MAT

1.1

Give a brief explanation of the Oil & GAS Industry

MAT
1.2

List at least four Mechanical Equipment used in the plant, their

criticality and importance. Identify & Explain Related Tag Nos.

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Instrument Air Compressor Provides utility air required mainly for the
instrumentation controls for the pneumatic signals.
Separator Vessel that separates the crude and gas
Pump Pumps the fluid or media to increase certain pressure
Gas Turbine - Its an engine or prime mover which is coupled to Pump. E.g. - WIP
EDG Emergency Diesel Generator
EFWP Electrical fire water pump
DFWP Diesel fire water pump
1

Jo

UNIT NUMBER
230
235
238
239
240
245
248
250
260
270
280/285/295/351
290
221
222
223

UNIT NUMBER DESCRIPTION

Gathering Station
Separation (OIL, GAS, WATER)
Flares
Water clarification
Pumping
Compression (Export Fuel, Gas)
Cooling (Export, Fuel, Gas)
Power Plant
Water Injection Plan
Structure
Accommodation
Common / Utilities
Northern Satellite
Southern Satellite
Western Satellite
Main Equipment Number
The main Equipment is numbered as
follows :
XXX X - XXX

Number
Code

Sequential
Main Equipment

A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T

Main Equipment Code

Air cooler
Package
Column
Diesel Engine
Exchanger
Filter
Generator (Electrical)
Heater
Ejector
Compressor
Piping
Motor (Electrical)
Fire and safety equipment
Pump
Insulation and Paint
Mechanical handing
Storage tank
Turbine

U Utilities
V Vessels
W Accommodation module
X Mixer
Y Temporary Facilities
Z Instruments.

Unit number
Example :
260P003A WATER INJECTION PUMP
P- PUMP
260B008A DRESSER 'A' PACKAGE UNIT
B- PACKAGE

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MAT
1.3

Jo

Give an example of cleaning procedures for equipment (externals &

internals) while under maintenance.
List the cleaning aids, tools and PPE used.

Cleaning Procedure

INTERNAL CLEANING PROCEDURE

HAZARDS IDENTIFIED

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Pyrophoric Iron.
Asphyxia.
Fluid back up.
Passing valves.
Electrical Hazard.
Hydrocarbon spill (Environment
Pollution).
Glycol spill.
Chemicals (Biocide, Corrosion Inhibitor,
Industrial cleaner).
Sludge.
H2S (Flare Header), Inert Gas media.
Equipment contamination (Confined
Space Entry).
Hose connections/disconnections.
Static electricity while using Fire Water
hoses.
Personnel working in confined area.
Open Sewer / Drains / Gutters.
Escape route.
Lighting inside.

HSE MEASURES TAKEN RESPECTIVELY

Wetting the surface with water.

Use fresh air line mask.
Use non-return valves on connections.
Positive isolation by spading.
Power isolation to equipment.
Ensure proper close draining / venting.
Containers available for draining.
Follow MSDS, use PPE.
Proper handling & disposal, use PPE.
Use fresh air line mask, Carry H2S
detector.
O2 test prior to entry/monitoring.
Fitting with depressurizing facility.
Proper earthing.
Personnel with fresh air mask, safety
belt / harness & lifeline. Fire watch
stand-by for rescue operation.
Sealed off.
Must be provided with proper
scaffolding and ladders.
Adequate lighting provided (either air
operated or 24 volts in confined space).

1. Preparation
1.1 Prepare sludge drum with all the connection.
1.2 Arrange cleaning chemical as per JSA and ensure MSDS is available on site.
1.3 Arrange all PPE including with NORM precautions.
1.4 Arrange fresh air mask on site.
1.5 Ensure vessel aeration is satisfactory.
1.6 Ensure required lighting is available as per JSA (pneumatic or 24V DC)
2. Cleaning
2.1 Confirm cleaning team is experienced and competent.
2.2 Issue work permit, vessel entry complementary confirming all other documents are
available. (MIC, electrical isolation and rescue plan)
2.3 Ensure proper access and adequate lighting is provided.
2.4 Check for NORM in assistance with HSE engineer.
2.5 If NORM present, use PPE designated for NORM.
2.6 During cleaning fresh air mask to be used. (ensure 424ROV-004 on hand jack and service
air line is tagged)
2.7 Follow JSA and PTW recommendation
3. Sludge Handling
3.1 Remove sludge dirt by hand shovel and keep it in plastic drums.
3.2 Remove solid sludge without diluting with water and load in Plastic drum so that
Pyrophoric iron and NORM will not be spraying around.
3.3 Use industrial cleaner to spray on the wall and wipe it out with broom
4. Rinsing and Housekeeping
4.1 After cleaning with industrial cleaner flush the whole surface with fire water and divert
the fluid to OTP.
4.2 Then rinse the inner surface with potable water and divert it to OTP.
4.3 Segregate the waste and clean the area to restore it to old status.

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MAT
1.4

Identify Static & Rotating Equipment and Explain the differences

between Static and Rotating equipment and the precautions to be
taken
Static Equipment
Pressure Vessel
Valves
Pipelines, Piping Spools
Heat Exchangers
knockout drums
Columns & Towers
Tanks
Heaters

MAT
1.5

Rotating Equipment

Pumps
Compressors
Turbines
Agitators
IC Engines
Gearboxes

List the Major types of Mechanical Equipment used in the Oil & Gas plant,
and utility plant relevant to your work area. (water injection, and WHPT for
UZ)

List of Major types of Mechanical Equipment used in Oil and Gas: Refer MAT 1.2 &
MAT 1.4
For the Upper Zakum Field Central Complex platform, the utilities can be described
under the following main headings:
1. Power Generation and Electrical Distribution
2. Fire Water Pumps and System
3. Compressed Air
4. Cooling Water
5. Service Water
6. Fuel Gas
7. Electro-chlorination
8. Potable Water
9. Drains
10. HVAC

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MAT
1.6

What is a Process Flow Diagram? Identify different system Tag nos &
their respective Locations
A process flow diagram (PFD) is a diagram commonly used in process industry to indicate
the general flow of plant processes and equipment. The PFD displays the relationship
between major equipment of a plant facility and does not show minor details such as
piping details and designations.
For Identification of Tag Nos and their respective location, please refer the following
diagram

Jo

MAT
1.7

(A) Identify Different Measuring Tools & know their use. (B) Identify
different lifting tool/tackles, their uses & Safe Working Loads.
Familiarize with Color Coding.
MEASURING TOOLS

MEASURING TAPE

RULER

FEELER GAUGE

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EXTERNAL MICROMETER

INTERNAL MICROMETER

DEPTH
MICROMETER

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10

VERNIER CALIPER

DIAL VERNIER CALIPER

VERNIER

HEIGHT

GAUGE

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11

DIAL GAUGE

Basic Measurements:
English Measurement System
The unit of length in the Imperial system is the inch. The inch can be divided into decimal or
fractional divisions. The common units and their abbreviations are as follows:
Inch: in.
Foot: ft.
Mile: mi.
The conversions from one unit to another are as follows:
12 inches = 1 foot.
3 feet = 1 yard.
5280 feet = 1 mile.
Metric system.
The unit of length in the Metric system is the metre. The metric system is based on
multiples of ten. The common units and their abbreviations are as follows:
Millimetre: mm.
Centimetre: cm.
Metre: m.
Kilometre: km.

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12

The conversions from one unit to another are as follows:

10 mm.= 1 cm.
100 cm.= 1m.
1000 mm.= 1m.
1000 m.= 1 km.
Basic conversions from imperial to metric are as follows:
1 mile = 1.61 kilometre.
1 kilometre = 0.62 miles.
1 yard = 0.91 metres.
1 metre = 1.09 yards.
1 foot = 0.30 metres
1 metre = 3.54 feet.
1 inch = 2.54 centimetres.
1 centimetre = 0.39 inch.

Identify Different Lifting Tools

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13

Hooks

Shackle

EYEBOLT

Rope Sling

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14

WEB SLING

WIRE ROPE SLING

Chain Hoist

Come-Along

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15

Lifting Colour Code

Refer the following link for more information,

http://team.portal.zadco.net/sites/BU_SU/HSE/HSE%20Gide/Part%20123.pdf#search=HSE%20Guide%20%2D%20Colour%20code

MAT
1.8

(A) Identify Different Hand tools (Types, Size & Uses). Demonstrate safe
uses.
(B). Identify Different Power Tools (Type, Size & uses).
Familiarize with Using/ operating the same
Please refer the Mechanical parts and Tools Mini Picture Dictionary

MAT
2.1

(1) Provide Different Types of Hose connections for utility Water,

Service Air , Inert Gas & different Chemicals. Identify individual lines in
the plant & List precautions to be followed for each.
(2)Identify different Gaskets(Type, Size, Rating, Material). Familiarize
with Use of each type of Gasket & Tightening of Flange Bolts.
Please refer the Mechanical parts and Tools Mini Picture Dictionary. For Identification
of individual plant and the list of precautions to be followed, please refer the link given
above in Module 1.7.

Jo

16

MAT 2.2

Identify Different Chemicals; List the Hazards associated with each &
precautions to be taken with each. What is MSDS for a chemical.(To
be done under senior Technician guidance)

MSDS: Material Safety Data Sheets

A Material Safety Data Sheet (MSDS) is a document that contains information on the
potential health effects of exposure to chemicals, or other potentially dangerous
substances, and on safe working procedures when handling chemical products.
Chemical handling procedure
1. Read the label and MSDS
Ensure that Chemicals are properly labeled.
Label tells you what you need to know about your chemical.
MSDS gives more technical information about the chemical than the label.
2. Dress adequate PPE:
Wear the proper safety protection - PPE, clothing, apron, gloves, boots and
face/eye protection equipment as required.
3. Follow directions.
If the label says, use only with adequate ventilation, make sure you do so. Never
mix chemicals unless you've been trained and authorized to do so.
4. Know emergency procedures.
Be familiar with first aid procedures, and be sure to know where the Emergency
eye wash & emergency showers are located; also know your Emergency phone
numbers.
5. Be Careful.
Don't work alone; make sure there is someone there to help you if necessary.
Don't try to hurry or take shortcuts, you just can't rush safety. Chemical safety is
part of your job.
6. Report any suspected problems.
If you notice any malfunctioning equipment or any electrical equipment that is in
need of repair, report it to your supervisor immediately.
7. Keep your work area neat, clean and organized.
You'll know where everything is, and you'll be able to work more efficiently.
8. Store everything properly.
Make sure to close containers tightly. Keep flammables in a safe area, and use
only the smallest amount necessary for the job.
9. Empting out Drums and Disposal of Remaining.

Pump out drums to the minimum possible.

Shift the empty drums to 427-S-001 (Surge Basin).

3.Fill water in the drum and pump out to 427-S-001 using pneumatic
pump, and make sure drums are completely emptied out.

NOTE: All above precautions to be applied while cleaning drums.

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17

MAT 2.3

Jo

Associate/ assist in Preparation of Vessel for Internal Inspection

under Close Supervision. Follow Confined Space Entry Procedure.
Provide Evidence.

18

MAT 2.4

Identify different Pipe Fittings & their uses. Associate with Identification,
uses, Servicing, testing of different Valves, including fabrication/ installation of
Test Fittings , Gauges, hook up & Use of Hydro Test Pump. Provide Evidence.

PIPE FITTINGS
Pipe fittings are used to join sections of pipe together, or to change the direction of
flow. They can be made of the following materials:

Steel

Cast iron

Bronze

Copper

Plastic
Glass

Most fittings are available in screw or welded types although the flanged type is also
common. Welded fittings are classed as permanent.
The main function of a pipe fitting is:

To join sections of pipe (Coupling, union or nipple).

To change the direction of flow (Elbow or "Y").
To change the size of pipe (Reducer or bushing).
To branch the line (Tee or cross).
To close the ends of pipe (Plug or cap).

The most common types of fitting are as follows:

a) Elbows:
They allow pipework to change direction at either a 90 or a 45 angle
(see figure 2.25 and 2.26).

Figure 2-25
b) A 45 elbow (see figure 2.26).
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19

Figure 2-26
c) Tee:
Allows pipe to branch in two directions. It can also be considered as the joining
of three pipes (see figure 2.27).

Figure 2-27
d) Cross:
A cross allows pipe to branch in three directions, or the joining of four different pipes
(see figure 2.28).

Figure 2-28

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20

e) Bushing. Bushing is threaded inside and outside to allow large pipe to be

connected to smaller pipe. The inside and outside thread dimensions come in
different sizes (see figure 2.29).

Figure 2-29
f) Cap. A cap is a threaded fitting that screws directly onto a pipe to close it off
(see figure 2.30).

Figure 2-30
g) Plug. A plug is a solid threaded fitting which screws into another fitting to plug
an opening (see figure 2.31).

Figure 2-31

21

h) Coupling/sockets. They are used to join two sections of pipe (see figure 2.32).

Figure 2-32
i) Nipple. A nipple is a short section of threaded pipe which usually fits
between two different pipe fittings. They can vary from 5 to 25 mm in length
(see figure 2.33)

Figure 2-33
j) Reducer (concentric and eccentric). The function of a reducer is to change
the diameter from a larger pipe size to a smaller pipe size.. This is done to
reduce the volume, or to increase the pressure in the pipe. They come in
various sizes (see figure 2.34).

Figure 2-34

22

k) Union. A union is a coupling which comes apart into two sections. It allows
two sections of pipe to be disconnected (see figure 2.35).

Figure 2-35
l) "Y" fitting. A "Y" fitting allows two branches to go off at 45 to each other (see
figure 2.36).

Figure 2.36
m) Return bend. A return bend allows a pipe to return parallel to itself
(see figure 2.37).

Figure 2.37

23

Blinds
A blind is a circular metal plate that can be placed between two flanges to stop
the flow. It is used to isolate a section of the plant, usually for maintenance
work. A spacer is placed between the flanges to allow for the thickness of the
blind. It is removed when the blind is to be used.
There are three types of blind.
a) Blank blind (see figure 2.38).

Figure 2-38

b) Spectacle
2.39).

blind

(see

figure

Figure 2-39
24

c) Blind flange (see figure 2.40).

Figure 2-40
To insert a blind:
Remove the spacer from between the flanges. Place the blind between the
circle of the flange bolts, then insert the gasket. The flange bolts are tightened
to make a leak-proof seal (see figure 2.41).

Figure 2-41

25

FABRICATING A PIPE SYSTEM.

To fabricate a pipe system it is necessary to know the dimensions of the fitting
and valve, and the thread engagement length. Figure 2.42 shows an example
of a pipe system using various common fittings (see figure 2.42).

Figure 2-42
The normal thread engagement length is the amount of threaded pipe turned
into the fitting to make a tight joint. A mechanical technician must be able to
accurately decide the length of pipe that is needed. When he calculates the
length, he must measure between the fittings, plus the thread engagement at
both sides. In figure 2.43 the total length of pipe required (L), is the thread
engagement length (Y), plus the length between the fittings (X) (see figure 243).

Figure 2-43

26

Examples:
Nominal pipe/fitting size.

Thread engagement size.

1/ "
4

3/ "
8

3/ "
8

3/ "
8

1/ "
2

1/ "
2

3/ "
4

9/ "
16

1"

11/ "
16

1 1/4"

11/ "
16

1 1/2"

11/ "
16

2"

3/ "
4

PIPE LEAKAGE
Unrepaired pipe leaks can cause very serious problems in petrochemical plants and
refineries. There are many common causes of leaks. They are:
n) Vibration.
o) Improper alignment of flanges.
p) Pipe stress.
q) Corrosion.
If the leaks go unrepaired they can lead to:
r) Corrosion to other lines.
s) Toxic contamination to humans.
t) Serious skin burns.
u) Explosions.
v) Fires.

27

PIPE HANGERS AND SUPPORTS

Pipe must be supported to keep it in a straight line and prevent it from
sagging. Sagging pipes put strain on the fittings, causing them to leak. A pipe
support must hold the pipe, but allow it some freedom for thermal expansion.
Pipe can be supported and fastened to the floor, walls, ceiling or to pillars.
There are many different types of pipe support, each one is used for a
particular job. Some common ones are as follows:

w) Spring hangers. This type absorbs vibration (see figure 2.46).

Figure 246

28

x) Adjustable swivel pipe roll.

Roll type supports allow the pipe to move as
it expands and contracts due to heat (see figure 2.47).

Figure 247

y) Single hook (see figure 2.48).

Figure 248

29

z) Ring and bolt hanger (see figure 2.49).

Figure 249

aa) Adjustable clevis and band hanger (see figure 2.50).

Figure 250

30

MAT 2.5

Associate/assist in use of High Pressure Cleaning Equipment under close

supervision. Provide evidence for the same.

A high pressure washer or power washer is a high-pressure mechanical sprayer used

to remove loose paint, mold, grime, dust, mud, and dirt from surfaces and objects
internally or externally.

MAT 2.6

Demonstrate clear feedback verbal or written report to the technician when

required ( English & Arabic) able to deliver clear information.

A clear information about the progress of the given task or the observation to report
to the seniors verbally or in written by email.
Features of effective verbal communication.
1.
2.
3.
4.
5.
6.
7.

Use simple and easy word.

Use proper English/Known Language.
Give examples.
Body language.
Clear & loud voice.
Telephone
Radio Messages

Features of effective written communication.

1.
2.
3.
4.

Official
Clear Objective
Clear language
Good printing quality.

Name written communication formats.

1.
2.
3.
4.

Technical Reports
Letters
E-mails
Permit to Work

31

MAT 2.7

1.
2.
3.
4.
5.

Associate /Assist in Performing Preventive Maintenance of static & Rotating

Equipment(s) Under Close Supervision. List various parameters monitored.
Provide Evidence.

Preventive Maintenance: The care and servicing done for the purpose of maintaining
equipment and facilities in satisfactory operating conditions.
PM is to be done by providing systematic inspection and correction of failures before
they occur or before they develop into major defects.
Preventive maintenance follow planned guidelines or check lists from time-to-time to
prevent equipment and machinery breakdown.
The work carried out on equipment in order to avoid its breakdown or malfunction. It is
a regular and routine action taken on equipment in order to prevent its breakdown.
Maintenance, including tests, measurements, adjustments, parts replacement, and
cleaning, performed specifically to prevent faults from occurring.

MAT 2.9

What is a Work Procedure? Give Examples?

Work Procedure is the method used to carry out the work safely to avoid risk to
people, Equipment and the facility.
1.
2.
3.
4.
5.
6.
7.
8.
9.

PTW
JSA
Electrical Isolation
Process Isolation
Mechanical Isolation
Spading List
Risk Identification
Supplementary Permit (In case)
Vessel Entry (In case)

32

MAT
3.1

What is PPE? Why is it mandatory to wear PPE in the Plant? List the
Basic requirements of PPE's?
Please refer Page 4

33

MAT 3.2

Explain H2S hazards & rescue procedures? Demonstrate use of escape

set.

Hydrogen sulphide is a highly toxic, colourless gas, heavier than air, with the smell of rotten
eggs.
It is one of the most deadly hazards in the oil and gas industry.
1) How to recognise the presence of H2S with Gas detectors
H2S is very toxic. If it is present at 0.13 p.p.m. (parts per million) of the air you breathe,
there is hardly any smell.
At 10.0 p.p.m. your eyes begin to irritate you, but it is still within the TLV (Threshold
Limit Value), which means you can still work in that area safely for 8 hours.
At 27.0 p.p.m. you notice a smell of rotten egg.
At 100 p.p.m. you begin to cough and there is no sense of smell.
At 700 p.p.m. you are unconscious and you stop breathing.
At any facility where there is a known hazard of H2S there must always be a way of
detecting it so any work can be done safely. There are three types of detection.
1) Gas Detector Tubes. These measure the content of gas by taking a sample with a
detector tube through a hand held suction pump. The crystals inside the tube change
colour against a measured scale which shows the % of H2S.
2) Continuous Monitors. These are used in plants where there is always a risk of leaks.
Sensors are fitted around an area and samples automatically. If the H2S safe limit is
exceeded the alarm will go off alerting any persons working in the area.
3) Personal Monitors. These are battery operated portable detectors that are attached to
workers clothing. These show the actual H2S content that is present in the area the
worker is in.
2) How to protect yourself from H2S
If you recognise the smell of H2S and you cannot evacuate your work area, it is vital that
you immediately put on escape sets Or Self Contained Breathing Apparatus (SCBA).
This will provide you with a source of breathable air until you can evacuate the area.

34

MAT 3.3

What are the main indications of Heat Stress? How do you avoid Heat
Stress? What personal protection is used for Noise Pollution?

Types of Heat Disorder

1. Heat Stroke
A condition where the bodys system of temperature regulation fails and body
temperature rises to critical levels. Heat stroke is a medical emergency since
very high body temperature can cause death.
2. Heat Exhaustion
This condition includes several clinical disorders with symptoms that may
resemble early symptoms of heat stroke and is caused by the loss of large
amounts of body fluid by sweating.
Signs and symptoms are those of fluid and body salts (electrolytes) depletion,
with normal or high body temperature; loss of consciousness may occur. Heat
exhaustion should also be considered a medical
emergency.
3. Heat Cramps
These are painful spasms of the skeletal muscles that occur among those who
sweat profusely in heat and is caused mainly by loss of body salts.
4. Fainting
This occurs in people who are not accustomed to hot environments and who
stand erect and immobile in the heat. The heat causes blood vessels to dilate,
the brain is deprived of oxygen and temporary loss of consciousness occurs.
5. Heat Rash
Also known as prickly heat, this condition is caused by plugging of the sweat
glands when sweat is not easily removed from the surface by evaporation.
e.g. Humid environments
How do you avoid Heat Stress?
1. If possible, schedule hot jobs for the cooler part of the day.
2. Alter rest/work regimen to permit more rest time.
3. Provide cool (shaded) areas for rest and recovery.
4. Ensure an adequate supply of cool (not iced) water is available at the work place
and employees take fluids at least hourly.
5. If workers diet is deficient in salt or an individual is susceptible to heat stress, the
water may be salted (half a level teaspoon of salt to 1 liter of water).
6. Salt tablets are not recommended. People on a salt restricted diet, e.g. high
blood
pressure, should consult a doctor before taking additional salt.
35

What personal protection is used for Noise Pollution?

1. Ear Plugs
Ear plugs fit inside the ear. They are made of polyurethane foam, or rubber and they
are disposable.
2. Ear Muffs
Ear muffs consist of rigid cups which fit over the ears. They are held in place by a
head band. The cups have acoustic seals of polyurethane foam or a liquid-filled
annular bag so that they fit tightly. The cups are filled with sound absorbing
material. The ear muffs do not protect the ears if objects, like spectacles, are put
under the annular seals.
MAT
3.4

Explain the types of warnings from the public address system in an

emergency (hooters and sirens) and what action to take? Indicate the
Muster Points.

36

MAT
3.5

Demonstrate the Lifting and moving of Mechanical equipment, in a proper

and safe manner. Demonstrate a good knowledge of Human Kinetics and
manual handling.

Manual Handling Technique Lifting and Carrying

Think before handling/lifting. Plan the lift/handling activity. Where is the load going
to be placed? Use appropriate handling aids where possible. Will help be needed
with the load? Remove obstructions, such as discarded wrapping materials. For long
lifts, such as from floor to shoulder height, consider resting the load mid-way on a
table or bench to change grip.

Keep the load close to the waist for as long as possible while lifting. The distance of
the load from the spine at waist height is an important factor in the overall load on
the spine and back muscles. Keep the heaviest side of the load next to the body.

37

Refer the following link for your reference:

http://hseopsguide.portal.zadco.net/Shared%20Documents/1%20Occupational%20S
afety/Safety/1.52%20-%20%20Manual%20Handling%20Rev%20A0.pdf

38

MAT
3.6

What are the Health Hazards associated with Insulation material and their
effect, such as Rock wool, Asbestos fibers?
HAZARDS TO HEALTH
The health hazard from the inhalation of asbestos fiber has been recognized for
many years with the observation that pulmonary fibrosis, a debilitating disease
known as asbestosis, could result from exposure. Afterwards an association was
shown between asbestosis and bronchial carcinoma, and this was followed some
years later by the observation that exposure to asbestos could lead to the
development of mesothelioma, a rare form of cancer arising in either the pleura or
peritoneum. The risk of developing such diseases largely depends on both level and
duration of exposure and is considerably increased in combination with the smoking
of cigarettes. The diseases may develop as many as 20 to 30 years after exposure has
ceased.
Overall, exposure to crocidolite (blue asbestos) is considered most dangerous,
followed by amosite and chrysotile in that order. The difference in hazard is thought
to be related to differences in physical properties (i.e. diameter, length, length to
diameter ratio). Although there is evidence of differences in risk between the
different types of asbestos, there is no firm scientific basis for different exposure
limits.
It is therefore prudent to realize that:
REPEATED AND PROLONGED INHALATION OF ANY FORM OF AIRBORNE ASBESTOS
FIBRE MAY CAUSE IRREVERSIBLE LUNG DISEASE AND CANCER.
Procedures
Each company and location where asbestos is or may be handled should have their
own written "Asbestos Procedures", specifying safe methods of handling, removal
and disposal.
Both personal and workplace air sampling may be required in surveys of exposure.
Workplace sampling would be required for clearance of work areas after completion
of e.g. stripping of asbestos insulation prior to allowing re-entry of personnel, and for
monitoring the spread of contamination outside a restricted area.
All persons handling asbestos should be adequately informed of the hazards and
should be fully trained in hygiene and work practices.
For more information please refer the following link,
http://team.portal.zadco.net/sites/BU_SU/HSE/ADNOC%20Guidelines/ADNOCCOPV3-13(Ver-1).pdf#search=Asbestos

39

MAT
3.7

Skill on handling and using of fresh air mask and using self-contained
breathing apparatus (SCBA)

Self-contained Compressed Air Breathing Apparatus:1. These sets are provided for emergency use where a portable supply of air is
required for a
short period of time.
2. The air for this apparatus is supplied under pressure either from compressed air
cylinders carried by the wearer, or from trolley sets.
3. Self-contained Compressed Air Breathing Apparatus (SCBA) shall be located in
the Control Room and at strategic points within hazardous areas. The apparatus
is housed in easily distinguishable boxes, or in wall-mounted containers, painted
green.
4. SCBA shall be inspected and the air pressures checked on a weekly basis, where
practicable (inspection, minimum of once per month). Minimum acceptable
pressures are specified, depending on the type of equipment being used. The
checks shall be recorded and faults reported to the Fire
5. After use, a breathing apparatus set shall be serviced and fitted with a fullycharged cylinder before being re-sited, The servicing shall include the cleaning
and decontamination of the face piece.
6. All persons required to use breathing apparatus must receive initial training and
refresher training at intervals not exceeding six months. The training shall be
recorded. BA Escape Sets 30 Minutes (Offshore) 10 Minutes Escape Sets for Zirku
Island Site HSE Engineer shall specify the most suitable sets for offshore use
taking into consideration such factors as weight, autonomy and reliability of the
escape set.

40

MAT
3.8

Explain safe practices and methods of embarking and disembarking from

transportation boats, fixed wing plane and/or helicopters?

SAFETY ON AIR / LAND / SEA TRANSPORT

Travel Documents
To travel to company sites, you will require the following valid cards:
An HSE Induction Card issued by HSE HQ
A valid Oilfield Security Pass
A Travel Card with a unique number (Possum Card) and a
Formal reservation
Safety on Air Transport
Fixed wing and helicopter operations are carried out under the standards imposed by the
Directorate of Civil Aviation in Abu Dhabi and current federal laws.
Safety on Fixed Wing Aircraft
The following safety guidelines shall be followed by all while boarding / travelling in
aircrafts.
Never approach the aircraft while the engines are running.
Follow the instructions of the in charge person while boarding or leaving
the aircraft.
Smoking is not permitted on board or at Zirku, Arzana terminals
Keep your seat belt fasten till the sign is switched off
Hand carry bags shall be of small size that fit into the overhead cabin
compartment and shall not weigh more than10 Kgs
Safety on Helicopters
Safe practices for helicopter operations, summarized below, are detailed in PART 1 Section
1.11 Helicopter Operations of: HSE 06.11. HSE Guide
All personnel shall be shown a flight safety video immediately before boarding the aircraft
for every trip.
The video presentation shall be followed up by a flight-specific briefing/demonstration at a
designated area.
Basic safety requirements for helicopter operations are detailed in ZADCO SERVICE NOTE
GM/016/01/0601 of 15 March 2006, the requirements of which are summarised below:

Passengers shall not wear any loose headgear such as caps, hats, etc. around
helicopters
Wearing any clothing that may obstruct evacuation or rescue operations
from the helicopter is prohibited. The only clothing allowed will be pants and
shirt or industrial coveralls
41

Passengers shall maintain a secure grip on lightweight articles such as

helmets, caps, jackets, newspaper etc.

WARNING: NEVER APPROACH THE HELICOPTER FROM THE REAR

In order to promote safe practices, helicopter passengers shall follow the guidelines listed
below:
Follow the instructions of the dispatcher onshore and Helideck Landing
Officer (HLO) offshore
Remain in a safe area until instructed to approach the helicopter by either
the helicopter pilot or the HLO
Always approach or leave the helicopter towards the front.
Walk to and from the helicopter; do not run
Do not walk around the tail.
Maintain a secure grip on lightweight articles to prevent them from being
drawn into the rotor blades
Hats/headgear shall not be worn
Use of plastic bags as containers for personal items or freight is not permitted
on board helicopters
On entering the cabin, put on one of the lifejackets provided, and ensure it is
properly adjusted and fastened
Take a seat as directed
The seat belt and shoulder harness, if installed, must be securely fastened
Doors must be closed and not opened again until the helicopter has firmly
landed, either on the helideck or onshore and a signal given by the pilot
(green light on)
Passengers must not attempt to put on or remove items of clothing during
flight
Baggage and equipment shall be stowed in the baggage compartment or
under the seats in the cabin
Clear access to exits/emergency exits, life-rafts and emergency equipment
must be maintained at all times
Freight placed under seats must be secured
Adequate hearing protection (ear plugs) must be worn
One of the English speaking passengers, if available, shall wear the cabin
communications headset at all times
Passengers must not interfere with the radio equipment controls in the cabin
Smoking is strictly forbidden on all helicopter flights
Tools and belongings shall be kept in the tail boom stowage compartment or
at the side wall seat
Cargo stored in the side wall seat shall be secured by a safety net
If fuel is low and wind speed exceeds start-up/shutdown speed during flight, the pilot can
hot fuel, i.e. the helicopter is not shut down.
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Safety while boarding / landing at WHPT:

WHPT helideck shall always be kept clean and clear from any loose object.
The crew leader shall be the first person to board on or land from helicopter
for ensuring safe approach & landing of the team.
The crew leader at WHPT and helicopter pilot shall exchange clear hand
signal to confirm the safe status before allowing the rest of the crew to land
or board the helicopter.
Helinets and helinet frames shall be maintained in safe condition to ensure
safe embarkation and disembarkation
List of Prohibited Articles in Fixed Wing Aircraft / Helicopters

Alcohol
Canned Drinks
Drugs ( e.g. Sedatives, Narcotics) / Poisons
Explosives / Firearms / Ammunitions / weapons
Flammable gases or liquids / oils and gases
Magnetic materials / Radio active materials
Aerosols / Paints & Solvents
Wet batteries.
Switched on electronics ( Laptops , cell phones, CD Players etc)

Safety on LAND Transport

Best Practices for Land Transport
ZADCO guidelines for safe procedures for land transport include the following subjects:
Driver's License Requirements
Passenger Safety
Use of Motor Vehicles
Wide Loads
Towing
Parking
Maintenance
Refuelling
Use of Bicycles on road

All vehicles shall be equipped with safety belts. Rear seat belts should be of the same
specification as those for front seats.

43

Safety on sea transport

Safety in Ports
Passenger access and exit routes shall be clearly marked and laid out in accordance
with national legal requirements
Internationally recognized visual symbols shall be used
Routes for foot passengers shall be segregated from vehicle routes
Passengers entry prohibited Areas shall be clearly marked
Access by passengers to the controls of ramps or other equipment shall be
prevented
All walkways, ramps, lifts, bridges, etc., used by passengers shall be clearly marked
with any relevant weight or other limitations
Appropriate facilities for the safe handling of passenger luggage shall be provided.
Where necessary facilities for security examination shall be installed
Travel to WHPT
Travel infield to the Well Head Platforms is by boat or by helicopter which are coordinated
between area authority and traffic supervisor and recorded in the daily book.
The captain shall confirm maximum sea swell for personnel transport.
A minimum of two persons will travel. They must have:
PPE
Potable water
Radio with spare battery
Life jackets
H2S monitor / portable detector (while visiting H2S designated WHPTs)
Escape set (while visiting H2S designated WHPTs)
Transfer from boat to WHPT or vice versa shall be via a properly secured gangway or
through the 2 stage extended access platform mounted on field boats or using WHPT
ladder.
Before boarding / landing, the crew leader shall ensure the following:
The boat is properly moored
Swing ropes are sound and secure, if available
Landing grating is unobstructed and sound
Landing is easily accessible
The captain has authorised the landing
44

 Keep both hands free

Heavy/cumbersome loads must be transferred by crane
Do not attempt to jump from the boat to the platform or vice versa in high wave
conditions
On the boat, you must:
Follow the Captains instructions
Wear a life jacket as instructed by the boat's crew
Remain seated while travelling

45

MAT
3.9

Demonstrate and strictly apply hearing protection in high noise areas such as
Gas Plant, Sidem, WIP, WHPT (water injection) Helicopters and boats. What
is the maximun noise level before having to wear protection?

HEARING PROTECTION

General Duties

Hearing conservation program should be established in all locations where

employees are exposed to noise levels above 85dB (A) for 8 hours (83dB (A)
for 12 hours).

Special precautions to prevent damage to hearing by exposure to excessive

or prolonged noise is obligatory.

Hearing protection must be worn in all areas where noise levels exceed
83dBA for a 12 hour shift or 85dBA for an 8 hour shift shall be designated as
Hearing Protection Areas.

No exposure to continuous or intermittent noise levels in excess of 115dBA is

allowed.

Types of Hearing Protection

There are three basic types of hearing protection which are widely used:

Aural Insert Protectors (Ear Plugs).

Semi-aural Protectors (Canal Caps).

Circum-aural Protectors (Ear Muffs).

46

MAT
4.1

Explain Plant Safety and at least 4 methods on how to achieve this? List the
different types of extinguishers and their uses?

Plant Safety:
1. RISK/HAZARD AWARENESS Tool Box Talk
2. SAFETY SIGNS Observation and Comply
3. PERMITS TO WORK Permit to work system
4. DANGEROUS SUBSTANCES
5. PERSONNEL PROTECTIVE EQUIPMENT
6. LADDERS/WORKING AT HEIGHTS

47

MAT
4.2

What methods do we use to achieve Environmental protection? Explain

Waste Management? Demonstrate how to access HSE web site.

Refer the following link to access HSE web site,

http://team.portal.zadco.net/sites/BU_SU/HSE/HSE%20References%20Documents%20Code
s%20and%20Standards/Waste%20Management%20Procedure%20Version%20%20HSE%20%20Rev%20%20A2%20Final.pdf

48

MAT
4.3

What is the definition of a Hazard and Risk? Provide examples of Hazardous

materials used in the plant. Explain Segregation of materials?
Industrial safety is about the prevention of accidents and damage to personnel and
equipment. But what is an accident?
Accident:
The most common definition of an Accident is: An unplanned, undesired
occurrence which results in loss of any kind.
Incidents:
The above definition of an incident is an event that could cause loss.
The definition of a Hazard:
Something with the potential to cause harm.
Examples of Hazards:

Filling a petrol tank.

Using a welding torch.

Using any electrical equipment.

Emptying chemicals from a drum.

Risk:
Risk is defined as The likelihood that the harm from particular hazards is realised.
An example of risk is working at height. The hazard is falling off the ladder onto the
factory floor. But the risk of falling increases if the ladder is placed in front of the
swing doors that let in the fork lifts.
HAZARD - means a substance has a property that may cause harm
RISK - is the chance of a hazardous substance causing harm.
For example, concentrated sulphuric acid is hazardous. However, if it is in a bottle,
properly stoppered, on a shelf in a locked cupboard, then the risk is minimal.
The safe storage and correct use of chemicals is very important. To reduce the
chance of an incident it is essential that the hazards and risks of the chemicals being
used is known and understood.

49

Authoritative guidance in relation to the health hazards of various substances is

given in the Control of Substances Hazardous to Health Regulations 1994 (COSHH).
Substances with any of the following properties are hazardous:

Explosive.

Oxidising.

Flammable.

Highly flammable.

Extremely flammable.

Toxic.

Very toxic.

Harmful.

Corrosive.

Irritant.

Carcinogenic (causes cancer).

Mutagenic (causes inherited changes).

Micro-organisms that create a hazard to health.

Substantial concentrations of dust.

Radio-active materials.

Any substance not mentioned above which creates a comparable hazard.

50

MAT
4.4

List General Safety Rules.

51

The rules are about driving our vision towards creating an accident-free
workplace, promoting a positive safety culture and enhancing our awareness of
safe practices. They are intended to move us closer to an effective management
of risks and ultimately responsible for their safety and the safety of those
around them.
"Everyone who works for, or on behalf of ZADCO, shall follow the golden rules of safety,
as compliance with these rules is fundamental to preventing accidents in our
operations"
1. Job Safety Analysis
Job Safety Analysis (JSA) is conducted for routine and non-routine activities
and jobs involving new equipment, material, methods or personnel.
2. Permit to Work
Do not perform work without a valid work permit.
3. Confined space entry
Only enter a confined space when safe entry conditions have been
established and maintained. Prior to entering a confined spaces.
4. Energy isolation
Verify isolation of energy systems before work starts.
5. Critical Equipment and Systems Override Obtain authorisation before
overriding or disabling safety critical equipment.
6. Working at heights
Do not work at height over two meters without using fall protection
equipment.
7. Lifting operations
Ensure that the lifting equipment is certified and stay clear of suspended
loads.
8. Personal Protective Equipment
Use PPEs in accordance with the safe work plan, work permit or mandatory
site requirements.

52

MAT
4.5

What is a JSA? Explain why we use JSA?

Job Safety Analysis (JSA) is one of several safety management tools used in EMPC,
we also use:

Work Permits

Safe Work Practices

Normal or Integrity Critical Procedures

Safety Manuals

Work Aids or Checklists

Every task must be appropriately managed to assure safe execution

Level of task management is based on:

Hazards associated with the activity

Where the task is done (site hazards)

Who is doing the work

What else is going on around the activity (SIMOPS)

Safety management tools are used in combination to meet safety needs of

the task

Simple task may require LMRA only

Complex job may require all tools listed above

JSA is a pre-job planning and safety tool used by the work team to:

Identify major steps of a job or task

Identify potential hazards for each step

Determine the best safeguards to prevent or mitigate the identified hazards

Clarify and coordinate responsibilities between team members

JSA is a living safety tool

Initially developed prior to task, but updated during task as needed if

situation changes

Team refers to JSA during task to verify appropriate mitigations are in place

JSA is not simply paperwork it is your Safety Plan

53

MAT
4.9

Explain the different types of Safety Signs in the plant

Safety signs
Safety signs are a way of communicating safety information. In order to ensure
international uniformity, the signs are usually pictures.
Safety signs have:

PICTURES FOR SYMBOLS

STANDARD SHAPES

STANDARD COLOURS

PROHIBITION SIGN (A Do Not Do Sign)

A round sign with a white background and a red border with a diagonal cross bar.
Symbols must be black.

Prohibition Sign
WARNING SIGN (Warning of a Particular Hazard) - Triangular with a yellow background,
black border and black symbols.

Hazard Warning Sign

MANDATORY SIGN (Must be Done/Worn) - Round sign with a blue background and white
symbols.

54

Mandatory Sign
SAFE CONDITION SIGN

(Information about Safe Conditions such as First Aid or

Emergency Routes) - Square or rectangular signs with white
symbols on a green background.

Safety Condition Sign

EXCEPTIONS (Fire Fighting and Rescue Equipment are excluded from the Regulations as
there is no International Agreement on these as yet). These are some examples of those
generally used.

55

DANGEROUS SUBSTANCES : (A different range of signs exist for the labelling of dangerous
substances, for use and road transportation. Following
are some examples)

Labels for Dangerous Substances

ROAD TRAFFIC: (Signs for the regulation of road traffic must conform to the countries
Road Traffic Laws)

Road Traffic Sign

56

57

MAT
6.2

Explain the importance of maintenance work in the plant including basic

safety related issues. What is PTW?

PERMITS TO WORK
If there is a high risk of serious injury or death involved in any activity when certain
procedures are not carried out, a permit-to-work system may be necessary. Examples of
activities often covered by a permit-to-work system are:
Work on electrical systems (not live!)
Maintenance work on machinery.
Entry into confined spaces.
Excavation work in areas where there are buried services.
Hot work - work involving flames or sparks in areas where there are flammable
materials.
Work on or near overhead cranes.
Work on operational pipelines.
Etc.
Permit to work is a companys system to allow work to be performed safely within a given
time scale.
Permit-to-Work Systems
Only authorized qualified personnel can Issue and Receive and Sign-Off a Work Permit. Any
person working on a job performed with a permit must be trained to understand its
meaning.
An effective permit-to-work system will include the following features:

Identification System:
The activities for which a permit is required must be clearly identified. This should be
by means of specific written information or signs and not general comments such as
a permit-to-work will be required for any high risk activity. For example:
A Hot Work Permit is required for any work where there is a source of ignition.

Issuer (Issues the permit).

58

The person issuing the permit must sign it to confirm that the necessary precautions
have been taken and that he has instructed the person receiving the permit about
the limits, restriction, precautions, conditions, etc.

Receiver (The person doing the job).

The person receiving the permit must sign to say that he has understood the
conditions imposed by the permit.

Issuer (Clearance)
Upon completion of the work, or expiry of the permit, the person in control of the
work must sign the permit to confirm that the work has been completed and all
personnel, equipment, etc. have been removed from the area.

Issuer (Cancellation).
The person authorized to issue permits must sign the permit to cancel it when he is
satisfied that it is safe to do so. The Valves can be opened, Machinery can be
switched on again, and Scaffolding can be removed.

59

MAT
6.8

What is MESC and item number? Demonstrate your ability to collect spare
parts from the warehouse.

MESC: Material Equipment Standard Code.

Codes and Standards - definitions & requirements

Definition of a Standard: A standard consists of technical definitions and guidelines that
function as instructions for designers/manufacturers and operators/users of equipment.
Standards can run from a few pages to a few hundred pages and are written by
professionals who serve on ASME committees. Standards are considered voluntary because
they are guidelines and not enforceable by law.
Definition of a Code: A code is a standard that has been adopted by one or more
governmental bodies and is enforceable by law.
Requirements for Codes and Standards: To be considered a valid ASME code or standard, a
document should be suitable for repetitive use. A major requirement of a code or standard
is that it can be used time and again. If a set of requirements is so specialized that it cannot
and will not be applied repeatedly, it is not a code or standard.
What is difference between code and standard and specification?
A Standard can be defined as a set of technical definitions and guidelines that
function as instructions for designers, manufacturers, operators, or users of
equipment.
A standard becomes a Code when it has been adopted by one or more
governmental bodies and is enforceable by law, or when it has been incorporated
into a business contract.

60

MAT
6.9

What do you need to know during an emergency?

EMERGENCY
An abnormal Event, which could result in danger to personnel, environment and
property such as; Fire, Explosion, Gas Leak, Pollution, Serious injuries etc. Either in
or outside the plant.
EMERGENCY CLASSIFICATION - events are classified into 3 levels:
LEVEL 1
(Least Hazardous) Is an event involving injuries to personnel or damage to facility,
but not requiring shutdown or total evacuation.
LEVEL 2
It is an event involving fatalities or serious damage to the facility, requiring shutdown
and evacuation of non-essential personnel, and outside assistance.
LEVEL 3
An event of potentially catastrophic proportions involving fatalities, serious
environmental damage, total evacuation, long term effects and damaging effect on
ZADCOs image or revenues.
In the initial stages of an emergency there is a sudden burst of communications.
The FCC Panel Operator would receive the emergency notification in one of the
following
ways:
1. By means of an alarm on his panel gas or fire.
2. By means of the phone 888.
3. By means of a radio message.
4. By means of an alarm on his panel activated by a break glass Manual Call
Point, of which there are several located on the CC.
He is strategically placed to now communicate this news to several others in order to
start a response. This is done as follows:
1. Verbally warn any others in the Control Room.
2. Activate the general alarm gas or fire.
3. Make a short Public Address announcement giving due warning.
4. Make a similar announcement over the appropriate radio channel.
5. Alert the Zakum Radio Room Operator by hotline.
6. Inform Control Rooms as appropriate.
61