduce noise. Normally 450centigrade temperature is used for this purpose.
Kinds of pipe cleaning: Air blowing, steam blowing, chemical cleaning, Hydro jetting, water
flushing, nitrogen purging.

Chemical cleaning steps:

A: First water flushing to remove all dust sand welding slugs etc.
B: Sodium nitrate is used to clean all welding sparks and shine of pipe.
C: Citric acid and water in third step
D: last step is ammonia blow to clean moisture etc.
After steam blowing nitrogen is used so that remaining water shall transform into vapors
and come out through bleeders. In fact nitrogen chills pipes. And no entry shall be allowed on
bleeders.
Isolation
Before start work (maintenance) it’s a procedure to isolate the equipment from all harmful
energy sources to bring it at zero energy state so that mistakenly startup of equipment or release of
stored energy may not result injury or loss. Breakers, switches, valves, double blocks, bleeders,
blinds and other devices are used.
Isolation with double block and bleed valves also considered as positive isolation, at restoration first
bleed valve shall be closed so that the material shall not be bleed out.
Lock out and tag out:
After Isolation it’s a procedure to lock out and tag out the isolation points of equipment to
prevent unplanned and undesired startup of the equipment or release of any stored energy which
can result injury or loss. Locks, Pad lock, locking pins, chains retainers and other hardware devices
are used for this purpose.

Kinds of Blinds
Spectacle blind Slip blind Flange blind
JSA
JSA is a document describing job activity, its hazards and steps to reduce hazards. It is prepared by
maintenance department.
Risk assessment:
It is carried out before starting high risk activity. It is an informative document describing about four
what’s (1) what can go wrong? (2) What can cause it going wrong? (3) What can be happen if hazard
release? (4) What can we do to prevent it for going wrong?
Method statement:
It is a documentation through that contractor shall inform the client about the methods that
how he will perform the job safely.
Kinds of work permit
Confined space entry (2) hot work permit (3) cold work permit (4) gas release
Scaffolding Tags:
We use three types of tags for scaffolding
(1) Green: It means that scaffolding is safe for use
(2) Yellow: Scaffolding is not safe or full body harness is required.
(3) Red: Only scaffold erectors can climb or in erection process.
Safety standards:
OSHA: Occupational Safety and Health Administration.
HSE: Health Safety Environment.
MSDS: Material Safety Data Sheet.
ANSI: American National Standard Institute.
SMS: Safe Method State.
SHEMS: Safety Health Environmental Management Standards
CANAPE:
Net used to protect the workers from falling objects.
Safe work plan: shall be submitted to client one day before starting a job. Field supervisor shall
conduct tool box talk based on safe work plan.

General short questions:

(Q) What is difference between bar and Psi?
(Ans) 14.3 Psi is equal to one bar?
(Q) What is difference between boiler and heat exchanger?
(Ans) Boiler prepares steam which is used to run different equipment as generators,
engines or turbines and pipe cleaning etc. And heat exchanger transforms heat into cooling
or cooling in to heat. It is thermal energy.
(Q) What is DBA?
(Ans) It is frequency of noise at which we use ear protection.85dba ear plug.
(Q) ELCB?
(Ans) earth leakage circuit breaker.
(Q) RCCB?
(Ans) Residual current circuit breakers
(Q) RPE?
(Ans) Respiratory Purifying Equipment
(Q) HYPO?
(Ans) It is insulation test of cables; we give more voltage than its capacity.
(Q) What is the length of body harness?
(Ans) lanyard 1.8+ shock absorber 0.7mtr=2.5mtr normally. And it is hooked at least 18 feet
above from the ground. It is capable to bear 2300kg (5000 lbs. 22.2 kilo newton’s) load and
without shock absorber if a 100kg man falls, it shall fall with the force of 2000kg. Shock
absorber reduces this force not greater than 600kg. Body harness shock absorber require
more than 200kg force for unzipping. For fall arrest we use these things as body harness,
guard rail, life line and safety net (mesh).
In temporary fall arrest system, and anchor should be 5000lbs or two time the maximum
arrest force.
(Q) What is the maximum capacity of load that refers to riggers levels
(Ans) Less than 20 ton lift by level 3 - rigger, less than 40 by level 2 and level 1 rigger can
perform all types of lifts
(Q) Which device we use for light measuring?
(Ans) Lux meter
(Q) Which device we use for wind measuring?
(Ans) Anemometer
(Q) How much distance should be from fire to fire extinguisher?
(Ans) 12 feet (pass method shall be use P pull out the pin A aim at fire S squeeze the
handle S spray side by side)
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(Q) What is RFSU?
(Ans) Ready For Start Up

(Q) What is PSSR?

(Ans) It is Pre-start up safety review, (before starting safety is reviewed).
(Q) What is PSV
(R) Pressure relief safety valve
(S) What is PHA?
(Ans) It is Process hazard analyses. (During the process of product safety audit and
observation are taken to analyze the hazards.
(Q) What is catastrophic?
(Ans) Anything which can cause great devastation is called catastrophic.
(Q) What is IDLH?
(Ans) IDLH immediate danger to life or health or an environment where life or health
threating hazard exist called IDLH. Concentration of toxic gases beyond permissible
exposure limit called IDLH. They can have irreversible adverse health hazard which
shall lead to asphyxia resulting brain ham ridge cause death example H2S, carbon
mono oxide, and nitrogen and oxygen deficiency.
H2S beyond 100 ppm
Carbon mono oxide 1200 PPM
Oxygen less than 19.5% 16% are considered IDLH environment
LEL 10 or above
Unknown environment (A place where it is not possible to evaluate the
environment)
Nitrogen above from 8100 ppm
Carbon di oxide above from 50000
(Q) What are the jobs need approvals to perform?
(Ans) IDLH, Excavation work, Electrical isolation work, Deviation work

(Q) what is inert gas

(Ans) An inert gas is a gas which shall not undergo chemical reaction under a set of certain
condition these gases are also called noble gases. Example argon, helium, nitrogen.
Nitrogen removes oxygen where there it exists, this is the reason that we use
nitrogen for purging. Why we do purging reason is that chemical or substance
existing in the place may have reaction with oxygen so we use nitrogen to remove
oxygen to prevent fire hazard.
(Q) What is catalyst?
(Ans) a substance that increases the rate of a chemical reaction without itself undergoing
any permanent chemical change.
(Q) What is pyrophoric material
Pyrophoric material are called auto ignite able material they have a flash
point below 55clc, when they are exposed to air they start reaction with oxygen and
produce heat so far the heat increases and reached at the level of plash point of that
substance it will catch fire. Example iron sulfide, uranium and plutonium
(Q) What is isotopic material?
(Ans) isotropic material means a material having identical values of a property in all
directions. Glass and metals are examples of isotropic materials.
 (Q) Combustible % LEL: (lower explosive limit)
(Ans) Minimum concentration of combustible gases or vapors in air, below which they
can’t catch fire on contact with ignition source.

(Q) PEL
(Ans) Permissible exposure limit (Acceptable limit of atmosphere as H2S less than 10ppm is
acceptable.

(Q) Which part of body is affected by electric?

(Ans) Heart, brain, lungs and muscles

(Q) If somebody is caught by electric what will u do then?

(Ans) electric power supply shall be disconnected through circuit breaker or main switch or
any other way if possible, Otherwise wooden piece or non-conducting thing shall be used to
pull the victim from cable. After pulling he shall be kept in wet sand. Water shall not be
given to him for drink. CPR shall be given for breath restoration.
(Q) How much barricading for high voltage testing?
(Ans) 300 volts 3 feet, 50kv 10 feet and above each KV 4 inches and for 250kv 7mtrs
normally

(Q) What is GFCI?

(Ans) Ground Fault Circuit Interrupter (it is not required less than 24 volts because human
hand have 15 volts resistance.
(Q) What is Hydro jetting pressure?
(Ans) It is cleaning of rust from the metal, 10000, 20000 to 40000 PSI in (PK 36000 pounds
were using).
(Q) What is STA?
(Ans) Safety Task Assessment
(Q) What are the kinds of life line?
(Ans) Two kind’s vertical horizontal
(Q) What is the gas tester speed to test some gas?
(Ans) Analyzer, sniffer or gas tester sampling time is .5 second/feet.
(Q) After how much time gas testing shall be in the confined space if hot work in
progress and why?
(Ans) Gas testing should after every hour or continually should be monitor if hot work in
progress in the confined space. Because fire use oxygen to burn
(Q) What are the kinds of accident?
(Ans) Fatality, lost time injury last work day case restricted work day case
near miss incident
(Q) which equipment is used additional with SCBA in the confined space
(Ans) SCOT PACK (SCBA alarm shall sound before 10 minutes of oxygen ending).
(Q) What is the requirement of excavation required entry attendant or to call it
confined space?
(Ans) 1.2mtr deep or deeper
(Q) What are lifting hazards?
(Ans) Unbalanced load over loading crane may fail slings can break
load can struck with worker, structure, building or live lines Obstacle
against boom radios
(Q) What is the validity of crane third party sticker?
(Ans) One year
(Q) What is TUV? Or what is third party?
(Ans) It is Technician’s uberwashung version. These are specialized in competency level
testing and certification to person or equipment.
(Q) What are the requirements to check portable compressor?
(Ans) Whip lash arrestor coupling should be in good position hoses shall be in good
order earthing barricading
(Q) What is berm?
(Ans) Pipelines are covered with sand and MC1 (Micro compound) is sprayed on that flat
strip it is called berm in safety.
(Q) Which warning tape is used for Commissioning?
(Ans) Red and Black
(Q) Which warning tape is used in pre-commissioning?
(Ans) Blue and white is used.
(Q) for Potential hazard
(Ans) Red and white
(Q) for little hazard (warning)
(Ans) Yellow and black, it is caution tape that you can pass if there is no hazard with your
own observation.
(Q) What are the hazards of pipe line work?
(Ans) presence of toxic gases, presence of chemical, acid or other material, electrocution
hazard, oxygen deficient environment, suffocation, high heat etc.

Slings load calculation: Length /height X weight/number of slings

6/4x2000kg=3000/2=1500

(Q) What will you check during scaffolding inspection?

(Ans) Foundation, posts, Runners and bearers, Tubing and coupling, Planks and plate
form, Guardrail and toe boards, Stability and Access.
(Q) What are the hazards of scaffolding?
(Ans) Collapse of scaffold, fall hazard fall of material or fall of person, over loading,
contact with electric line can cause electrocution hazard, unstable foundation (sole
board),insufficient fitting, substandard material, psychological problem.
(Q) What is written on the scaffolding tag?
(Ans) Area location inspection date scaffold erector name and signature
Requested by Scaffolding capacity and type
(Q) What is safe management?
Asset integrity Leader Ship accountability Risk assessment
Training orientations off the job safety awareness dealing with contractor
safe operation Communication Emergency preparedness
Incident reporting and investigation
(Q) How far fire extinguisher should be from welding machine?
(Ans) One meter
(Q) For fire safety which devices we use?
(Ans) Fire extinguisher, fire blanket, fire hose, smoke detector and fire hydrant are used.
(Q) What is NFPA?
(Ans) National Fire Protection Association
 (Q) What are the methods to extinguish fire?

(Ans) Cooling: is the process of depriving the fire from heat (use of water to reduce the
heat
Smothering: this method is to deprive the fire of oxygen supply
Starvation: this method is to remove or eliminate fuel
(Q) What are the classed of fire?
(Ans) Class A fires consist of ordinary combustibles such as wood, paper, fabric, and most kinds of
trash
Class B: These are the fires whose fuel is flammable material such as petrol diesel,
thinner grease etc.
Class C: Electrical fires are fires involving potentially
energized electrical equipment’s.
Class D: Fires consist of combustible metals such as
Magnesium, potassium, titanium, sodium and zirconium
Class K: Fires involve unsaturated cooking oils in well-insulated cooking appliances
located in commercial kitchens
Class E: Flammable gasses or burning gasses as natural gas, LPG etc. According to the
US system these are designated as "Class E"; but the Australian system designates
them "Class C".
(Q) What is risk hierarchy control?

(Ans)

Fire Safety measures

Fire is the chain reaction of three things fuel, heat and oxygen. These three things
combine to a certain proportion it will be fire.
Awareness should be given to employs about fire safety.

General: Flammable and combustible materials shall be kept to minimum at site.

Ignition: sources shall be kept away from flammable and combustible material materials
such as
Hot plates Electrical cords that are damaged Asphalt cattle’s
Welding, Cutting, Grinding, Brazing, use of open flames, burning, use of power
tools (heat gun, drilling )
 Flammable liquids give off fumes they have a flash point below 37.8 centigrade, so
ground all dispensing drums to the main supply and bond the receiver to the drum. Use
approved cables and clumps to bond the receiver with drum.
Label all containers as to content.
Flammable shall not be poured within 50 feet of ignition sources.
Flammable material should be 50 and combustible materials should be 35 feet away from
welding, cutting brazing.
While refueling engine shall be kept off.
Metal solvent safety cans shall have FM or UL label.
Transportation shall be in closed metal containers plastic is prohibited.
Storage of flammables shall be in well ventilated areas.
Diesel engine shall be operated only in well ventilated areas.
Mobile phones shall not be allowed inside of the plants.
Cigarettes shall be smoked only in smoking area which should be designed at a place free
of hazards.

HAZARDS OF FIRE:
Inhalation of toxic fumes produced by combustion
Suffocation due to smoke
Lack of visibility due to smoke
Burns due to heat or flame
Suffocation due to lack of oxygen
Collapse of building

Combustible Liquids:
Combustible liquids also give off fume; they have a flash point at or above 54c. So
Separate flammable from combustible materials. Bulk storage should be 50 feet away
from ignition sources, buildings and plants.

CRANE SAFETY MEASURES

 All permits shall be obtained (Vehicle entry + road permit + Hot work permit +lifting
permit)
 Crane shall bear valid inspection sticker. (Third party) if expiry or removed crane shall
not be allowed to operate.
 Operator shall have both Saudi Arabian Government crane operating license and third
party certification.
 Rigger shall also be third party certified.
 Preoperational check list shall be checked if any deficiency report immediately to
supervisor for corrective action.
 Load chart and range diagram shall be displayed in every crane cabin.
 Lifting plan.
 Tag line to control the load.
 If the object load is unknown use load cell, LMI or weighing scale.
 Outriggers shall be fully extended for the stability of crane.
  Crane shall be earthed
 Tire shall be off from the ground. (2inches)
 Float pad shall be used.
 Work shall be stopped if wind velocity is 32km/hr. (9 MT. /second) or follow load chart to
reduce according to the manufacturer’s specification.
 Crane shall be leveled as per bubble level 1%.
 Crane boom shall be kept away 20 feet from 250000v power lines and more than 250000v
it shall be kept 25 feet. For this purpose goal post shall be used 25feet down from power
lines and 50mtr away both sides of power lines.
 Crane shall be kept twice times the depth of excavation.
 All crane accidents and incidents shall be immediately reported to the Loss Prevention
department.
 Accident scene shall not be disturbed until loss prevention agreement.
TRAVEL OF CRANE:
Requires removal of jibs, boom shall be fully lowered and retracted swing lock
engaged and hook block secured.
RIGGING:
Rigging includes all attachments attached to the load and all devices attached to the crane
hook.
Wire rope slings and chain slings shall bear a permanent manufacturer label showing
capacity (SWL) in metric tons
Manufactures name and trade mark
Serial number by manufacturer
Chain Slings shall also show their steel grade.
Synthetic web sling and fiber rope slings shall bear a durable label showing
Capacity in metric tons for straight pull, basket hitch and chocker hitch.
Date sling was manufactured
What are critical lifts?
Around energized electrical line, on barges, vessels, long range, multiple lifts (two cranes lift one
object), tailing lift ( two cranes lift one object one from top and other from tail as vessel, column),
Rubber pick, man basket, high level , near or over hydrocarbon pressurized pipelines,

Kinds of crane:

Mobile cranes
All truck mounted cranes
Crawling crane
Floating cranes
Side boom cranes

Fixed cranes
Tower crane
Gantry crane
Deck crane
Self-erecting crane
Overhead crane
Type of boom:
Hydraulic boom or telescopic boom
Lattice boom

Lifting plan: Object wait, Boom angle, length and jibs length, Crane type &capacity, crane
location, area number, contractor name, crane inspection sticker, date and time.

Rigger: Shall inspect the slings and all rigging equipment. He shall use universal hand signal to
give direction to the crane operator or shall use radio.
Riggers have three classes: A class above (40tons) B class (40tons) C class (20tons)
Lifting requirements: Third party inspection sticker, lifting plan, lifting permit, weather condition,
JSA, certified operator and license of Saudi Arabian Government, Certified rigger,
All Cranes shall have fire extinguisher, back up alarm, emergency shut off switch, seat belt and
revolving lights.

Scaffolding

Scaffolding is a temporary elevated work plate form.

Components:

(a) Planks (boards (b) Bearers (Transom)

(c) Longitudinal bracing (Facade) (d) Transverse (sectional) bracing
(e) Top rail (f) mid rail
(g) Toe board (h) Post (standard)
(i) Runners (lagers) (j) Base plate
(k) Sole board (sill sole board) (l) Self closing drop bar
(m) Base lift (kicker lift) (n) False upright (puncheon)
(o) Coupler (p) Intermediate Bearer

Kinds of scaffolding:
1. Base supported (Tower scaffolding)
2. Tube and coupler scaffolding
3. System scaffolding
4. Tower scaffolding
5. Birdcage scaffolding
6. Mobile scaffolding
7. Bracket scaffolding (around tank column)
8. Under hung scaffolding

Erection:
 Work permit (cold work permit).
 Erection plan shall be submitted to loss prevention for all scaffolding above 40feet
(12.2meters) high.
 Tube and coupler scaffolding 125feet high shall be designed by a competent
engineer.
  Surface shall be compacted or solid enough to bear the load.
 Planks shall be cleated, overlapped or secured to prevent slipping or tripping.
 Planks shall not be painted, cut or cracked.
 Planks shall not be nailed with each other.
 Planks shall not be split more than 1 inch and if more than it and less than 12
inches it shall be banded with metal.
 Planks shall be extended at least 6 to12 inches beyond the end frame.
 Floor shall be fully planked, if gap, less than 1 inch.
 Scaffolding shall be erected 14 inches away from the facing of building or structure.
 Top rail shall be (39)/38 to 45 inches high from toe board and should be capable to
bear 200 lbs. side force.
 Mid rail should be in between the top rail and toe board and shall be capable to
bear 150lbs side force.
 Toe board shall be at least 4 inches high one inch thick wood (metal 4mm) and
capable to support 50 lbs. side force.
 Overlap planks 12 inches but over the support.
 Bay width for heavy duty 3feet.
 For medium duty 1.5 meters (4.6feet).
 For light duty 6.2 feet (2meters).
 Base plate thickens 4mm and 6x6 inches.
 Sole board thickness 1.5 inches and 9inches wide and spam at least two posts.
 Post standard radius 1.90inches.
 Tie scaffolding at least more than the four times of base width or at every 7.9
meter (26feet) vertically height and 9.1meter (30feet) horizontally distance but at
least once in each direction.
 Ladder shall be 3 feet high from landing point.
 Rest platform every 20 to 30 feet.
 When vertical height increases 100feet 2means of exit and when horizontal
distance increase 50 feet at least two means of entry shall be provided.
 Ladders should be 75 or ¼ angle.
 Scaffolding shall be erected 1.5 times away from the depth of excavation.
 And ten feet from live lines. Base lift or first lift height should be 6 feet high.
 Light duty scaffolding is capable to support one man and 20kg per square meter.
 Medium duty scaffolding is capable to support two men and 40kg per square
meter.
 1.8 meter high scaffolding requires sufficient guard rail system and body harness.
TUBE-AND-COUPLER SCAFFOLD SPECIFICATIONS 2. a)
What is the maximum specified height for a tube-and-coupler scaffold? 45m
(b) What is the maximum bay width for a light duty independent scaffold? 2.4m (or planks)
(c) What is the maximum bay length for a light duty independent scaffold? 3m
(d) What is the minimum bay width for a medium duty independent scaffold? 950mm (or 4
planks)
(e) What is the maximum bay length for a medium duty independent scaffold? 2.4m
(d) What is the maximum bay width for a heavy duty independent scaffold? 1.275m (or 5
planks)
(e) What is the maximum bay length for a heavy duty independent scaffold? 1.8m
(h) What is the maximum bay length for a single-pole scaffold? 1.8m
(i) What is the maximum lift height for a normal independent scaffold? 2m
  Mobile scaffolding:

Mobile scaffolding:
 Height shall not exceed four times of base dimension.(above 12 mtr or more than
four times of base dimension it shall be considered engineering scaffolding)
 Nobody shall ride mobile scaffolding.
 Caster and wheel brakes shall be chocked.
 Out riggers shall be deployed before use.
Couplers:
 A component which is used to join scaffolding two tubes together.

Kinds of couplers:
Right angle coupler, right angle double coupler
End to end coupler adjustable coupler (swivel)
Girder coupler put log coupler
 Right angle coupler is used to connect two tubes at right angle.
 End to end coupler is used for externally joining two scaffolding tubes co-axially
end to end.

 Adjustable coupler (swivel) is used for connecting two tubes together at an angle
other than 90.
 Girder coupler is used for connecting a scaffolding tube to a steel wide flange
beam. It shall be used in pairs.
 Put log (bearer) coupler is used for connecting bearer with runner.

Gas welding/Arc welding and cutting and brazing

Safety Measures:
 Work permit (hot work permit) before commencement of work
 All welding operators shall be qualified to operate the welding equipment.
 Personal protective equipment shall be worn by all employee (helmet gloves safety glass
(goggles) long sleeves or leather apron).
 Area (35feet SABIC and 50feet ARAMCO) shall be cleaned from combustible and
flammable materials.
 Cover all doors panels, sewers and man holes within 50 feet of operation area.
 Barricade with warning sign
 Wet the area and keep running water supply on.
 Erect welding curtains (fire blanket) to stop welding sparks.
 Fire watch shall be assigned.
 Fire extinguisher shall be provided within 10 feet of operational area and their access shall
be easy and clear.
Arc welding:
 Arc welding machine shall be grounded to the main supply.
 Ground the work piece to the main supply (welding machine).
 Provide GFCI to the arc welding machine auxiliary outlets if power tools needs to be use.
  Electric shall not exceed 125 volts AC.
 Electrode shall be removed from the holder if it is left un-attendant.
 Welding cables shall have no splice.
 Welding machine shall be shut off while refueling.
 Airline respirators are required if fume hazards cannot remove by ventilation.
 Confined space work requires force ventilation (air mover).
 Metal container to put welding rods rubbish or sparks.

 Welding rods shall be kept in containers which keep them hot.

 Arc welding lens shade 10 to 14 according to exposure.
 Torch cutting 3 to 6.
 Gas welding 4 to 8.

Gas welding:
 Store cylinders in the upright position, especially acetylene. Acetylene is dissolved with
acetone in an acetylene cylinder. When acetylene cylinder is stored in its side, it may
separate from acetone and become unstable and cause an internal explosion.
 Acetylene regulator pressure shall not exceed 15Psi (acetylene can explode above 15Psi).
 Separate oxygen cylinders from fuel (acetylene) cylinders 20feet away or with fire proof
5feet high wall.
 Separate empty cylinders and mark as Mt.
 Cylinder storage shall be well ventilated and under sunshades.
 Secure cylinders with wire, rope or chain to prevent fall over.
 Oil, grease or any hydrocarbon shall not be used in any oxygen cylinder fitting or system.
 Copper or silver shall not be used in any system acetylene.
 Flash back flame arresters shall be used for torches and hoses.
 Color code hoses as oxygen or fuel.
 Torches shall be constructed of brass or bronze or stainless steel and have FM or UL label.
 Valve caps shall be in place when cylinder not in use.
 Color of oxygen green\
 Acetylene yellow
 Organ silver
 Lighter or matchbox shall not be used to light the hoses.
 Sop water shall be used for leakage checking.

HOT work activities:

• Cutting with the aid of a torch.
• Burning
• Grinding & Buffing
• Drilling
• Power-actuated tools (e.g. Red head nail driver guns)
• Abrasive blasting operations.
• Use of portable gas or electric space heater
• Use of internal combustion engines.
• Electrical equipment not listed e.g. battery powered diagnostic equipment, sample pumps.
 • Chipping/breaking concrete.
• Opening explosion proof equipment in enclosure in classified area.
• Use of any open flame.
• Use of power tools.

PRESSURE TESTING:
 Notify inspection department, loss prevention and company representative before
preparing for the test (Hydrostatic, pneumatic and leakage etc.).
 Written approved procedure shall be obtained 2days before the test with high potential
hazards and pressure test diagram shall be kept at site.
 Work permit shall be obtained.
 Isolation and lock out and tagging out the equipment.
 Access shall be controlled by barricading sign boards. (For 10bar 3mtr and for 15bars 4mtr
and 20bar 5mtr barricading is procedure.
 Test personal shall remain at a safe place from which to view and control the test.
 Safety glass, ear protection, helmet foot protection and face shield shall be worn by test
personal.
 Emergency equipment (fire extinguisher) shall be readily available.
 Calibrated and tested relief valves shall be installed to protect the system.
 Pressure gauges calibrated and tested with (double) block and bleed valves shall be
installed on the system.
 Vent air prior to the test from system.
 A relief valve shall be provided on the test system.
 Only authorized person shall enter in the area.
 Safety watch shall be assigned on the entry and exit point.

Equation to calculate the required area for barricade for hydro test
 0.15 x D x A x 0.4 x P x 0.6

D= Diameter A= Length / DiameterP= test pressure

Hazards of pressure test.

 Equipment may fail / injury (line burst)
 Spill or leak of chemicals/ burns to skin contaminate environment.
 Equipment or fitting may fail. (Valve or nut bolts breakage).
 Water not drained / “water hammering” jumping lines. (Pig is used for water hammering).
 Heat high noise.
 Possible pressure- burns /eye injury/ fire/ gas leakage.
 Electric shock.
 Flying parts of failing equipment.

NFPA - Diamond Label

 Red for fire
Blue for health
Yellow for reactivity
White for special hazards
Red:
(4) Below 73F
(3) Below 100F
(2) Below200F
(1) Above200F
(0) will not burn
Blue:
(4) Deadly
(3) Extreme danger
(2) Hazardous
(1) Slightly hazardous
(0)Normal material

Yellow:
(4) May detonate
(3) Shock or heat may detonate
(2) Violent change chemical
(1) Unstable if heated
(0) Stable
White:
Oxidizer Oxy
Acid ACD
Alkali ALK
Corrosive COR
Use no water
Radiation hazard

CHEMICALS HANDLING

 International hazard identification label shall be affix with every chemical container,
drum, carboy bottles and boxes showing fire, health, reactivity and special hazards.
 Chemical containers shall have label showing specific content and strength percentage.
 All chemicals shall have MSDS and copy shall be given to company representative.
 Don’t store incompatible chemicals, follow the MSDS.
 Chemical handling requires face shield, gloves, protective clothing, footwear and SCBA.
 Eye and face wash facilities shall be provided where hazard exist.
 Limit stored hazardous chemicals supplies in the work areas to one day.
 Contractor shall ensure that chemical storage is reviewed by loss prevention.
 Appropriate type of fire extinguishers shall be available.
 Don’t smell or detect chemicals by breathing.
  Storage shall be kept to minimum and shall not be on tables or high places.
 Storage shall be well ventilated
 Don’t chew or smoke near chemicals.

Housekeeping:

Good housekeeping means not only cleaning or sweeping, it also means to keep things in their
right order.
 Housekeeping shall be priority.
 Collect debris refuse and trash daily.
 Use covered containers for refuse.
 Bend down nails in boards.
 Keep walking aisles, road ways clear.
 Storage yards should be orderly.
 Proponent approved lay down yards should be at least 50feet away from buildings.
 Fire protection shall be provided.
 A sturdy grounded perimeter fence, with fire engine access gates shall enclose the area.
Hazards of bad housekeeping:
Slipping, tripping, material loss, damage of equipment, accident, incident,

Sanitary welfare facilities:

 Keep eating areas clean.
 Employs shall take their lunch and breaks in designated areas which shall be free of
hazardous environment.
 After break all trash debris and food refuse shall be collected.
 Consumption of food shall be under sunshade and ventilated area.
 Provide one toilet for every 15 workers.
 Toilets shall have proper ventilation and tissue and shall be kept clean when necessary to
provide good sanitation.
 Hand wash facility shall be available as water, soap or hand wash and trash container and
tissue.
 Provide drinking water and separate cup for every worker.
 Water container shall be cleaned on daily basis.
 Individual assigned for this task shall wash their hands with good soap and use disposable
rubber gloves.
 Containers shall be rinsed off outside before open. Containers shall be washed with
detergent, dish wash, hot water and sponge or scrub.
 Containers shall be rinsed in a solution of 2 tablespoon of chlorine bleach in one gallon of
water.

First Aid
Every contractor shall provide first aid facilities for his employs.
 A first aid cabinet shall be on each job site.
 Cabinet shall be stocked at all the times.
  Cabinet shall be equipped with basic first aid facilities.
1. A sink with running water.
2. Soap and towel/paper towels.
3. Drinking water.(disposable cup)
4. Clean garments for first aid.
5. Pillow, blanket, proper cleaning of room, stretcher, portable oxygen, sterile
water, and bandage.
 A dedicated vehicle (ambulance) to transport the injured person to contractor’s
medical facility.
 Remote sites shall have one vehicle with a first aid kit for each crew. And vehicle
placarded to alert the workers of the first aid kit.
 Post emergency numbers of doctors at each site.
 At least one man at every remote site shall be trained in first aid.
 When more than 50 employs work inside a radius of 15km there shall be a nurse
and first aid kit.
 Safety officers shall be trained in CPR.
 All major or minor accidents or incidents shall be immediately reported to client.

WORK PERMIT:

Work permit is a written document authorizing a person or group to perform an identified

job subject to specific condition and precautions.
Cold work permit receiver shift can be extended
Hot issuer shift not extend able
Confined space entry issuer shift can be extended
Vehicle entry issuer shift can be extended

Additional permits are Gas release, IDLH, Excavation work, Electrical isolation work, Deviation
work
All permits are cancelled during plant emergencies.
If job is abandoned for more than one issuer shift, the permit becomes invalid and a new
permit must be attained.

Permit Issuer is a person authorized by his department supervision, trained on Sipchem

procedure and certified by safety department.

Issuer responsibility:
 Must have clear understanding of the job acquiring permit.
 He shall prepare all necessary permit for safe execution of work
 He shall fill all the section of the permit.
 Clear understanding about scope before filling up the permit.
 Preparing and planning for safe execution of work
 Confirm preparation of equipment (Check that all controls have locked and tagged in the
off position) and area.
 Isolation and gas testing.
 Communicate all effected personnel
  Communicate all special hazards, precautions and emergency procedure with the
permit receiver.
 Ensure that permit receiver communication all permit requirement with the group
working under the permit
 Periodic inspection of the area until completion of job (every two hours)
 If condition change cancel the permit and communicate with the receiver
 Ensure all safety gears required to complete the job are available at site
 Issuer shall sign the work permit.
 After completing the job inspect the equipment and the area

Permit Receiver is a person who is performing the job, must be authorized by his
department supervision, trained on Sipchem procedure and certified by safety
department.

Receiver responsibilities:
 State the correct job going to perform
 Take the correct permit for the job
 Discuss all the hazards and precautions with the issuer
 Review the permit after fill up by the issuer
 Ensure all isolation points have been isolated and equipment is in its zero energy
state
 Check all locks in the off service position and put his tags
 Communicate all permit requirement (emergency procedure hazards and
precautions) with the crew members working under the permit
 Keep the permit at site at a visible place
 Stop work and communicate with issuer if condition s change to take new permit
according to new job condition

CONFIED SPACE:
A place having limited or restricted means of entry and exit, where toxic gasses can be
collect and which is not designed to continually occupy for the employs as tanks, boilers, vessels,
columns, pits sumps and excavations 1.2meter deep or deeper.
Safety measures:
Preparation of confined space:

 Work permit.
 Confined space shall be isolated with double block and bleed valves, blinding and setting
locks and holding tags. All electric circuits shall be disconnected by switches and breakers
and setting locks and holding tags.
  Place shall be decontaminated by purging (cleaning or washing) with steam or water to
remove hazardous substances or gases.
 Heat stress shall be reduced.
 Ventilation if not adequate force ventilation (air mover).But during gas test it shall be kept
off.
 Gas test to verify oxygen19.5/23.5persent, H2S should be less than 10PPM, carbon mono
oxide should be less than 35PPM and combustible (explosive) gas) should be 0.0 percent.
 Once the equipment has been properly isolated, the equipment must be verified to be
decontaminated and in zero energy state by opening bleeders to depressurize energy and
trying to start the equipment for electrical energy isolation, etc.
 If zero energy state cannot be verified, then effective barriers like thermal blankets,
chemical splash suits, barricades etc. must be used and documented on the permit for
each affected work group.
 NOTE: Proper PPE may be required to verify that the equipment is in a controlled energy
state.

Operation:
 Work permit confined space entry and other according to job and it shall be placed
near the job on visible place.
 Awareness shall be given to all employs about job activity and employs should be
trained to perform the job.
 Airline respirators shall be required if hazardous atmosphere exist.
 Trained entry attendant shall be provided with log book.
 Full body harness shall be provided if vertical arise increase 6feet.
 An exit ladder at every 25feet shall be fixed at an angle 75/ ¼
 Power tools shall be grounded.
 If hot work in progress gas test shall be continually monitor.
 Fire extinguisher shall be provided.
 Electric shall not exceed 24volts for lightning and for other purpose 110volts AC.
 Gas cylinder shall not be kept inside of confined space.
 Lightning shall be explosion proof.
 Barriers and sign boards on the exposed sides of confined space.
 Only authorized person shall enter.
 Non spark able tools (brass hammer) or pneumatic tools shall be used if fire hazard
exist as.

Responsibilities of entry attendant:

 He shall note the employs that who is inside the confined space or coming out of it.
He shall stay in front of the hole. If there is no body in the confined space he shall
put sign board (no entry) on the hole of confined space. And in case of emergency
entry attendant shall call ERT team (or shout help, help).He shall not enter in the
confined space. He shall have communication with the employs which are in the
confined space time and time.

Restoration of confined space:

 Work permit shall be used as check list as all personal are out of the space.
 All equipment and tools have removed.
 All man holes and flanges have closed and sealed.
 All tags and locks removed and all isolation points restored (blinds removed).
  All relief valves have been restored to operate normal operating condition.
 All electrical circuits and breakers have become in their normal position
Hazards of confined space:
 Oxygen deficiency or oxygen enriches.
 Presence of toxic gases
 Extreme temperature.
 High noise.
 Poor visibility.
 Psychological factor.
 Electric shock.
 Contents of pipe lines and supply lines.
 Lock out may fail.
 Horse play may cause accident.
 Explosive, combustible gases or flammable gases can cause hazard.

Electricity

 Work permit (hot work permit)

 Qualified electrician (2)
 Non conducted tools
 Rubber gloves
 Floor mats
 CPR qualified person
 Barriers and warning signs
 Flammable and combustible material shall be removed from the area.
 All temporary connections shall have prior approval by the company representative.
 Contractor shall provide a competent person to review all temporary installation for
electrical safety and shall remain at site during the hot work to supervise.
 Only qualified person shall make electrical connection.
 GFCI for all portable electrical tools.
 Electric supply shall not exceed 125 volts AC.
 Only FM, UL having cords shall be use.
 Remove electrical cords that are damaged.
 Shop made electrical cords shall not be allowed.
 Qualified electricians shall work.
 Over head or underground power lines shall be de-energized or rerouted, but this shall be
done by company representative approval.
 Electricians shall not use ring, wrist watch or chains.
 Blown fuse shall be removed by approved fuse pullers.
 Fire extinguishers dry chemicals

Electrical power tools portable

 Electric power tools shall have GFCI.
 Safety glasses shall be worn during use.
 Shall have a 3 wire ground cord and 3 prong ground plugs.
 Electric supply shall not exceed 125v AC.
 Cords shall have no splice or cut.
 Cords shall have FM UL label.
 No job made cords are allowed.
 All portable electric tools shall have dead man switch or trigger locking button.
 Any power tool designed with guard shall be equipped with that guard.
 Hand saws shall have guard that can be adjusted so that only exposed part of the blade can
cut.

Sand blasting

 Prepare an HIP and obtain loss prevention and industrial hygiene review and concurrence.
 Sand blasting workers shall have chest X-Ray and pulmonary function test and attach with
the HIP.
 Work permit shall be obtained.
 Hearing protection shall be worn by sand blasters.
 Each abrasive blast cleaning operator shall have breathing air hood.
 Air compressor shall meat,
Pressure relief valve,
Periodic carbon mono oxide monitor and alarm,
High temperature alarm,
Oxygen 19.5/23.5 percent
 Each incidental worker shall wear cartridge style respirator.
 Paper masks are not allowed.
 Bond all sand blasting components with the compressor and compressor with the
permanent ground.
 Barricade, warning sign shall surround the area.
 Sand blasting wand shall have dead man switch.
 Sand blaster and the workers assigned to dispose blasted sand shall wear disposable
clothes.

Driver’s responsibilities

 Inspect the vehicle to verify its condition.

 Report any accident or damage to management immediately.
 Obey traffic rules and post speed limits.
 Open truck beds shall not be used to transport passengers.
 Seat belts shall be worn by drivers and all passengers in cars, trucks and other vehicles as
required.
 The drivers shall not allow the passengers to ride in the vehicle unless they fasten their
seat belts.
 Except busses where seat belt is mandated only for the drivers.
 Man basket
 Man basket must be inspected and shall have inspection sticker by crane inspection
department.
 It shall have sticker showing maximum number of employees and safe load capacity of the
basket.
 Before using it shall be hoisted above the ground to check that it is well planked and
secured.
 Lifting and lowering speed shall not exceed 30meters per minute.
 Workers shall not to enter or exit during lifting or lowering and keep their body inside the
man basket.
 Good communication between the hoisted person and crane operator or signal man.
 Area shall be barricaded.
 Man basket lift shall not be operated at wind speed 25 kilometers.

EXCAVATION

It is digging the land by machine or man.

 A qualified person shall design the excavation knowing underground utilities (pipe lines
for water, oil and cables for electric or communication).
 Digging supervisor shall obtain proper drawing of the area to be excavated.
 Work permit.
 Excavation checklist shall be checked on daily bases.
 Area shall be barricaded and warning signs shall be posted.
 He shall provide a safe mean of entry or egress at every 25 feet at the angle75degree and
ladder shall be 3 feet high from the ground.
 He shall check that proper shoring, sloping or benching is done when depth increases
more than 1.8meters.
 For lose sand C 34
 Clay, sand and stone B 45
 Clay, cohesive and stone A 53
 Stable rock 90
 Shoring trench boxes shall be design by a competent person.
 Ground loading from structure, vibration, weather and overlay shall be considered in the
shoring design.
 Keep shoring trench boxes unoccupied during installation and traveling.
 Brace against the movement.
 Extend trench shield box to the ground.
 All excavated soil shall be at least 2feet away from the edge of excavation.
 Crane shall be more than the depth of excavation.
 Barricading shall be 1.5mtrs away from the edge of excavation.
 Mechanical equipment shall be 2.0mtrs away from excavation.
 Emergency equipment as full body harness, life line, respiratory system shall be available.

Underground utilities: shall have 6inches sand, warning tape, net (mesh) and after buried mc
1and catholic protection.
 Responsibilities of safety officer/supervisor

 Inspect the site daily.

 Conduct and participate in toolbox talks.
 Conduct safety orientation classes for all new employs.
 Establish and communicate safety rules and standards to all employs and contractors.
 Prepare and Collect observation reports daily and raise them in the safety meeting with
contractor.
 Coordinate with safety manager to implement safety procedure.
 Ensure that sub-contractors are following up the clients work permit procedure.
 Inspect the workers, tools and equipment at the job site to ensure that proper safety
procedure is as per the client’s requirement.
 Conduct safety meetings with subcontractor.
 Investigate injuries, spills and other incidents and promptly provide corrective actions.
 Assist the manager to organize weekly site inspection tour and safety meeting.
 Assist the manager in clerical works.
 Keep the record of all safety meetings, reports findings, accident and heavy equipment
accidents and fires.
 Interact with company representative on health and safety issues.
 Prepare and conduct safety trainings to coach all employs.

H2S (HYDROGEN SULPHIDE)

 Colorless gas and highly flammable and transparent.
 It is heavier than other gasses.
 Never try to detect H2S by breathing.
 Its fire is colorless.
 On hearing an H2S alarm personal shall immediately leave the area.
 Walk cross-wind direction.
 It should be less than 10PPM in the air.
 SCBA or airline respiratory system require where it is 100PPM in the air.
 Personal shall not be allowed to enter.
 Its smell is like rotten eggs.
 Hazards: eye irritation, pulmonary function disturbs dizziness, unconsciousness and
death.
 When above 10PPM H2S is detected, warning sings shall be establish and immediately
leave the area.
 Walk cross-wind direction on hearing an alarm but if u are working in some area where
possibility of gas release then move upwind direction.

Half face and full face mask respiratory purifying equipment require
  Sanitary and clean conditions all the time.
 Users medically fit,
 Trained users.
 Users fit tested for proper seal of face to rubber to keep out contamination, no hair
interferes.
 Oxygen 19.5/23.5.
 Choose specific filter cartridge for the identified hazard.
 No substitutes are allowed.
 Common filter cartridges are: Asbestos fiber and airborne, sand blast dust cartridge for
blasted sand that blows over incidental area, radio nuclides, chemical fumes and mists
metal fumes and metal dust cartridges.
 Paper or dust masks are only allowed for dust storm or pollen.
Supply airline respirators are used for specific hazardous operations,
 They shall be tested for grade D breathing air standard.
 Air source shall deliver 6 SCFM continuous for each man.
 Example: sand blasting air hood, spray painting, power sanding and welding.
Compressors supplying airline respirator shall be tested for grade D air quality.
 Have filters in the delivery air hose to continually remove moisture, oil and other
particulates.
 Have carbon monoxide (co) monitor and alarm between the oil lubricated compressor and
respirator air intake.
 Have 100F (38centigrade) high temperature alarm on the air intake of air hood.
 Have 140F (60centigrade) high temperature alarm on the air intake of airline respirator.
 Have minimum air flow 6 SCFM without vortex tube and 25 SCFM with vortex tube.
SCBA: users shall be medically fit. It is use for entry and work in hazardous atmospheres. As
 Confined space entry.
 Firefighting.
 Rescue and escape from hazardous atmosphere.
 Testing of gasses but toxic

Cartridge operated tools:

These devices normally use a 0.25 or0.27 caliber cartridge as the driving force for fastener.
Therefore they shall be treated like a fire arm. User shall be qualified and certified. Certificate
shall be obtained by an authorized vendor. Work permit for restricted areas. Safety glasses and
face shield shall be used by operators. Hearing protection shall be worn. Ares shall be barricaded
and warning signs should be erected. Area shall be clean from unauthorized persons.

Hot Tapping: Hot work permit with design and drawing review. No wilding on pressurized
lines with zero flow rates. Hot tap machine shall be rated greater than the maximum operating
pressure of the line. No welding on lines containing greater than 19.5 percent oxygen.

Grinder safety:
Electric supply shall not exceed 110volts
GFCI is required for electric safety
Flammable combustible material shall be removed
Fire blanket shall be provided
Fire extinguisher shall be provided
Cutting disk shall be used for cutting and grinding disk for grinding purpose no
alternate disk shall be used.
Disk rpm should match with grinder also disk size shall not be increased after
modification of disk guard
Disk guard shall be ok no modification is allowed
Inspection of physical condition of grinder and color coding shall be inspected
Grinder operator shall wear face shield as additional PPE