Hazardous energy

Energy (anything that can provide power to a system- machinery, equipment or processes, to allow it to
perform work) such as - electrical, mechanical, pneumatic, chemical, nuclear, thermal, gravitational, or
other energy. Such energy can harm people. Some are obvious, such as electricity, heat in a furnace, or
something that might fall. Others may be hidden, such as air pressure in a system or a tightly wound spring.
The hazardous energies are:-
 Gravity, Motion, Mechanical,
Electrical,Pressure, Temperature,
Chemical, Biological, Radiation,
Sound
Energy sources hierarchy of Control
 Remove the energy source
 Prevent the release of energy
 Protect from release
 Use stop work authority

Isolation of Hazardous energy

LOTO is a critical component of a safety program. It refers to the main mechanism used by the Energy
Control Program to ensure the safety of workers performing service & or maintenance on machines or
equipment that may expose them to an unexpected energization, startup or release of hazardous energy
potential for any incident (fatality, personal injury, illness or damages to human & property).
LOTO Steps
The following steps must be accomplished in sequence according to specific provision of the respective
equipment / machinery‘s energy control system:
 Identify the energy sources ( Inspection )
 Prepare the work area
 Shut down the equipment
 Isolate the energy sources
 Release stored energy (dispersal)
 Lockout& tag out
 Test for zero energy state
 Complete the task
 Check equipment & clean the work area
 Remove locks & tags
 Remove isolation devices
 Test the equipment
 Return equipment to service
Safe practices
 Personnel trained in LOTO only shall involve in this
processes.
 Adequate work permit, notification to all concerned prior the activity.
 The initial lock shall be removed at last only by the authorized personal.

General Safety Guidelines

 It is every employee’s primary obligations to understand & obey HS&E (Health, Safety & Environmental)
rules & regulations of the client & company.
 Safety is paramount. All shall consider his own safety, others, equipment & environment as part of his
duty of care.
 Maintain positive safety culture all the time and No horseplay & bullying.
 Smoking is forbidden in all restricted area of Oil & Gas (exploration, production & processing) facilities,
until authorized. No naked flame (match boxes & lighter)& any other source of ignition to restricted area.
 Extrinsic items (mobile phones, cameras, battery operated items &flashlights etc.) are forbidden. No
Photography in restricted area unless authorized.
 Observe LOTO while working with hazardous energy, especially electricity.

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 Wear Mandatory PPE (hardhat, coverall, safety goggles, safety shoes & hand gloves)while at work.
Additional PPE shall be selected & worn according to the scope of work. Example- Safety harness with
lanyard for work at height& anchored properly, face shield for cutting & grinding etc.
 For entry in to restricted areas of client, all motor operable vehicle &equipment (mobile/static) should
have valid safety certificate issued by client &be displayed with the equipment all the time. However, all
such certified vehicle& equipment shall be maintained in the certified condition too.
 Obtain valid calibration/test certificate (TPI) for all vulnerable equipment& tools. Such as -fuel tankers,
vacuum tankers, pressurized tanks, air compressors, weld machines, safety valves, cranes, hydro test
equipment, lifting trucks ,accessories, electrical, electronic & instrumentation equipment etc..
 All vehicle & mobile equipment shall be road worthy &speed limit of the Client shall be observed all the
time.
 Reverse parking at designated places only.
 Never obstruct access to emergency equipment/facilities or firefighting facilities.
 Permit to work is applied &shall be covering all maintenance& construction activities in client-restricted
facilities, except routine &normal courses.
 Report all incidents (accidents, near misses& dangerous occurrence) to supervisory staff (channel of
reporting) immediately.
 Maintain good housekeeping all the time.
 Make shifts arrangements of any kind are strictly prohibited.
 Be sure you are physically & mentally fit to perform the job safely.
 Emergency action plans of the Client & company shall be practiced for actual emergencies.
 Client emergency sirens shall be recognized & acted promptly for disciplined & safe evacuation.
 All kinds of waste shall be managed in environment friendly manner.

Hazardous Area Classification

Substance handled in petroleum industries are
flammable/ combustible in nature & in the form of
liquid, gas & vapors. To have a safe working
environment, those hazards shall be identified &
controls developed. Hence such areas are classified &
grouped according to the nature of hazards &its likely
hood. It helps in identifying the extent of areas in which
explosive mixtures with air may occur under normal &
expected abnormal conditions.
a)Controlled area- Entire premises of the
Client/Owner(fenced or freed area) in which access is controlled or restricted. In general, “Controlled area
“shall be considered aswork permit areaswith thefollowing exemptions.
1. Ares are classified as work permit free areas.Examples-designated smoking points, fabrication
workshops etc.
2. Routine activities in “Non Hazardous area” such as office work, driving on unrestricted roads etc &
those areas shall be clearly identified.
Nonhazardous areas- anarea, which is not recognized as presenting any particular fire risk or not identified
as a zone in which a flammable atmosphere may exist.
Unclassified Area- an area, which is not classified as any zones, but such areas may not necessarily be
considered as “safe”.
b) Restricted Area - anarea within the “controlled area” in which entry is permitted only to authorized
personnel &certified equipment.Avalid access pass is necessary to enter these premises.
c) Hazardous area-an area within the “restricted area” where flammable atmosphere is more likely to be
present than the rest of the area. Examples-Processing units, tank farms enclosed with bund walls.
Hazardous area is further classified in to-
Class I-Items from Group A, B, C & D (from below) includes all flammable gases & liquids. Examples-
Acetylene, Hydrogen,Hydrogen Sulfideor gases or vapors of equivalent hazards, mostHydrocarbons like-
benzene,butane, propane, gasoline, naphtha & methane etc.
Locations - areas inwhich flammable gas or vapors may be present in the air in sufficient quantities to
produce explosive or ignitable mixtures.

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Class II- Items from Group E, F & G, which include all combustible dusts. Examples- metal dust,
carbonaceous dust (charcoal,coke dust etc). Sulfur, magnesium &granite etc.
Locations-areas,that ishazardous because of the presence of combustible dust as above.
Class III- items -all combustible fibers. Examples- Plastic &Rubber etc.
Locations-areasdealing with suchcombustible fibers.
Area classifications accordance to materials groups
Class III Group
Class I Group(Gases & Vapor) Class II Group (Dust)
(Combustible fibers)
A- Acetylene
E- Metal dust
B- Hydrogen & ethylene
F- Carbonaceous dust ( coke dust
C-H2S/ gases or vapors of equivalent
& charcoal etc) All Combustible fibers
hazards
G-Other dust (sulfur dust, grain
D- Most hydrocarbons like benzene,
dust etc).
butane, propane, gasoline & naphtha.

Moreover, in particularOil & Gas facilities, the area are termed as divisions as under also:-
Division I-areas in which explosive gases/ mixtures are likely to exist under normal operating conditions.Eg-
areas which are immediately surrounding open vents or open transfer of flammable or combustible
materials.
Division II-areas in which explosive gasesmay acquirein abnormal conditions. Eg-equipment leakage or
failure.
Hazardous area is the zone in which a flammable atmosphere may be present during normal operation or
under abnormal or fault conditions.
Meanwhile, in IEC (European)standards these areas are calledas Zones,that is:-
For gases & vapors
Zone 0-a zone in which a flammable atmosphere is continuously present or present for a long period of
time(typically more than 1000 hours/ year).Example-inside the tank including floating roof which contain
hazardous contents.
Zone 1-azone in which a flammable atmosphere is likely to occur in normal operating conditions (typically)
less than 10 to 1000 hours per year. Example-sumppits,tank farm areas with bund walls.
Zone 2-a zone in which a flammable atmosphere is likely to occur only under abnormal operatingconditions
(typically less than 10 hours per year). Examples-
For Dust &Fiber.
Zone 20, Zone 21 & Zone 22 (The same as equivalent to zone 0, 1& 2 simultaneously)

HSSE Roles& Responsibilities

Top Management-Shall ensuresall the HSS &E risks arising fromcompany activities are well managed (it is a
legal requirement). Shall be role model for obeying HSEstandards & regulations adhered by the client. The
welfare of employees issolely the responsibility of top management. Carry out HSE visibility audit to the
project sites.
Managers & Engineers-Fully responsible for observance ofall applicable HS&E rules&regulations of the
Client & the company. Shall be competent in their field of expertise, excellence &positively cultured.
Responsible for safe execution of job by observing behavior, safety of employees, equipment,materials
&the environment. Shall ensure welfare facilities, first aid, sanitation, basic fire prevention arrangements,
emergency response plan as well as waste management are adequate. Shall carry out audit/ inspection to
sites on regular intervals.
Safety Representatives-Be adequately qualified & experienced for their posts for managementof HSEMS of
the client &organization effectivelyfor the safety of people, equipment, process &environment. Shall be
answerable &responsible forall the HSE aspects. Preparation& maintenance of HSEMS&procedures, it’s
monitoring& review. Submittal &maintenance of HSE reports
& returns, HSEaudits&inspections, provision of training to
employees, maintaining health records,competency,
equipment&its certifications etc..
Site Supervisors/Foremen -Befully responsible for the safety
of people, equipment, process&environment by safe planning

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& execution of tasks. Shall promote positive behavior safety at all times. Work with proper work permit by
adhering all safe work practices. Coordinate with safety division& site safety representatives for bestsafe
execution of the job. Shall inspect/ audit work place on regular intervals. Shall communicate (tool talk)daily
for the scope of work. Ensure adequate PPE is available & worm by him& workers.

Workers: The success of any HSE programis largelydepends on the attention, knowledge &prudent action of
every employee,all shallresponsible for own safety &his colleagues. No carelessness or disregard of
acceptable HSSE standards.Shall use correct tools &proper P.P.E. for the tasks.Shall carry out last minute risk
assessment (LMRA) of the work to be performed &report all untoward actions &conditions in written
format, as well as incidents (accidents, near misses, dangerous occurrences) to his immediate supervisor.
Shall respect allsigns & posters.

HSE meetings & Communications

Communication is aknitting agent of success, a two way process, helps to transmit/exchange ideas, news, &
feelings for the success in an organization. It is a connecting tool for various levels. Importance of the right
communication at right time is valid to achieve not only the HSSE objectives but other course of actions too.
Communication are in three forms – Verbal, visual & written.
Internal communication(within the organization) - via- e mails, inter office memos, circulars, meetings,
tool talks, training/ awareness, posters, safety bulletins, campaigns, HSE notice boards & site visits.

External communication(to outside agencies) to clients, stake holders, visitor &or other interested
parties&shall be through transmittals, letters, meetings& e-mails etc.
The objective of the internal communication, especiallythe formal HSSE Meetings are, to provide a review of
monthly/ weekly/daily HSS&E issues at work, its outcome & matters of special concerns arising during
execution of work. Meetings,held at worksite offices &all work managers, engineers, supervisor/foreman &
worker representatives must attend. Which shall cover:-
 The review of previous month/week’s HSSE issues & concerns (accident / incident, unsafe act or
conditions or any environmental issues).
 HSE moment, presentations on any current and apt HSE issues.
 Lesson learnt from an incident on or adjacent & discussions on it.
 HSE trends & patterns.
 Motivating actions.
Workers shall be involved to comment or question on HSSE issues or potential hazards, from which they
come across during the course of work activities& experiences. This help achieve the involvement of all level
of participation & co-operation in the HSE matters are achieved.
The agenda of the meetings shall be minutes &circulated to respective, duly signed by all attendees &the
head of the departments.
Pre job safety Talk(Tool Box talk)- Work supervisor shall conduct daily pre job talk, which last for 5 to 10
minutes, at the first hours of the days job, about the work to be done, hazards, risks & control measures
including PPE,work permit instructions, stop work authority, LMRA, up keeping of site &action plans on
emergency etc. Record for it shall be maintained & site safety representative shall witness the tool talk.
Weekly SafetyTalk-Shall be held for 15 - 20 minutes, at the beginning of the shift of the first working day
of the weekpreferably on Saturdays, conducted by the approved Safety representative for the site &the
site supervisory staff shall be witnessing it.
Weekly Progress Meeting-Shall held at project site office with keypersonnel ofthe site (project manager,
site engineer, supervisor/Forman, worker representative). The discussion points shall be work progress,
Health, Safety, Security& Environmental matters, client inspections, internal walk around results etc. It shall
be recorded.
Monthly HSE Review Meeting-Chaired by chairman or his representative, Project/ contract managers,
project engineers, supervisors / foreman, worker representatives & safety representative to discuss all
HS&E concerns for the whole month & the action taken from the project manager & his representatives.
The frequency of this meeting may be increased, if deemed necessary. Minutes of meeting shall be
maintained & tracked for follow up actions.Superintendent or his representative from the Client may
present for the monthly HSE review meetings.

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Special Meetings -May be called to address special circumstances, e.g. work involving novel construction
techniques ie heavy lifts(if any),work requiring special instructions & precautions, visits by HSE Inspectors or
local regulatory authorities, poor performance by specific sections or after an accident resulted to loss
&concerns of audit & inspection findings which need urgent attentions.

HSE Inspections/Audits
Audit &Inspections (internal or external) areproactive assessment of Health, Safety & Environment (HSE)
standards of the organization for review& corrective actions. It enhances the standard of HS&E system by
evaluatingthe effectiveness&determines the status of compliance to the standard for a continual
improvement. Audits & inspectionare for:-
 Identifyaspects that can be resulted to impacts.
 Review, occupational standards in accordance with legal
&company requirements.
 Provision of systematic means to mitigate risks.
 Apply hazard control strategy(hierarchy of hazard
control )
 The success of the audit/ inspections depend on :-
 In depth HIRA Studies (HAZID,HAZOP, EIA, QRA,
PHSER, FTA, ETA &its combinations).
 Systematic inspections using checklists to cover all
aspects.
 PTW & JSA.
 Communications & Training.
Time to time audit by top management (visibility audit) to various aspects/areas shall also be carried out for
improvement. Every project shall conduct daily, weekly & monthly inspections as well as Quarterly internal
audits. Tools and equipment shall be color coded as under:-

Quarter 1(Apr-Jun) Quarter2(Jul-Sep) Quarter3(Oct-Dec) Quarter4(Jan-Mar)

External Audits-The HSE management systems of the organization shall be audited by an external third
party on its due renewal. More over the certification &calibration process for equipment, tools & other shall
also be carried out by a third party.
Audit review & follow up -Audit action items, shall be followed up by concerned department & shall be
closed within the time frame & completion report shall be maintained in this regards,the follow up actions
shall be reviewed in the succeeding audits.Audits results shall be communicated to all department for
praises or adequacy & system improvement if any.

Human performance & Behavior Safety

“To err is human, toforgive divine” Human error has been a factor in every incident, either small or fatal.
For an incident Free State, must focuson improving human performance.Distraction can happen to anyone
at any time.It is true thatover familiarity with taskshall be easier to lose concentration & mayleads to an
error. The high qualification, experience, competency&best available tools &equipment cannot perform the
job safe until the personality is ready to do it on his highest capacity. The first & foremost requirement for
the success of BBS is to understanding the purpose of it & for what BBS for?
An employee’s behavior at work is an observable act. Each observable act could result in either of the
following:-
 Safe behavior
 At risk behavior

The motive of SOLAR(Safety Observation Leads to Accident Reduction) is to the subject Behavior Based
Safety (BBS) process is concentrated for preventing accidents through reinforcement of safe (positive)
behavior & reduction of at risk (negative) behavior in employees, whether in occupational &or non-
occupational instances.

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This behavioral accident prevention program
encourages, continuous improvement through
the recognition & reduction of at risk behavior.
These elements of BBS include employee
training, observation of work places, positive
feedback & behavioral matrix.

The SOLARidentifies the behavior of an

employee at work, which is an underlying
&most valuable element for an incident/
accident. SOLAR aims for continuous safety
improvement to eliminate at risk behavior in
employees. The BBS process depends on site
observations & includes individual feedback,
which is the most valuable element of BBS
process. In order to conduct the observation,
the trained observer shall meet the worker at
site with self-introduction& observingthe work performance for both safe& at risk behavior. Once the
observation is over, the immediate feedback shall be communicated to the worker with praising for
positive acts & followed by at risk acts & bad consequences that could be resulted from the at risk
behavior.
Both (observer & worker) shall then agree on a recommendation, as to how the at risk behavior of the
worker can be corrected. This recommendation shall be for all risks observed.

The immediate feedback, discussion on negative consequences & agreement on the appropriate
recommendations to correct the at risk behavior help to persuade the worker to change his behavior.
Company leaders & supervisory staff shall demonstrate commitment, cooperation, coordination&actively
participate in the BBS process by conducting observations regularly.Company employees shall participate in
the BBS process observations & or being observed.Initial training shall be provided to all our employees
followed by refresher classes in order to ensure the quality of the observations & feedback. All shall attend
the training &refreshers on due courses.Action plans based on the data analysis shall be developed & traced
until closed out.

Work Permit System (PTW)

It is an authorization/written system, that uses a document to control the work within the controlled area
(work permit required area) by identifying potential hazards, mitigating risks for incident/accidents. The
document of agreement between issuer & executor.Responsibilities are fixed for each party for the safe
execution. The objective is a coordinated, communicated & controlled safe system of work. The PTW is
required to protect people, property & environment against the potential hazards.
PTW is required for all non- routine works including maintenance, construction, project activities, vehicle
entry in to hazardous area, inspection & condition monitoring activities using equipment that are not
intrinsically safe, activities requiring entry in to confined space &excavation jobs.
General Rules
a.Executing authority/Work supervisor(the person responsible for performing the work) shall obtain the
appropriate work permit before any job is started. The valid of the permit for the duration mentioned
therein. It can be renewed for one week.
b.Work permit issuer -usuallyfrom Operation department/ Control room or other custodian department.
c. Permit Applicant (in KOC) - are member of the sponsoring team nominated by respective team
leaderhaving detailed knowledge in PTW& technically competent to executes the work safely .
c. Executing authority shall get the permit revalidated if the work continues beyond the expiry time.
d. If work is not started or is stopped for over two hours for other than safety considerations, the executor
shall get the permit revalidated by the issuing authority before the work is started or resumed.
e. All work shall immediately stop when a fire or emergency alarm is sounded or accident of any kind occurs.
Approval from the Incident Controller shall be obtained after necessary preliminary investigations, to
resume such work. The Work Permit shall be revalidated to resume the work after the fire or emergency is
over.

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f.If the permit conditions or safety regulations are violated &or if the conditions around work area have
changed,which may lead to an imminently hazardous situation, authorized personnel (Field operator or
above of Operations Dept. or (concerned department) or Client safety) shall suspendthe work& withdraw
the work Permit, The person stopping the work shall immediately inform the reasons for stopping the work
to the Issuing Authority.The work shall only be resumed after establishing safe conditions &or renewal of
the Work Permit.
Types of permits&authorizations
Mainly there are four types of permit/authorizations commonly available in KPC facilities. Two work permits
(Hot & Cold work permits) & two authorizations (Confined space entry & excavation). All the forms are
being identified with color.
Work Permits &Authorizations:
A. Cold Work Permit– This permit is for all kinds of maintenancejob & other jobs which is not involved in
use of ignition or not any generation or release of heat. Examples- erection of scaffold in hazardous area,
survey works, visual inspection of equipment in process areas& tagging etc. To perform cold work- the
equipment shall be isolated in all means using LOTO, adequate PPE used & there should be no leaking of
flammable&toxic gas or liquid.

B. Hot Work Permit-it is required for any work to be carried out in a work permit area involving the use of a
local source of ignition capable of igniting flammable gases, liquid or any other material. Examples - welding,
burning, gauzing, grinding, blasting, soldering, any open fire, use of non-explosion proof equipment, vehicle
entry, opening up of electrical equipment in gaseous areas etc. To perform hot work, adequatebasic safety
precautions shall be taken prior the commencement of it. Like- gas testing, provision of 2 no of fire
extinguishers, fire warden, charged fire hose, removal of combustible, confining the place & atmosphere
monitoring arrangements.
C. Confined Space Entry Authorization–it is required in addition to the hot/cold work permit for entry into
any confined space; eg vessel, tank, furnace, sewer, pits or excavation deeperthan 1.2 meteretc. This entry
authorization/permit ensures, personnel are protected against hazards of oxygen deficiency, toxic &
flammable material, power driven equipment etc. This can only be authorized by the Permit issuer.
D. Electrical Isolation- is required for any work on electrical system. LOTO(multi lock system) shall be
followed when more than one craft are involved.
E. Excavation Authorization Within the restricted area, excavation authorization is required in addition to
the hot / cold work permit for all excavations regardless of depth. For excavation work outside the restricted
area, for diggingdeeper than half a meter require an excavation authorization.

General Responsibilities of Executor:

 According to the work scope theexecutor shall request the respectiveapplicant/ issuer for a work
permit.
 Identify all hazards related to the work as well as adjacent hazards to mitigate it or select proper
PPE.
 Identify proper tools & equipment necessary forperforming the work& ensure its condition.
Provision ofsafety certificates for vehicles & engine driven equipment.
 Carryout pre task talk with work men, which describes the job & associated hazards.
 Signature indicates understanding & compliance to relevant conditions of the permit.
 Adequate supervision for the job.
 Permit & associated authorizations shall be available at the site.
 Close the permit at the end of job & preserve the closed copies for the next one month.

General Conditions of Work Permit

 No work shall ne commenced without a valid work permit.
 Adequate work risk assessment shall be completed &mitigated.
 All columns of the permit shall be completed by responsible personnel.
 All permit requirements (safety requirements) shall be met before the issuance of work permit.
 Display the permit at work site with associated authorizations.
 Separate permits shall be obtained for differenttask& locations.
 Only authorized personnel holding “work permit authorization card” shall sign the permit.

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  Permit issuer shall inspect the site prior the issue & closure of work permit.
 Permit issuer is responsible for preparation of the equipment, i.e.Depressurizing, draining, flushing
&purging etc..
 Issuer /designated personnel shall visit job site frequently for safe execution of the job.
 All tools used for the work shall be meeting the safetystandards & shall be secured properly.
 The work place shall be house kept before & after the work.
 Any unsafe of hazardous situation must be reported to the permit issuer or fire station.
 In case of any dangerous situation the work shall be stopped immediately &work permit is endorsed by
the PI.
 Work shall be commenced once the area is rendered safe.
 No hot work shall be carried out during hydrocarbon venting & painting etc.. Hot work is allowed only if
the LEL of any flammable gas is 1% (Max) or less.
 In case of violation of work permit conditions, PI,PA, HSE Personnel, Fire personnel or any responsible
personnelfrom the custodian / assets owner can stop the work.
Work permit risk assessment (WPRA)-It shall be completed in the entire manner prior the job is started.
The WPRA shall be carried out by people with the process knowledge. A team led by section head, safety
engineer, maintenance engineer &shift supervisor & any engineer if considered necessary for the job.
The WPRA stepsare:-
 Identification of hazards
 Assessment of Risks
 Putting control / safe guard in place
 Re assess the risk with controls in place
 Confirmation of residual risk.
Closing of work permitthe following shall be completed by the work supervisor (executor):-All the
precautions orisolations taken at the beginning of the work shall be removed or withdrawn.Check & ensure
all the tools &equipment& removed. Proper housekeeping has completed.Informing the PA (in KOC) to sign
off the Permit. Close & retain the copy of permit for three months for audits.

Emergency Action Plan

An emergency may occur any time inOil & Gas facilities in the form of fire, explosion & toxic gas release.
However, natural calamities (flood, avalanches, and earth quakes) epidemic& terrorist attacks etc. shall also
be listed in the form of emergencies.The safe guarding of human life is the prime importance during an
actual emergency.There are certain procedures formed &based on it,emergency drills shallbe practicedto
act smartly in actualemergency situations with no confusion. Everybody working inside the industry should
know the procedures& bided to adhere it.
Emergency Alarm
The emergency alarm varies from industry to industry. It is a three minutes siren.

Emergency Situation Distinct Tone – Frequency

____________
Alert Two tone warbling note _ __ _ __ _ _ _ _ _ _ _

Evacuation Deep Sound, short blast

───────────
All Clear Steady uninterrupted note
───────────-
Signal Identification
1. Broken tone (Alert)
2. Wavy tone-Danger occurred- go to the nearest gathering (transfer) point.
3. Continuous tone- All clear, go back to your work place in an orderly manner.
Action on hearing Alarm
 Know the siren.
 Do not panic, keep your calm.
 Stop the job & put off machinery / equipmentsafely on what you are working.

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  Keep noise as lowas possible to hear instructions.
 Remain alert & wait for instruction for evacuation.
 Observe the wind direction from the wind socks provided in the Premises.
 Proceed smartly to the closest transfer point on instructions from group leader.Movesmartly (never run)
taking the shortest way cross wind direction or up wind direction. Assemble at the transfer point forming
a "Queue" representing your company & make available for the "Head Count". Give information about
college for his absence/ missing. If situation worsens you shall be transported to main gathering point for
safe haven.Never use elevators. Those working at tower cranes etc&other elevatedplaces shall decanted
slowly with three points contact to the ladder provided.
 Wait for further instructions / transport to evacuate.
General Guidelines
 Get familiar with the evacuation route, transfer point & gathering point.
 Know the date & siren timing for testing & for actual emergency evacuation.
 Do not panic, keep calm.
 Keep noise to a minimum so that instructions can be easily heard.
 No panic driving or overspending shall be done.
 Give way to emergency response vehicle&no hindrance to emergency vehicle, evacuating pedestrians or
others.
 Do not re-enter to the work location unless instructed.
Emergency telephone numbers
Kuwait Oil Company KNPC Joint Operations Kuwait Operations
Fire, Ambulance & Fire Emergency – 888 Fire station-23984444 112
Emergency-160 EDC MAA-81111 Emergency -112 &
EDC MAB-83111 23811701
Burgan fire station – EDC-Sabhan-86500
KOC Wafra Clinic-23985465
2398-22221, EDC- Ahmad-86328
KOC Ambulance-60604835
22222,66669 & EOC, Sabhan- 86690
3986373 EOC, Ahmadi-86308
EOC MAB- 83222
West Kuwait Fire SAT Wafra Clinic-23985428
Ambulance- 81300
Station- 2398-20348, SAC Ambulance-66432111
Clinic- 81306/
20320, 20278, 20276
81303/81304
North Kuwait Fire VOIPD -23985407
Station- 2398-23111,
23100, 23199

Fire Prevention
It is a rapid chemical reaction known as combustion, in which Oxygen combines with a combustible
substance (fuel) in the presence of source of ignition (heat) to produce light & smoke.Human life,
property&environment are at risk in the event of fire. Protection from fire (occupational & non-
occupational) is of vital importance to all employees. Every employee should know what is expected from
him,prior a fire occurs or in the event of fire. Learn emergency procedure, if in doubt ask superior without
fail.
Firefighting equipment-Portable fire extinguishers &hose reel are the first aid firefighting equipment held at
site& company installations. It shall be used by the trained workmen for initial & minor firefighting. Make
sure you know how to operate them.
Fire notification/communication-Alert, using breaking of fire glass or activating portable fire alarm (electric
bell).Know the emergency call numbers (given in the succeeding section) & inform emergency control
center at once.Notification shall be clear & consisted message with who, what, where,how&when.
Dos &Don’ts
 Smoking at designated points only.
 Maintain good housekeeping.
 Strictly follow the firesafety rules & regulations.

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  Never overload electrical sockets.
 Never use tools with damaged electrical cords.
 Do not run electrical cords across doorways, under rugs/ carpets, where they could be stepped on or get
damaged.
 Store flammable materials in approved safety containers in store room in ambient temperature, exits,
stairways & easels shall be cleared of flammable materials.
 No unauthorized cooking appliance at kitchen.
Adopt 5S management technique for performance excellence, that are (1)sweep/sort,(2) set in order(3)
shine (4) standardize & (5)sustain (detailed in section below)
Classification of Fire & extinguishing agents
Class A-(Solid fire)Ordinary combustiblematerials: -wood, Fabrics, paper, rubber, many plastics&other
carbonaceous materials.
Class B- (Flammable liquid& gasesfire):- petroleum Products-petrol, oils, grease, paint, lacquer, tar,LPG,
(propane, butane, acetylene) & hydrogen etc.
Class C-Electric Fire: - Electrical gadgets, equipment,where electrical current is present.
Class D-(Metal fire) involving burning metals& alloys: - sodium potassium &magnesium etc.
Class K-(Cooking Oil &Fats fire) -vegetable oil, animal’s oil, other oils, butter& fats.

Suitability of Fire extinguishers

Extinguisher Type & Color A B C D K
Flammable
Electrical Metal Cooking
Type Color Solid liquid &
fire Fire Oil& Fats
Gas
Water Red ✓ X X X X

Foam Cream ✓ ✓ X X X

Dry Powder Blue ✓ ✓ ✓ ✓ X

CO2 Gas Black X ✓ ✓ X X

Wet Chemical Yellow ✓ X X X ✓

Any person who intends to use a fire extinguisher must be trained & implement the PASS method in its
use.
 Pull the pin located at the top of the
extinguisher to unlock the extinguisher
& allow it to discharge its contents
when the trigger is pulled.
 Aim the extinguisher at the base of
the fire, not the flames.
 Squeeze the lever to release the
extinguishing agent. If the lever is
released, the discharge will stop.
 Sweep from side to side. Using a
sweeping motion, move the fire
extinguisher back & forth until the fire
is completely out.

All minor fires to be confronted using available portable firefighting appliances. Operate the extinguisher
from a safe distance, several feet away, & then move towards the fire once it starts to diminish.

Accident/Incident Reporting& Investigation

10
There is a possibilityof an incident(accidents, near misses, dangerous occurrences)in every sphere of human
life, either at home, while travelling, at play or at work. Accident results from the combined effect of
physical circumstances, which can often be recognized as hazards.
Accident –An undesired event that results in personal injury or property damage.
Incident -An unplanned, undesired event that adversely affects completion of a task. Work- related event(s)
in which an injury or ill health (regardless of severity) or fatality occurred, or could have occurred. Incidents
are two (1) reportable incidents & (2) recordable incidents.
Reportable Incident- Those incidents, without considerations to severity, potentiality, category, location &
time of occurrence that has to be reported to the management for onsite damage control support,
internal record keeping, investigation purpose & preventive measures. All incidents of company business are
reportable.
Recordable Incident- All reportable incidents of companybusiness are recordable & action shall be taken for
a complete investigation process & shall be incorporating n the HSE statistics.
Near Miss - Which describe incidents where no property was damaged & no personal injury sustained, but
where, given a slight shift in time or position, damage &/or injury easily could have occurred.
Injury or Illness-An abnormal condition or disorder. Examples for injuries - a cut, fracture, sprain, or
amputation. Example for Illnesses (both acute & chronic illnesses) - skin disease, respiratory disorder or
poisoning.
Industrial Disabling Injury (IDI) -Occupational injury resulting in one or more full days away from work.
Examples are:
Lost (Time) work day case (LWDC) &Fatal Cases.
Industrial Non-Disabling Injury(INDI) -Any occupational injury, which requires medical treatment only,
without causing disablement. Examples are: -Medical Treatment only Cases (MTOC) & First aid cases.
Restricted Work Day Activity case (RWC) - Any work-related injury other than a fatality or lost work day
case (LWDC) which results in a person being unfit for full performance of the regular job on any day after
the occupational injury. Work performed might be: & assignment to a temporary job; part-time work at the
regular job; working full-time in the regular job but not performing all the usual duties of the job. Where no
meaningful restricted work is being performed, the incident should be recorded as a lost work day case
(LWDC). This is a recordable incident.
Motor Vehicle Accident(MVA)-Any event involving vehicle (light & heavy) & mobile equipment, including
(owned, leased, or rented by Al Magwa)- or a personal vehicle being operated for company business.
Fire / Explosion- Any undesired occurrence involving company or client property, equipment or operations
that result in flames, excessive heat or combustion & resulting in a fire or explosion. This could include
damage to 3rd party property from company activities.
Property Damage (Dangerous occurrences)- The loss or damage to company/client property, equipment or
material resulting from an incident which will require some form of repair, restoration or replacement. This
could include damage to 3rd party property from our activities.
Environmental Event-Any situation where a person observes or becomes aware of an event, which
adversely affects the environmental, such as: leaks or spills, uncontrolled emissions, non-compliance & non-
conformances.
General Requirements-When an incident occurs, that could have caused serious harm to personnel,
property,environment, or business interruption. The immediate aim of anincident investigation is to obtain
/accurate full information about the circumstances & cause of the accident. Three things must occur to
ensure safety, efficiency, & continued quality:-
1) Prompt, safe & efficient handling of the incident to reduce the severity.
2) A thorough investigation aimed at correcting the root cause of the incident.
3) Sharing the result of theincident (lesson learnt) &knowledge gained from the investigation with the work

11
groups & departments, helps prevent similar occurrences.
All incidents shall be reported in order to:
 Prevent recurrence of similar accidents.
 To uncover new hazards& device adequate measures to
control.
 Maintain a capability to promptly investigate incidents in
order to initiate & support corrective
&/or preventive action.
 Provide statistical information for use in analyzing all phases
of incidents(HSE record& statistics).
 Provide the means for complying with the reporting
requirements for occupational injuries & illness.
 It is also the objective company to create, maintain & file
Incident reports as required by law&for insurance.
 To learn lesson & correct ( learn from others mistake, to
make amendments)
Action over an Incident- All kinds of incident/accident i.e.
personal accident, dangerous occurrence, traffic accident &
near miss, however minor, shall be immediately reported to the company or client by the senior responsible
personal or safety representative. Allaccidents (occupational or non-occupational) shall be left undisturbed
unless it is absolutely required to tackle the emergency &/or to make the area safe, until the arrival of
responsible personal.
Personal incidents- Medical attention to the injured shall be the first priority in case of any accident. Injured
shall be transported to the industrial/MOH medical facilityby a trained medical personal by thefastest
means. Adequate reporting of the incident shall be made in the prescribed formatwithin the time.
Motor vehicle Accident-Investigation procedure (inside the client/company premise or Kuwait roads) to be
followed for reporting&investigating ofall trafficaccidents. Traffic Accident involving personal injury shall be
reported & investigated as both Traffic Accident & Personal Accident. Similarly traffic accidents involving
property damage shall be treated as both Traffic Accident & Dangerous Occurrence.Accidents to vehicles
outside client premises shall be referred to the Traffic Police immediately. Driver of the vehicle/witness
shall inform company responsiblepersonal &ECCC & advise if ambulance/fire equipment is
required.Responsible senior staff or Safety representative shall assess the situation & advice necessary steps
to avoid escalation of the incident. Vehicles(s) involved in the accident shall not be moved from the site until
cleared by Security or traffic department.No repair shall be undertaken until theinitial investigation has
been completed & report is submitted. Initial Investigation shall be completed within 48 hours.Obtain Police
report for repair.

Personal Protective Equipment

It is a last resort of protection, providedto anindividual onlyagainst the residual risks thatcannot be
removed after the implementing of other means of controls. eg. (1)Engineering control-control of risk at
source) (isolation- isolating the equipment by the means of enclosure, barrier or guard),
insulation(insulating electrical or temperature hazard) & ventilation(ventilating away any hazardous fumes
or gases either naturally or by the means of extractor fans & hoods) etc.) (2) Administrative control,
procedural controls, training & disciplining.
PPE does not eliminate the hazard & will present the wearer with the maximum health risk if the equipment
fails.Successful use of PPE relies on good user training, the availability of the correct equipment at all times
& good supervision & enforcement.
Limitations of PPE are:-
 Only protects person wearing theequipment, no mass protection.
 Protection relies on people wearing the equipment at all the time.
 Must be used properly.
 Must be replaced when it no longer offers the correct level of protection (esp. for respiratory protection)

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Benefits ofwearing PPE
 It gives immediate protection to allow a job tocontinue while engineeringcontrols are put in place.
 In an emergency, it can only be the practicable way of effecting rescue or shutting down plant in the
hazardousatmosphere.
 It can be used to carryout work in confined space where alternatives are impracticable,but it should
never beused to allow people to work in dangerous atmosphere, which are forexample enriched with
oxygen & explosives.
General Rules -User are responsible for the maintenance & care of their PPE. Shall be well groomed to wear
all personal safety gears with no instructions- such as goggles & face shields when performing chipping,
grinding & other such works, correct shade of lens, goggles & welding face shields, apron & ankle protection
during welding jobs, wearing full protective clothing when handling acid, alkalis & other such chemicals,
wearing tight fitting sleeves& no loose ornaments while working near or on moving machinery, wearing
ear plugs / ear muffs when working in noisy areas of 85 dB(A)& above or where hazard sign is posted,
weaning normal safety gloves when handling sharp objects,wearing electrically insulating shoes, gloves &
helmet while working on live electrical equipment & using rubber insulating mats for standing as well as
using proper respiratory protecting/ lifesavingequipment for inhalation hazards.
Always make sure, the PPE offers adequate protection for the job.
Follow instruction for use & report any defects to responsible supervisor. Never return defective PPE to
store non reported.
Never modify any PPE, either by painting it or some other modifications like cutting the brims& making
holes in helmet.
For maintenance of a machinery (wiping away debris), use brushes instead of hands.

Types of PPE
A. Non respiratory PPEs
Safety Shoes- Ankle high safety boots commonlyprovides
protection against impact, compressions, oils, heat, static
electricity, falling objects, slipping & penetration of sharp
objects. Some special boots are required for welders,
chemical handlers, fire fighters & concrete workers.
Safety Helmet- Provides head protection against impact,
falling objects, hot surface & electric shock. Chin strap
keeps helmet in position while working at height, in high
wind & in confined space. Suspension system (crown) shall
be cleaned using mild soap solution. Never mishandle
helmet either by throwing or using it for seating purpose.
No painting, drilling holes or cleaning with chemical on shell
which increases the brittleness. The safety helmet shall be
replaced after 5 years from the date of manufacture.
Safety Coverall- Provides protection against absorption of dust& some extent against heat &bruises. Non
static, flame proof safety coverall for O & G industries. No loose cloth shall be worn while working near
rotating equipment. Disposable coveralls/ PVC suits shall be worn when having nuisance dust like coke,
catalyst dust, while handling chemicals & corrosives, cements & de-sludging activities. Contaminated
coverall shall be disposed off & never carry to home.
Hand Gloves-Al ways wear gloves to protect hands from, heat, electric shock, acids, caustics,oils, sharps &
general tear & wear. Gpglove for general works, PVC/ rubber gloves for chemicals & corrosives & for
electrical shocks, neoprene or electrical protective rubber gloves shall be worn. No gloves hall be used
while dealing with a rotating equipment esp. Lathe machine. MSDS shall be refereed for hand gloves for
hazardous substances.
Hearing protection-Continuous exposure to high noise may result to acute or chronic hearing loss. Hearing
loss is generally gradual, painless & invisible, but is a permanent. If the noise level is above 85 dB(A) wear
hearing protection(ear plug/ muff or the combination). These shall be kept clean all the time.
Eye & face protection-protection against flying particles, foreign bodies, chemical flashing, irritant gases,
dusts& radiation. For hazardous activities like welding, grinding, gauzing, chipping, jack hammering, dealing
with agitate fluids& chemicals like sulfuric acid, whole face protection along with goggles shall be used.

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Fall protection-In the fall category (fall elimination, fall prevention &fall protection) the same is described
in details in the work at height. When the first & second methods are not practicable the fall protection
shall be adopted by allindividual employees who are working over 1.8 meter (6 feet) height.
Life jacket- For off shore works, allemployees shallwear non inflatable type life jacket per the personal
protection.
B. Respiratory PPEs
Respiratory protection equipment can
be sub-divided into two categories-
respirators (or face masks), which filter
& clean the air, &breathing apparatus
which supplies breathable air.
Respirators should not be worn in air
which is dangerous to health, including
oxygen deficient atmospheres. They
are available in several different forms
but the common ones are:-
Air purifying respirators-These types are designed to filter the air&never provide additional oxygen to the
user. There are a number of types of respirator that provide a variety of degrees of protection to the user.
Such masks to be used when atmosphere contain sufficient oxygen to sustain (min 19.5 % by volume)&
these are suitable for protection against nuisance dust & never used against harmful dusts& aerosols (mists
& fibers).Supervisorsshall be responsible for identifying the hazard & appropriate RPE requirements to
control the risk/exposure to the employee & adjacent workers.

Gas Mask- For protection against specific hazards(chemical vapors &gases), cartridge or canister type
respirator designed for specific gas to be used. The canister mask can be used within the limit usually 2% for
toxic gases, specified on the canister. It shall not be used after expiry or the seal is found broken.
Types of Respirators
(1)Filtering half mask- (disposable respirator)-made of the filtering material. It covers the nose &mouth,
whichremoves irrespirable size dust particles. It is normally replaced after 8/10 hours of use. It offers
protection against some vapors& gases.
(2)Half mask respirator-made of rubber or plastic & covers the nose & mouth. Air is drawn through a
replaceable filter cartridge. These can be used for vapors, gases or dusts but it is very important that the
correct filter is used (a dust filter will not filter vapors).
(3)Full face mask respirator- similar to the half masks type but covers the eyes with a visor.
(4)Powered respirator-a battery-operated fan delivers air through a filter to the face mask, hood, helmet or
visor.
Advantages- Cheaper, light weight,offers unrestricted movement, able to use comfortably for extended
periods period of time
Limitations–Purifies air by drawing it through a filter to remove contaminants. Can only be used where
sufficient oxygen is in the local atmosphere.Cartridges must be monitored for time used & replaced as
recommended.Success relies on user making sure it is correctly fit.Can be incompatible with other
PPE&interferes with sense of smell.
Air supplied Respirators–These respirators (Breathing apparatus) provides a separate source of supply of air
to that which is present in the local environment. Due to the “self-contained” nature of breathing apparatus
it may be used to provide a high degree of protection from a toxic environment.
Types of Breathing Apparatus
(1)Self-contained breathing apparatus (SCBA)-It consist of a compressed air cylinder, full face piece, air
supply hose, pressure regulator, gauge & low pressure alarm. Where air is supplied from compressed air in a
cylinder & forms a completely sealed system.It offers respiratory protection for 15- 30 minutes in an oxygen
deficient toxic atmosphere.
Escape breathing apparatus setcan be used for a short duration of 15 minutes to provide full respiratory
protection so as to enable to escape from the hazardous atmosphere in emergency.

14
(2)Fresh air hose apparatus– Consist of compressed air in two cylinders, two full face piece, air supply hose,
pressure regulator & low pressure alarm. Fresh air is delivered through a hose to a sealed face mask from an
uncontaminated source. The air may be delivered by the wearer, by natural breathing or mechanically by a
fan.Fresh Air Mask ( trolley Type)-One cylinder offers breath air for 1 hour normally. 2 personnel can able to
use two masks at a time.
(3)Compressed air line apparatus-air is delivered through a hose from a compressed air line. This can be
either continuous flow or on demand. The air must be properly filtered to remove oil, excess water & other
contaminants & the air pressure must be reduced.
Advantages-Supplies clean air from uncontaminated source. May be used in oxygen deficient environments
& has High Assigned Protection Factor (APF). May be used in atmosphere of high levels of toxic substance.
Where type of work allows, may be used for long periods if connected to a permanent supply of air.
Limitations-Can be heavy & cumbersome, thus restricting movement. Requires selection of competent
persons to administer & use. Operators require complete specific training in use of equipment & emergency
situations. Requires manpower, (supervision & monitoring). Cylinders require storage facilities. Can be
incompatible with other PPE .More expensive than Respirators
Safety Requirements
 Breathing Apparatus (BA) brought to site must be approved by company &client management.
 Cylinders, regulators & associated hoses must be in sound working order & accompanied by relevant
certification(TPI).
 Face masks must be free from damage. Seals, straps & (if installed) demand valves shall be tested as part
of employee “fit test”.
 As with any PPE, BA sets & associated equipment must be inspected prior to use by the Supervisor, BA
set attendant & user.
 The user shall be trained adequately for the use of supplied air masks from a third party & shall be
holding the valid authorization card approved by the client.

Manual Material Handling (MMH)

The movement of load by a human effort alone. Transporting or supporting of a load by hand or body force.
This includes, lifting, carrying, pushing, pulling, moving, supporting or puttying down. The manual handling
shall be kept to minimum to avoid strain & back injuries. The hazards & risk from MMH depends on “LITE”
 The Load, The Individual, The Task, The Working Environment
MMH brings acute (sprains, cuts etc. heals within short period) &chronic (irreversible) injuries like arthritics
& spinal injuries to the worker. The most common Injuries resulted from poor MMH are:-
 Muscular sprains & strains, Back injuries, Trapped nerves, Hernia, Cuts, Bruise & abrasions, Fractures
MMH Guidelines
 Always assess the weight of the object to be lifted&
get help if it is beyond capacity.
 Use the availability of lifting equipment & or
mechanical aid. The appropriate lifting devices shall
be utilized for heavy items & bulk handling of
materials.
 Stop & think. Visual check the item to be lifted for
any protruded parts etc.
 Wear correct type of hand gloves for the right usage.
 Adopt a good posture,Keep your feet apart, feet
close to the load& bend your knees not your
back.Bend as close to the object as possible, tuck
your chin in & keep your back straight (not vertical).
 Get a firm grip, never change the grip while carrying.
 Begin with the load between the feet; the leading
foot should be in line with side of the load, pointing
in the direction of movement.
 Generally grip the opposite corner with the other
hand. (Ensure the palm, not fingers, take the weight).

15
 Keep your arms close to your body. Moverear hand forward along the lower edge of the load. Stand up in
one movement keeping the load in contact with the body at all times. To lower the load, reverse the
procedure, bending your knees whilst tilting the load to avoid trapping fingers.
 Lift slowly by straightening legs.
 Don’t jerk.
 Move the feet.
 If posture not comfortable, Put down, & then adjust.
 Never lift the load over chest high.
 Extreme precaution shall be applied while handling hazardous, explosive, toxic or flammable materials.
 The materials should always be stacked considering accessibility & movement.
 For mutual multi personnel handling of a load, personal shall be of equal maneuverability, height,
fitness & shall be guided / directed/ signaled by a single leader.

Mechanical Material Handling

The use of lifting equipment & accessories (Cranes, Boom truck, Fork lift, hoists, Derricks, Jacks & lifting
accessories like slings&shackles)are subjected to certain hazards that cannot be prevented by mechanical
means alone, but only by the exercise of intelligence, care & commonsense. It is therefore essential that
only competent, trained & authorized personnel operate/deal with such equipment.
Working on lifting equipment need skill & experience, so unless you are not qualified & experienced to do
so, do not try to or experiment on the lifting equipment or any other lifting appliances.
 The manufacture's specifications & limitations & operating guidelines shall be strictly followed.
 Client HSE procedure for the subject lifting shall also strictly adhered.
 Only trained, competent & authorized personnel (Crane operator & rigger) shall be posted for rigging
activities.
 The rigging crew shall be safety concerned & working on instruction of
rigger & lifting supervisor.
 Never use or allow the use of lifting equipment &accessories which is
not in perfect working condition or with damaged parts etc.
 Lifting equipment should be positioned on terrain that is as level as
possible.
 Locating the lifting equipment as much close proximity to the load
shall be ensured to avoid over-reaching by the crane.
 Instructions regarding rated load capacities, operating speeds &
special hazard warnings are to be followed without fail.
 Always follow a standard hand signaling system.
 The lift/ swing/ drop area shall be barricaded prior the lift activity to
prevent the visitors, or un indented approachesof vehicle etc.
 Only trained,competent&approved rigger with valid authorization
card& in high visibility reflective jacket shall be making signaling.
 All equipment should be certified for its integrity by an approved third
party. The operator &rigger shallcheck the equipment&accessories
before use. Defects if any should be reported immediately & removed
from site at once.
 No repair to lifting appliance shall be accepted.
 Keep Lift trucks & crane away from overhead power lines. When
operating near energized electrical lines, work with extra care under
instructions. Safe distance shall be maintained as per the ministry of
electricity & water ( Kuwait) as under :-

Voltage level of existing Minimum vertical distance/ clearance from the

Overhead power lines lowest conductor to the top most part of the
equipment/ vehicle
11 KV lines 2 meters
33 to 132 KV Lines 5 meters
300 KV Lines 06 Meters
400 KV Lines 07 Meters

16
 Do not use the cranes for transporting loads if it is notintended for the purpose. If yes, shall be used for
short duration away from the public road & crowd.
 Use correct type of slings(alloy steel chain, wire rope, metal mesh natural or synthetic fiber rope &
synthetic web) to best suit the item to be lifted.
 The sling angle to be considered before lifting. Vertical sling ankle shall not over 60 0(length of the sling /
height from the center of the load to the hook) L/H.
 Observe crane &sling load application.
 Centre the hook on the load before lifting to avoid swinging of load. Centre of gravity of the load to be
identified & suitable sized slings shall be used to maintain it to avoid tilting of the load. The load shall be
lifted little high from the ground to check the center especially for shapeless objects.
 All hooks used for the lifting shall be with latch/lock to avoid slipping of load while lifting.
 The load shall be guidedusing tag lines/ guide lines attached to a suitable point.
 Never jerk lift the load while lifting. Apply the load to sling gradually.
 Never exceed the safe working load of the lifting equipment & tackles.
 Sharp edges of the load shall be adjusted with softeners to avoid cut/abrasion to fiber rope/ webbing.
 Multiple slings 2,3 or 4 legged) must have their legs connected to an ‘O’ ring or a center shackle to
distribute the load equally.
 Never tie a knot or bolt with chain to reduce the length or adjust with different length of slings.
 As much as possible avoid choke hitch,basket hitch, inverted basket hitch & toggle hitch, make use of
straight hitch using shackles or hooks.
 Ensure the load is hooked correctly before lifting. No load shall be left suspended & unattended. Never
work/ walk under suspended load& do not stand under suspended loads.
 During high wind speed conditions& less vision operation of cranes should be suspended, otherwise,
advice from client safety department shall be sought before in such conditions.
 Multiple crane lifting operations must be planned with extreme care under a common rigger with
necessary communicating facility.
 Never overload cranes, operations shall be strictly as per load chart / operating manual.
 All equipment backing up to be equipped with back up to alarm signaling device.
 Two numbers of portable fire extinguishers (certified by the client fire) shall be mounted in the crane
body.
 No lifting equipment or load shall object the access to emergency facilities in the client premises as well
as emergency services.
 Man lifts( aerial lifts) /Man baskets/ scissors lift & sky climbers or other man lifting equipment/ cages
shall be used only if they have been tested & certified (TPI) for use. Aerial lift shall be operated by TP
trained operator. The cage shall be closed while people on board. Overloading (SWL) is forbidden.
 Employees riding in a crane suspended work platforms, aerial lifts etc.., shall wear a body harness &
lanyard attached to the grab rail of the platform or
the “O” ring independently connected from the hook
of crane.

Driving & Traffic Safety

For some of us, the most dangerous thing we do every
day is drive to and from work. For others, driving is
simply part of the job. In order to complete these tasks
safely on a daily basis we must practice defensive
driving.

Defensive driving is the ability to reduce the risk of

accident or collision by anticipating dangerous situations,
despite adverse conditions and the actions or mistakes
of others. This can be achieved through adherence to a
variety of general rules and incorporating a set of specific
driving techniques into our everyday commute.

1. Do a quick walk around your vehicle to evaluate the

condition of your vehicle prior to getting on the road. 2.

17
Secure all loose items in your vehicle. Do not attempt to catch items sliding around in your car.
3. Always keep your eyes moving, constantly looking at your side and rear view mirrors, up, behind and to
both sides of the vehicle. Maintain a visual of two to three car lengths in front of you.
4. When changing lanes, physically turn your head around to check your blind spot, followed by checking
your side and rear view mirrors.
5. Look out for motorcycles, bicycles, pedestrians and smaller vehicles.
6. Leave at least two car lengths between you and the car in front of you. During inclement weather,
increase this to five car lengths.
7. Always give yourself an out. Avoid remaining next to other vehicles, move ahead or drop behind them to
allow yourself room for maneuvering in case something happens.
8. Stop prior to stop signs and then roll forward slightly to get a better look in each direction.
9. Always use signal lights and be sure to signal ahead of time to communicate your intensions to other
drivers.
10. Avoid using a cell phone. In Saskatchewan it is illegal to use a mobile devise will operating a vehicle. If
necessary, always use a hands free device.
11. Follow the speed limit and pay attention at all times.

Working at height
One of the biggest causes of fatalities & major injuries. For any activity, where the fall potential is greater
than 1.8 meters, shall be considered as work at height, this includes fall below grade level, ie, excavation
workor work in any place where, there were no precautions in place, a person could fall a distance liable to
cause personal injury (for example a fall through a fragile roof).
Working at height include:-
 Working on a permanent or temporary platform like scaffold or from a mobile elevated work platform
(MEWP).
 Working on a ladder at & over the acceptable height.
Working at height potential significant hazards
 Inadequate equipment, improper use or nonuse of fall protection, barricades, ladders & scaffolding
increases the risk of serious injury.
 Falling of personnel from heightdue to unprotectededges risk of death or serious injury.
 Environmental conditions (wind, bad weather, rain, lighting & thunder)
 Live electrical lines.
 Inadequately supported services (weak support, such as roof, interior ceilings, decking &
 grating etc)
 Suspension trauma (harness hang syndrome (HHS) - the human body is held upright without any movement for
a period of time may resulted to fainting

18
Before working at height,work through these simple steps:-
(1)Avoid it, where it's reasonably practicable to do so for avoidance or elimination.
Fall Elimination-The first & foremost step in thisapproach is to assess the workplace & the work in advance
i.e. planning/engineering stages of all work. The objective is to eliminate all fall hazards. This assessment of
the project/site & the work not only helps eliminate hazards, but also identifies alternative approaches to
the work that can measurably enhance productivity.
(2)Prevent -Where work at height cannot be easily avoided, prevent falls using either an existing place of
work that is already safe or the right type of equipment.
Fall Prevention-The second step in continuous fall protection also requires assessing the workplace & work
processes. Proactive approach to avoid fall can be done by installation of stairs, guardrails, barriers, & travel
restriction systems.
Minimize the distance & consequences of a fall, by using the right type of equipment where the risk cannot
be eliminated.
(3)Fall Arresting - The third step, the last line of defense against falls, is to use fall-arresting equipment.
Equipment such as harnesses, lanyards with shock absorbers, fall arresters, lifelines& anchorages will be
used to reduce the risk of injury if a fall occurs.
Personal fall arrest systems used on scaffolds will be attached by a lanyard to a vertical lifeline, horizontal
lifeline, or scaffold structural member.
Cross bracing is acceptable in the place of a mid-rail when the crossing point of the two (2) braces is
between 0.5 meters (20 inches) & 0.8 meters (30 inches) above the work platform or as no more than 1.3
meters (48 inches) apart
For each step, always consider measures that protect everyone at risk (collective protection) before
measures that only protect the individual (personal protection).
Collective protection is equipment that does not require the person working at height to act for it to be
effective. Examples - permanent or temporary guardrails, scissor lifts & tower scaffolds.
Personal protection is equipment that requires the individual to act for it to be effective. Examples- putting
on a safety harness correctly & connecting it, with an energy-absorbing lanyard, to a suitable anchor point.
When any work is required to take place at heights of 1.8 meters or above the ground level, work should not
proceed unless we observe the following:
 A fixed platform can be used which is fitted with both guard rails & toe-boards to prevent the falls of
personnel or materials from a height.
 The platform has been inspected & verified safe to use by a competent person(s)
 Where this is not possible the work should be performed by personnel competent in the using of fall
arrest equipment which has the following characteristics:
 A full body harness complete with rear ‘D’ link. Synthetic fiber lanyard & Shock absorber terminated
with a spring loaded karabiner or two numbers of scaffold hook.
 Suitable anchor points preferably located overhead.
Dos & don’ts
Do….
 As much work as possible from the ground.
 Ensure workers can get safely to & from where they work at height.
 Ensure equipment is suitable, stable & strong enough for the job, maintained & checked regularly.
 Take precautions when working on or near fragile surfaces.
 Provide protection from falling objects.
 Consider emergency evacuation & rescue procedures.

Don’t…
 Overload ladders.
 Overreach on ladders,stepladders or from work platform.
 Rest a ladder against weak upper surfaces, eg glazing or plastic gutters.
 Use ladders or stepladders for strenuous or heavy tasks, only use them for light work of short duration (a
maximum of 30 minutes at a time).

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  Let anyone who is not competent (who doesn’t have the skills, knowledge & experience to do the job)
work at height.
Don’t use ladder as a scaffold.
General Requirements- Work at height
 As much as practicable, permanent stairs floors, decking, handrail & walls are installed as the structure is
being built. Also, material & equipment such as structural steel & tanks are erected in sections & painted
on the ground to reduce fall exposures.
 Methods to provide safe access to work areas are required. Access includes ladders, scaffold, stairway &
ramps.Climbing over structural steel& equipment is not allowed.
 Riding on mobile elevated platform, the rider/riders shall beanchored the full body harness to the
anchoring point in the platform .The cage shall be securelyclosed & material elevated in the cage shall be
secure from falling.
 Transferring men or material from a mobile elevated wok equipment (scissors lift/Jig lift) to roof top or
vice versa is forbidden except emergencies.
 A 100 %fall protection shall be ensured all the time, when exposed to a fall over of 6 feet( 1.82 Meters
) or when required by additional rules. Full fall protection is required whether climbing, travelling from
one point to another at height, especially at floating roofs or erecting scaffolds& or other temporary
platforms.
 When vertical lifelines are used, a separate lifeline shall protect each employee.
 Supervisor shall ensure that, fall protection is available & used as required by all employees while work at
height.
 Anchorage shall be strong enough & high enough so that fall

Scaffolding
Scaffold- A temporary elevated platform(supported or un supported) built above 1.8 meters height, used
for supporting men or material.
Types of scaffold
 Tower scaffold( Mobile(max height 12m)& Stationary( max height 18m)
 Truss/ Cantilever/jib scaffold( having one work platform)
 Independent tied scaffold(tube & coupler)(lightweight (60m), medium weight(45m)& heavy
weight(40m))
 Bracket scaffold (used for tank construction)
 Slung scaffold(from the roof)
 Adjustable suspension scaffold ( using hoist & wire rope) example-Boatswains chair.
 Bird cage / System /unit/frame scaffold.( around vassals )
 Fabricated tubular frame scaffold.
Parts of Scaffold
Standard- Tube used as column, transmitting
load via a base plate.
Ledger- Tube spanning horizontally & tying a
scaffold longitudinally.
Board bearer-Tube spanning across ledgers
between transoms to support working
platform.
Brace-Tube incorporated diagonally across two
or more members in a scaffold to provide
stability.
Decking- A close boarded scaffold platform.
Tie- Tube used to connect scaffold to a rigid
anchorage.
Guard Rail- Tube connected at the edge of the platform & other places to prevent personnel falling from
platform.
Handrail- Tube used on stairs to prevent the fall of personnel.
Bay- The space between two adjacent standards along the face of scaffold on the ground.
Base Plate- The plate on which the standards rests on ground.

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Sole plate-A timber, concrete or metal spreader of adequate size & suitable quality used to distribute the
load from the baser plate over an area of ground.
Toe board- A board positioned at the edge of the platform so as to prevent tools, materials falling from the
platform.
Scaffolding Hazards
 Worker's fall from a height.
 Collapsing of scaffolding due to lose of integrity & or over loading.
 Fall of materials / tools on persons who are working under/ near the scaffolding.
 Slipping of unsecured ladder.
General Requirements of a Scaffolding:
 A steel plate of minimum 1000sq.cm area shall be provided, if the soil / ground is loose or not strong
enough to take the point load of scaffolding.
 Base plate shall be provided for all scaffolding.
 Bracing shall be provided for all scaffolding.
 All decking shall be close-boarded, each board resting evenly on at least three supporters. Ends of the
boards should extend at least 50mm.
 Toe boards shall be provided in four sides of the working platforms which are 6'6" (1.98m) above from
the ground.
 Guardrail &midrail shall be provided for all working platforms. Guard rails shall not be less than 3'
(920mm) & not more than 3'9" (1150mm) high, & the space between toe board & guard-rails shall not
exceed 2'6" (760mm)
 Ladders shall be provided for easy & safe access to the working platform.
 In mobile scaffolding,lock the castor wheels before use &should not move the tower with men or
material on it.
 In normal case, maximum height of the scaffolding should be 3 times the minimum base dimension.
 For any scaffolding, the maximum allowable vertical deviation is 50mm over full height & maximum
allowable horizontal deviation is 50mm over full length.
 For general walk through access on upper lifts, a maximum lift height of 2.0m should be maintained. But
where access under is required, a maximum lift height of 2.7m is allowable.

Type of Platform Loadings Max. Bay

Use Max. work platform
Scaffolding KN/m2 Kg/m2 Centers
Inspection, painting, Light
Very light duty 0.75 76 2,7 m 1
access
Plastering ,Painting &C
Light Duty 1.5 153 2.4 m 2
leaning
Building works, Light brick 2 Plus, 1 very light
General Purpose 2.0 204 2.1
works duty
2 Plus, 1 very light
Heavy Duty Brickwork, heavy cladding 2.5 255 2.0m
duty
Masonry Works, Concrete I1 Plus 1 very light
Special Duty 3.0 306 1.8 m
works duty
Putlog New Brick work 2.5 255 2.0m 1
Light duty bird Inspection, Painting,
0.75 76 2.5m 1
cage Cleaning

Construction of a Scaffold- Check points

Foundation- firm& even, good base, leveled, hardened & consolidated base plate, sole plate shall be
provided on the ground condition.
Standard- shall be vertical, pitched on base plate. Joints in standard should not occur in same lift,Joints to
be close to the ledger. Staggered joints, right spacing & not damaged.
Ledger-shall be level &horizontal, securely fixed to the standard with double or universal couplers.Joints
shall be staggered.
Transoms- Right spacing, not loose & right support.
Bracing- strong, equally spaced, continual.

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Ties- none missing & not loose.
Fittings- right fittings, not loose, check couplers.
Ladders- proper angle, secured & right extension.
Decking/ Working platform( boards)-not warped, close boarded, resting evenly on at least 2” ( 50 cm) but
shall not over sail by more than 4 times their thickness. No gaps(opening more than 1 “( 25 cm) between
adjacent boards or scaffold member).Boards shall be secured/tiedfrom movement by clamps or metal
wiring.
Guard Rail & Toe board- right height, right length, none missing ,guardrails & toe boards shall be fitted at
edges of decking from which persons or material could fall a distance exceeding 6 feet (1.8 m). Top
guardrail shall be not less than 3' (90 cm) & not more than 3' 9" (1.15 m) high. Midrail shall be provided.
Toe boards should be 6" (15 cm) high & secured in position by toe board clips or other means.Guardrails &
toeboards shall be fitted to the inside of standards to prevent outward movement, unless they are so
designed & used as to prevent such movement.
If guardrails & toe boards are removed for the movement of materials, they shall be restored as soon as
practicable (ex. heat exchanger jobs).
Guarding material-Where materials are to be stacked on a working platform or working place above the
height of the toeboards, suitable barriers such as nets or metal sheets shall be positioned so as to prevent
the fall of such material from the platform or place.
Access-Access shall not be obstructed.Access to a working platform is best achieved by providing a separate
ladder tower or cantilevered access platform so as not to obstruct the platform & to minimize the possibility
of persons falling through the gap in the guardrail or decking, if this is not practical, the top handrail should
be hinged or a hinged short bar provided at access point.Use of monkey ladder to access working platforms
on scaffolds is not recommended, as it will obstruct free entry through the ladder cage.
All exposed cables & wires near the erection of scaffolding should be treated as "live". Put RED tag during
the erection, dismantling & for uncompleted scaffolding. Display warning notices for the hazard awareness.
Gin wheels (pulley & rope) can be used for lifting light loads (up to 50 kg) on to scaffolding when use of
other standard lifting appliances is not practical or safe.
Erection & dismantling of Scaffold
Erection & dismantling of scaffold shall be done under supervision by competent scaffolder. No work shall
be done in inclement weather (wind speed over 40 KMPH) & nooutdoor scaffold work in lighting&
thunderstorms. All scaffolders &scaffold users shall wear safety harness with shock absorbing double
lanyards&hooked at proper anchor point.No modification without approval.Dismantling shall be from top
to bottom. No dismantling in bad weather or strong wind. Dropping of scaffolding material is forbidden.
Lowering of clips, clamps shall be done using carry bags. Erection / dismantling area shall be barricaded for
un authorized entry. Dismantled material shall be kept in an orderly manner to shift as early as possible to
storage place.
Scaffold Tags & Check lists
 Green & red tags are used to inform/ warn user about the readiness of a scaffold.
 Scaffold check list is used while inspecting scaffold before certifying it for use.
 Tags shall be displayed near access point at eye level.
 Executer shall prominently display RED tag( Do not use scaffold) when scaffolding is incomplete,
whetherit is during erection dismantling or alteration.
 Competent supervisor from the client & the contractor shall inspect the scaffold using check list before
certifying it .
 All scaffold shall be inspected in seven days &or after every modification/ alteration & adverse climate
like heavy wind or storm for its stability . Record of inspection shall be maintained.
Scaffolding User's Responsibility.
 The user should satisfy himself that the scaffolding meets his requirements.
 The scaffolding must be inspected everyday by the user before his use.
 The user should keep a clear passage way on the working platform.
 No alterations, removal of ties, bracings, boards, toe boards or guardrails etc., should be undertaken by
any persons other than the scaffolding erectors.
 The scaffolding should only be used for the purpose for which it was erected & must only be loaded to
the amount for which it was designed.
 Should not use the scaffolding if there is no green tag or the scaffolding with red tag.

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  Any event or circumstance that may affect the strength or stability of the scaffolding, must be reported
to the scaffolding erectors/ supervisor immediately.
 Don't start to work on the scaffolding while the erection is in the finishing stage. Employees shall not
work on scaffolding during storms or winds.
 Warning notices to be prominently displayed ("MEN WORKING OVER HEAVY") at all times whilst working
on the top of scaffolding.

Ladders
Ladders (portable or fixed) are extensively used to carry out work at heights for a short period of time.
Misuse of ladders is a cause of many accidents. The safety of ladders depends upon three important factors:
 The selection of the right ladder for the job to be done.
 The condition of the ladder.
 The safe use of the ladder
Ladder selection
 All aluminum ladders shall confirm to BS 2017.A ladder
shall be of proper length for the job to be done.
 Ladder should project at least 1.07m (3’6”) above the
landing place, having one rung level with or slightly above
the landings.
 Vertical distance between two successive landings should
not exceed 9 meters. If the platform height is more than
9.0m, then two ladders shall be used with staging
platform. For extension ladders minimum overlap should
be 4 rungs.
 Ladders shall be provided with proper sloping of 75
degree (approximate) to the horizontal(i.e., Height: Base=
4 : 1).
 In mobile scaffolding, ladder should be fixed to the
narrower width of tower & the bottom of ladder should
be supported by transom.
 Rungs of ladder should coincide with the frame members.
Rungs shall not be used for supporting the board.Rungs
shall not be used to fix the ladder to the scaffolding.
 Both Stiles shall be lashed or clamped to the structure to
prevent movement.
 If two ladders join together then the minimum overlap
should be 4 rungs, but no lashing & splicing is allowed.
 Only one man should be there on the ladder at a time &
nobody should carry tools & materials except in the pocket or belt where it is securely fitted. A three
point contact shall be maintained all time while ascending &descending the ladder.
 No aluminum ladder for electric jobs &no wooden ladder for hazardous area.
 No ladder shall be used as a platform to work at height.
 Movement of ladder( vertical / horizontal ) shall be done with care for personnel, overhead electric lines
other objects.
 All ladders shall be inspected before use, Once work is completed. The ladders shall be returned to store
& safely stored.

De- sludging &Prewashing

Sludge -A semi-solid slurry(soupy substance) settled at the
base of tanks & vessels in petroleum product or water
staring facilities. Tanks, contained crude oil or petroleum
products may present one or more of the following hazards
during some phase of preparing the tank for entry &
cleaning:
(1)Fire & Explosion Hazard- potential for fire within or
outside a tank can exist during all phases of tank work from

23
decommissioning through re-commissioning. Depending upon a number of factors, including tank design,
its integrity, air/fuel ratio & the number of open vents, fire inside a tank may cause an explosion
due to expanding gas.
(2)Oxygen Deficiency- can exist in tank for a number of reasons. (1) The vapors of some hydrocarbons
stored in atmospheric or low pressure tank s are heavier than air & will displace or dilute air. (2)If tank has
been closed, oxidation (rust) can deplete the tank oxygen content. (3)A tank that is maintained under an
inert gas will be almost devoid ofOxygen.
(3)Oxygen Enrichment-( above 23.5%) examples - Occasionally, oxygen bottles or cylinders used during tank
work may leak & provide a source of oxygen enrichment.
(4)Toxic Substances- Such hazards H2S,Dusts(removal rust, paint & tank insulation) , Petroleum
substances(inhalation of high concentration of hydrocarbon vapors can cause sign & symptoms of
intoxication, symptoms range from dizziness to excitement tounconsciousness; similar to those
produced by alcohol or anesthetic )
(5)Welding Fumes-Toxic fumes generated during welding on metalscoated with or containing alloys of
lead, zinc, cadmium, beryllium & certain other metals. Some produces toxic fumes when heated with
welding torch. The potential health effects vary in type & severity depending composition & concentration
of fumes generated.
(6)Lead Based Paints- Significant lead exposure can occur during removal of paint from surfaces
previously coated with lead-based paint. Cumulative exposure to lead may result in damage to the blood,
nervous system, kidneys, bones, heart & reproductive system.
(7)Ionizing Radiations- from Naturally Occurring Radioactive Materials (NORM).
(8)Physical & Other Hazard- Structural failure of the tank shell, roof, roof support members, swing line
cables, falls through corroded roofs or from scaffolds, stairs & ladders, accidental discharge of steam, high-
pressure air, water or oil either into the tank or against personnel working outside, from inadequate
isolation from all source of energy, failure to disconnect or make electrical or mechanical equipment in
operative, use of lighting fixtures inappropriate to hazardous area classification, sharp angles, welding
lugs etc. within the tank that can snagclothing or skin in addition to tangling or cutting retrieval lines &
falling down of unprotected tools or materials.

Additional hazards for floating roofed tanks are:-

 Hydrocarbon Entrapment Hazard
 Potential Fire Hazard:
 Potential Physical Hazards:
The following precautions but not limited to must be taken while preparing the tank for safe entry &
cleaning:
 Review of tank configuration, piping details, site layout & determine scope of work.
 Review of information concerning the products contained in the tank to beentered & assess potential
safety & health hazard for the job
 Preparation of a safety & work plan for the entire job mentioning -the equipment needed & its suitability
for area classification, establishment of work permit & emergency response system.
 Positive isolation
 Empty, all recoverable products via tank discharge nozzle & line or other suitable connections. The left
over shall be removed using the main pump until it nearly loses suction. Or use temporary field pump for
the process, the safety & integrity of the pump, hose & other accessories including conformance to
hazardous area classification.
 If the gas test result is negative & the permit system is satisfied, move the temporary pump & hose to
the dike area.
 Confirm that temporary equipment is electrically bonded &grounded.
 Pump out remaining liquid with the field pump until it loses suction or removing remaining product is by
filling water into the tank & the remaining oily product will float onwater & can be removed through
discharge line.
 Upon opening the manhole, hose can be inserted into the tank & any liquid inside can be further
transferred to thedesignated location.
Safety Considerations
Isolating the Tank- The tank shall be isolated from all lines by using blanks / blinds or double block & bleed
valves, all of whichshall be as close as possible to the tank. If the tank valve or line isto be removed & the

24
tank has cathodic protection, it should be turned off.A bond wire shall be installed from the tank to the line.
The valve or line shall be disconnected & removedalong with the bond wire.
Entry in to tank- Gas testing by authorized tester. (no ventilating equipment shall be operated within 15
minutes prior the test,allowing tank atmosphere to reach equilibrium conditions beforetesting the
interior).Work permit, lockout / tag out including isolating(close all suction & discharge lines at the tank &
install lockout/tag out devices(all energy sources such as pump, motors, mixers & instrumentation
devices).Safety instructions. Notifying emergency rescue team.Certified/medically fit entrants, certified
user for masks (air line).Certified attendant with communication systemto monitor activities, record
entrants, control potential hazards & co-ordinate for rescue operations.Certified motorized
equipment,(automobiles including vacuum tanker, trucks, forklifts, welding machines &compressors etc.. )
applicable third party certified & safety certified, kept away at safe areas with signs &
barricading.Adequate ventilation(Compressor for ventilation, equipped with filters to remove scale, rust, oil,
moisture& dust particles, which can be a source of ignition due tostatic electricity).
De - sludging-Opening of the man way cover under supervision.Gas test from the man hole using probe by
authorized gas tester&continuous monitoring.Opening of all covers at lower level & at roof for mechanical
ventilation/ blowers.Maximum extraction of sludges using vacuum truck & later clean out door open for
personnel entry. Entry,medically certified, trained & authorized airline mask user with air supply& with
appropriate PPE.Safety harness worn &connected to the retractable life line. Adequate communication
with attendant to the entrant,closely monitoring particularlyduring warm climates.Availability of charged
water hose & minor fire fighting appliances.Electrically operable lights or tools or any below 24 volts .The
control over potential ignition sources, continuously maintained. Not using sparking tools. All electrical
cables cleared off to overhead& independent of the tank.Pyrophoric deposits e wetted all the time,
removed immediately& disposed under EPA regulations.The ventilating equipment & hoses are electrically
bonded to the tank.
Emergency rescue-An emergency action plan prepared for retrieval & rescue operation.The confined space
attendant alert &not entering the space for rescue.Rescue team shall be notified for immediate help.
Rescue kit including SCBAreadilyavailable for rescue operation by trained personnel.

Surface Preparation(Grit blasting)

The major surface preparation methods are - grit /slag blasting &high pressure water or steam jetting.
Moreover, hand or power tool cleaning includes grinders, sanders, rotary wire brushes, impact tools, chisels,
hammers.Chemical cleaning using paint removersor solvents, alkali, acids or detergents.
Grit blasting is carried out by blowing abrasive grit, under air pressure to scour away the surfaces.
Equipment &materials used in surface preparation for paints &coatings can be hazardous, if used
carelessly.Waste generated shall also be disposed as hazardous or non-hazardous waste depending on the
contents.
Hazards&risks of grit blasting
Hazards Risks Control
Intense& prolonged exposure results to
Noise ear plug & muff or combination of both
harmful effects in ear
inhalation cause irreversible lung
Silica Silica free grit
damage. (Cu-slag)
Respiratory protection, Barricading &
Dust Lungs ailments
Signage
long term exposure result in damage to Respirator protective equipment(RPE),
Lead nervous system, reproductive system, exposure profile & Monitoring( IH ) of risk
kidneys & blood forming system group,
long term exposure result in kidney respiratory protective equipment(RPE)
Cadmium damage, increased risk of prostate & exposure profile & Monitoring( IH ) of risk
lung cancer group,
Conduct air monitoring to measure worker
Inorganic skin irritant, damage to nervous
exposure. exposure profile & Monitoring(
arsenic system, liver & may cause lung cancer
IH ) of risk group,

25
 Being shot by Procedure, training,safe work practices,
Injury, fatality
another blaster disciplinary action& supervision
Examine for "soft spots" &hose wear.
Not allowing vehicles to run
Jammed hose Rupture, Abrasive blow out &explosion
over blast hoses. Laying hose straight & no
entangling.
Whiplash of
Injury, fatality Whip lash arrestorsat all connections
hose
Potential Air Contaminants Associated with Abrasive Blasting
Source Potential Air Contaminants
Base Material (e.g., steel, aluminum, stainless steel, Aluminum, cadmium, chromium, copper, iron,
galvanized steel, copper-nickel & other copper alloys) lead, manganese, nickel, & zinc
Surface Coatings (e.g., pre-construction primers, Copper, barium, cadmium, chromium, lead,
anticorrosive & antifouling paints) tributyl tin compounds, zinc
Arsenic, beryllium, amorphous silica, cadmium,
Abrasive Blasting Media (e.g., coal slag, copper slag,
chromium, cobalt, crystalline silica, lead,
nickel slag, glass, steel grit, garnet, silica sand)
manganese, nickel, silver, titanium, & vanadium
Sources: EPA, 1997; EPA, 2000; NFESC, 1996; NIOSH, 1998.

Other Precautions to reduce the risk-Establishing procedure, barricading the hazardous blasting zone
&sheeted so that escaping dust is reduced to a minimum,warnings signage to prevent the public.

Air compressorshall be used for both supply

of air tooperator & for grit blasting.The
compressor must be in good repair
according to the manufacturer’s
instructions. TPI for air receiver, safety
certificate shall be available. Compressors
shall be fitted with highly efficient filters to
trap air intake dust to prevent excessive
engine wear & the air being compressed be
free of dust. The CO level of the air shall be
monitored with a properly calibrated &
maintained, direct reading instrument
preferably equipped with an alarm.The
three electrical safety relays that detect
high ambient,oil,or discharge air
temperature & automatically shut the
compressor, is working. According to OSHA,
the breathing air compressor shall have certain safety devices (high temperature or CO alarm or both) to
protect the air quality.A scrubber can be incorporated into the air filtration system to assist compliance with
Grade D air requirements. (Oxygen content:19.5-23.5%,CO2 :<1000 ppm,CO:<10ppm,Oil vapors:5mg per
cubic meter.) Monthly testing of breathing air from the system shall be done in a qualified laboratory.Oil
lubricants in air compressors may break down at high temperature & produce dangerous CO levels.
Additional charcoal filter(air filter) shall also be connected to the air line & the filters shall be replaced in
one month or after 100 hours, which ever falls first.
Operator must be trained, competent & certified by a third party for the job & shall wear heavy duty
protective overalls & gauntlets against dust & reboundinggrit. Shall equipped with blasting hood (air line
helmet) with clean air (using in line filter) supplied to his helmet all the time, protecting theeyes & face, & in
which a positive air pressure is maintained. Shall wear ear muff when the noise levelexceeds 85 dB(A) 8 hr.
Nozzles, blast hoses(treated & electro statically insulated with gaskets nylon fittings)&couplings shall be
sound of rating &be inspected prior use. All couplings(uniform brand) & nozzle with gaskets & holders
including connecting to compressor shall be fitted with safety pin &whip check arresters. No jubilee clip

26
shall be used. Severally worn nozzle &/or nozzle holder threads should not be used. Avoid harsh field use to
reduce breakage or distortion. Hose shall laid properly to avoid STF hazards.
Components of blast machines/tank (shell/ cone, machine's piping) etc, must be inspected frequently for
any defects, holes & dents. Check blast machines, valves,gaskets, couplings, nozzle holders & nozzles&other
fittings to ensure they are tight.No welding on blast machines is allowed. All blast machines shall be
equipped with remote control systems to start &stop the blasting process. Mufflers muse not be covered as
this will interfere with the controls.
Air pressure gun, shall be fitted with a “dead man handle”, shall be functional& neverbe compromised.
No unauthorized personnel must adjust the compressor settings. In any case, max working pressure should
never be exceeded in the blast equipment.Compressors shall be positioned in such a way to avoid entry of
exhaust gasses to the air inlets as well as upwind of dust being generated by the blasting process. The
compressor attendant shall be communicating with the operator all the time through suitable means.
Attendant shall station near the running compressor to adjust, shut off/ act in emergencies. All required
safety arrangement shall be made including, fire extinguisher, clearance of combustible etc.. All equipment
(compressor, blast machine, hoses up to the blasting nozzle) shall be earthed properly for dispersing fault
current.
Periodic Medical Examinations, including x-rays, to all potentially exposed employees & record shall be
maintained.Practice good personal hygiene. No food, drink in blasting area. Workers should wash their
hands & face before eating&drinking.Shower & change clothesfacilities before leaving the worksite. All
vehiclesshall be kept away from blasting hazard zone.All unsafe actions shall be avoided.
Spent grits must be removed at regular intervals & disposedproperly inenvironment friendly mannerin EPA
approved disposal areas at regular intervals.

Painting & Coating

Painting areais hazardous work, where flammable vapors, mists or combustible residues, dusts or deposits
may be present due to the activity.Work supervisor shall ensureall painting &coating works are carried out
in a safest manner by suitably trained &competent personnel. PTW with JSA shall cover such work&all in
accordance with defined safe working practices & procedures.All shall with proper PPEsuch as eye & face
protection, respiratory & body protection &any other PPE as per the specific instructions / MSDS given by
the paint manufacturer& shall be readily available.
Safety Requirements-All equipment shall be in good
working order &all safety guards installed.No painting in
occupiedareas &in official hours. Spray gun should not be
pointed at anyone or part of the user's body.Air supplied
respirator shallbe usedby workers when are continuously
exposed in spray painting inside a confined space.

Strict attention tocleanliness&protection of the

environment shall be observed in all painting & coating
operations. All debris, spilled paint / solvent, used or
unwanted paint / solvents, used up cans / drums & used
abrasives shall be collected & disposed of in accordance
acceptable procedure.
Painting Booth /area shall be adequately ventilated,suitably barricaded&signage,to restrict unauthorized
entry. The ground should be covered to avoid spillage of paint causing soil & drain (water) contamination.
Extraction fans shall be ducted to exhaust safely, away from ignition hazards, & occupied working areas.
They shall be fitted with filters such that the exhaust poses no threat to personnel or the environment.No
foodstuffs shall brought into or consumed on premises where paint is stored, handled or sprayed.Adequate
washing & cleaning arrangement including lobby room shall be provided. All paint spraying devices shall be
electrically bonded to the item being sprayed & metal to metal contact must be ensured while bonding.
The spray painting operation should be conducted from the upwind side of the object being coated,
wherever practicable. For airless spray equipment, all guards shall be in place & the system shall be in
good order & correctly grounded to prevent static build-up.

27
Personnel involved with using paints & solvents shall be in good health & have periodic medical
examinations / biological monitoring (specific to exposed chemicals) by professional medical staff.
Fire Precautions- All potential sources of ignition shall be kept away from areas where flammable paints,
coatings & their associated solvents are stored, handled or used. No hot work in the surrounding. All
electrical lighting, wiring & equipment shall be explosion-proof & must be suitable as per hazardous area
classification (class I, division I or class II, division1).All electrical equipment such as switches, panel boards,
electrical motors & associated equipment must be de-energized before spray painting to eliminate
explosion hazards. Extension cords or other electrical plug-in cords should not be used in a spray paint
booth.Solvents &solvent based paints shall not be applied to surfaces exceeding Kuwait summer ambient
temperatures & solvent spray painting shall not be done on hot surfaces/tanks, pipelines
&vessels/containers.Fire extinguishers should be provided at the work area or storage facility. All workers
shall be trained on the use of fire extinguisher. Adequate ventilation shall be provided in all store houses,
handling or using area, in order to prevent the build- up of vapors to above the LEL.Unknown chemicals
should not be added to paint to avoid fire by mixing incompatible agents (oxidizing agents).
Stores for paints, coatings & their associated solvents &shall be in a safe area, away from active work place.
The store shall bewell ventilated& ambienttemperature maintainedto prevent build-up of hazardous&
explosive condition inside.Open containers of paint, or other substances shall not be stored in paint
stores.Partially used containers of paint or thinners remaining unused at the end of the day shall be
resealed, cleaned & returned to the store.Dispensing or decanting of material from one container to
another shall not take place within the store but shall be in the open air away from hazardous areas of
operation. Spillage shall be avoided
Adequate signage of `No Smoking’ &`Flammable’ shallprominently displayin all areas where flammable
paints, coatings & associated solvents are stored.All potential sources of ignition shall be kept away from
areas where flammable paints, coatings & their associated solvents are stored or handled.The receptacles
containing lead based paint must be legibly marked to alert about lead hazard.

Gas test should be carried out before & after painting works to ensure that area is not in flammable
range.For painting/coating at height, adequate fall protection &barricading the area underneath shall
beobserved.Painting in confined areas should have fresh air availability &good ventilation system. The
fresh air systemshould be located near the top of the confined space, & the discharge should be located
near the bottom, positioned to eliminate dead air spaces. Supplementary fans may be necessary to ensure
good air circulation. No hot work shall not be permittedsurrounding thepainting worksas the LELshall be
over 1% .

Confined Space
Confined spaces are a space that meets all the three following conditions:-
 Is large enough &so configured that an employee can bodily enter &perform the assigned work.
 Has limited or restricted means for entry & exit.
 Is not designated for continuous human occupancy.

Eg. Vessels, tanks, furnaces, heat exchanger shell open

from one end or from both ends, culverts or
excavations or pits or manholes or sewers or trenches.
etc, deeper than 1.2 meter including pits in head office
and other buildings, entry on floating roof tanks when
the roof is more than 3 meters down from the top, AC
ducting systems, very large diameter piping and ducts
etc.

Hazardous atmosphere of Confined space-Is an

atmosphere, that may expose employees to the risk of
death, incapacitation & impairment of ability to self-
rescue (IDLH), injury or acute illness from one or more of the under mentioned reasons :-
 There could be presence of flammable /dangerous gas, vapor, and mist in excess of 10 % of its LEL.
 Presence of toxic, corrosive or hazardous material Example H2S, Hydrocarbons, NH3, Sulfur& Coke dust
etc.

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 Oxygen deficient & enriched atmosphere (below19.5% & above 23.5%)
 Airborne combustible dust at or above its LEL. (if the dust obscure vision distance of 1.52 meter ( 5 feet )
or less , it can be considered as at LEL.
Hazards of Confined Space
 Restricted access – Limited number of entry &exit points
 Restricted freedom of movement inside confined space.
 STF hazards.
 Poor illumination/ visibility & communication.
 High temperature & humidity.
 Stored energy (Electrical, liquid, gas static& radio active hazards.)
 Mechanical Hazards (in adverting movement of machinery, falling of tools from high etc..)
 Pyrophoric substances.
 Reptiles & snakes.
Requirement for Confined Space Entry
 Equipment Preparation including Electric power isolation (LOTO)
 Blinding or Blanking, miss aligning or removing sections of lines pipes& ducts.
 Depressurizing, venting.
 Draining, steaming & washing
 Opening man ways & covers
 Mechanical ventilation ( educators, blowers, fans )
 Use Airline mask or SCBA, if Oxygen concentration is below 19%, toxic gases are above TLV (eg:- C12-
1ppm; Sot - 2ppm; Nh4- 25ppm;CO-50ppm & above) & combustible gases are between 1% -20% of
Lower Explosive Limits (LEL). No entry authorized if combustible gases are above 20% of LEL.
 All power driven internal equipment shall be positively isolated.
 Adequate illumination shall be provided using 24 volt or below explosion proof lamps.
 Rest breaks at regular intervals (in 30 minutes) shall be planned.
 Not more than two men shall be allowed to work in such spaces.

Permissible Limit ( TLV)

Gases
W/O BA Set With BA Set
<10% of LEL ( CWP)
HC 20% of LEL Max
<1% LEL ( HWP)
CO <25 ppm 25-400 ppm
H2S <10 ppm 10-30 ppm
SO2 <02ppm -
Cl2 <0.5 ppm -
NH3 <25 ppm -
O2 19.5 % by volume ( Minimum) 19.5 % by volume ( Minimum)
O2 limit for
inert entry Not allowed ≤ 5%

1/3rd of
Gases TLV-TWA STEL IDLH LEL UEL
IDLH

H2S 10 ppm 15 ppm 33 ppm 100 ppm 4.3% 46%

SO2 2ppm 5 ppm 33 ppm 100 ppm - -

Cl2 0.5 ppm 1 ppm 3.3 ppm 10 ppm - -

CO 25 ppm 400ppm 400ppm 1200ppm 12.5 % 74%

CO2 5000ppm 30000ppm - - - -

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 NH3 25 ppm 35 ppm 100ppm 300 ppm 16% 25%

Check for
 Access & egress free from STF hazards.
 Permit to work & permit to entry.
 Positive Isolation (Physical disconnection, Blanking / Spading (using correctly rated blind / spade),
Double isolation valve with bleed valve in between & any combination of the above) of process
equipment
 Check for flammable vapors, toxic gases, oxygen deficiency, by doing gas testing before entry &
periodically as per the condition & temperature & humidity.
 All the times availability of trained attendant at outside the confined space entry point equipped to deal
with likely emergency situations. Shall replace with equally qualified person.In an actual emergency
situation, the standby person should summon ERT (emergency rescue team) immediately.
 Check for communication between entrant & attendant are clear.
 Check for emergency services are informed for work location & activity.
 Check for entrants are medically fit, trained & equipped with life saving & retrieval equipment.

Hazardous Substances

This is to assess the health risk, implement & monitor effective control.The COSHH ( control of substance
hazardous to health) program helps to :-
 Improve productivity due to lower level of ill health & more effective use of materials.
 Improved employee morals.
 Lower number of civil claims.
 Better understanding of H&S legal requirements.
Carcinogenic substances-which are known or suspected of promoting abnormal development of body cells
to become cancers. Asbestos, hard wood dust, creosote & some mineral oils are carcinogenic. It is very
important that the health & safety rules accompanying the substance are strictly followed.
Mutagenic substancesare those which damage genetic material within cells causing abnormal changes that
can be passed from one generation to another.
The effects on health of hazardous substances may be either acute or chronic.
Acute effects are of short duration & appear fairly rapidly, usually during or after a single or short-term
exposure to a hazardous substance. Such effects may be severe & require hospital treatment but are usually
reversible. Examples include asthma-type attacks, nausea & fainting.
Chroniceffects develop over a period of time which may extend to many years. The word ‘chronic’ means
‘with time’ & should not be confused with ‘severe’ as its use in everyday speech often implies. Chronic
health effects are produced from prolonged or repeated exposures to hazardous substances resulting in a
gradual, latent & often irreversible illness, which may remain undiagnosed for many years. Many cancers &
mental diseases fall into the chronic category. During the development stage of a chronic disease, the
individual may experience no symptoms.
The hazardous gases enter to the body from the following methods:-
inhalation- breathing in the substance with normal air intake. This is the main route of contaminants in to
the body.
absorption through the skin- the substance comes into contact with the skin & enters either through the
pores or a wound. Tetanus can enter in this way as can toluene, benzene & various phenols
ingestion-through the mouth & swallowed into the stomach & the digestive system. This is not a significant
route of entry to the body. The most common occurrences are due to airborne dust or poor personal
hygiene (not washing hands before eating food).
Injection. Examples :- fromaccidents involving hypodermic syringes in a health or veterinary service & the
abuse of compressed air lines by shooting high pressure air at the skin can lead to air bubbles entering the
bloodstream.

Classification of Chemicals

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 Type material Consequences Control Measures
May explode under the effect of Use only as directed.Keep containers
Explosive, chemicals
flame , heat, hit or dry condition. tightly closed in ambient
Gases/Vapor
Sympathetic detonation of temperature.Keep away from the
explosives over crossing of its shelf source of heat & ignition.Disposal of
life. material & container in safe manner.
Use only as directed.Keep containers
tightly closed in cold & ventilated
Reacts with other substances may
Oxidizing Chemicals area.Keep away from the source of
resulted to explosion or fire.
heat & ignition.Disposal of material
& container in safe manner.
Keep containers tightly closed in
cold temperature.Keep away from
Flammable gases & Flammable ,Flash point 0oC & boiling the source of heat & ignition.No
chemicals point 350C or below . breathing of vapor / spray.
Precautionary measures against
static charges.
Keep containers tightly closed in
cold & ventilated area.Keep away
Highly flammable flash point is up to from the source of heat & ignition.No
Highly flammable chemicals
210C breathing of vapor /
spray.Precautionary measures
against static charges.
Engineering Control (Glove box,
Toxic Substance-( Forced ventilation (LEV & dilute
Impede or prevent thefunction of
gases/Fumes) ventilation) Reduced frequency of
one or more organ within the body.
Lead, Mercury, CO. H2S, exposure
Such as kidney, liver & heart.
pesticides, Chlorine Industrial monitoring

Minimize exposure
Corrosive (sulfuric acid, Use PPE , Water resistant protective
Attacks by burning living tissues
Caustic soda aprons, Safety shower& Eye wash
stations
Harmful(substance
swallowed, inhaled or
penetrated (bitumen base Follow instruction of MSDS
Limited health risks.
paints, trichloroethylene) PPE.
some harmful substance are
irritant too.
Irritant(non corrosive) Reduce exposure
Dermatitis (skin) or bronchial (lungs)
examples wood Reduce concentration
inflammation.
preservatives, solvents PPE ( mask)

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,bleaches, formaldehyde,
ozone & glues.
Carcinogenic( Asbestos,
Abnormal development of body Strict adherence of H& S rules for the
Hard wood dust, Creosote,
cells to become cancers subject substances.
some mineral oils
Genetic cells damage for abnormal Limit the exposure to harmful
Mutagenic
changes. substance, medical fitness evaluation
Storage & handling of Hazardous materials
 Always read the label on any container.
 Always refer the MSDS of the material
 Always wear the recommended PPE when working with chemical or breaking pipelines or unit which has
contained them.
 Always make sure equipment & plant has been made safer for you to work on & a safety permit
obtained.
 Always slacken the nuts on the side away from you first. Position yourself above.
 Always carryout instructions carefully when transferring chemicals from one vessel to another. The use
of contaminated container may be dangerous.
 Always use earth leads provided when transferring flammable liquids.
 When Acid or Alkali is to be diluted, pour acid or alkali into water & not vice versa.
 Store Corrosive substance in glass l containers with spill collecting facility
Does & Don’ts
 Never look up if a drop of chemical fall on you, move away first.
 Know the emergency facility (safety shower & Eye wash stations) & its operations.
 Know the emergency action plan in emergency (combined) situations.
 Trained in use of berating/ escape mask & handy.

MSDS (Material Safety Data Sheet)

A document issued by the manufacture that contains 16 sections about
information on the potential hazards (health, fire, reactivity &
environmental etc..) & how to work safely with the chemical product. It
is an essential starting point for the development of a complete health &
safety program. It also contains information on the use, storage,
handling & emergency procedures all related to the hazards of the
material. The MSDS contains much more information about the material
than the label. It is intended to tell what the hazards of the product are,
how to use the product safely, what to expect if the recommendations
are not followed, what to do if accidents occur, how to recognize
symptoms of overexposure, & what to do if such incidents occur.
Every material that is controlled by WHMIS (Workplace Hazardous
Materials Information System) must have an accompanying MSDS that is
specific to each individual product or material.
Hazardous gases
Hydrogen Sulfides ( H2S)- Held in sour gas(natural gas) &
crude, a highly toxic, highly flammable, explosive, colorless
corrosive gas, heavier than air with smell of rotten eggs,
slightly soluble in water, reacts violently to strong oxides,
metal oxides, peroxides, strong alkalis, active metals, rubber
& some plastics. It forms the spontaneously ignitable by
product Iron sulfide. Accumulate at low lying area with poor
ventilation, pungent at first &quickly deadens the sense of
smell. It has broad spectrum poison (can poison several
different systems in the body)
Symptoms- exposure to short & lower concentration brings - Eye irritation, sore throat & cough, nausea,
shortness of breath, & fluid in the lungs (pulmonary edema). Exposure to long & lower concentration
brings- fatigue, loss of appetite, headaches, irritability, poor memory,dizziness& miscarriage. Exposure to

32
short-term, high-level concentration can bring- immediate collapse, with loss of breathing & a high
probability of death. If death does not occur, high exposure to hydrogen sulfide can lead to cortical pseudo
laminar necrosis, degeneration of the basal ganglia & cerebral edema. Although respiratory paralysis may be
immediate, it can also be delayed up to 72 hours.
Treatment- Immediate inhalation of amyl nitrate, injections of sodium nitrate & administering 4 diethyl
aminophenol in combination with pure oxygen.
Ammonia- A compound of Nitrogen & Hydrogen, produced from putrefaction (decay) of nitrogenous animal
& vegetable matter colorless gas, lighter than air with a distinctive odor which, even in small
concentrations, causes the eyes to smart & run & a tightening of the chest. It is a corrosive substance,can
burn the skin, burn & seriously damage the eye, cause soreness & ulceration of the throat & severe
bronchitis & edema (excess of fluid) of the lungs.
PPE- Good eye & respiratory protective equipment is essential when maintaining equipment containing
ammonia. Any such equipment should be tested regularly for leaks & repaired promptly if required.

Use- Ammonia is also used in the production of fertilizers & synthetic fibers. Most work on ammonia plant
should require a permit-to-work procedure

Chlorine - a greenish, toxic gas with a pungent smell, highly irritant to the respiratory system, producing
severe bronchitis & edema of the lungs & may also cause abdominal pain, nausea & vomiting.
Use - disinfectant for drinking water & swimming pool water & in the manufacture of chemicals

Carbon monoxide- colorless, tasteless & odorless gas which

makes it impossible to detect without special measuring
equipment. Which enters the blood (red cells) more readily than
oxygen & restricts the supply of oxygen to vital organs. At low
concentrations in the blood (less than 5%), headaches &
breathlessness will occur, while at higher concentrations
unconsciousness & death will result. The most common
occurrence of carbon monoxide is as an exhaust gas either from
a vehicle or a heating system. In either case, it results from
inefficient combustion &, possibly, poor maintenance.

Isocyanates- volatile organic compounds, irritants & sensitizers. Inflammation of the nasal passages, the
throat &bronchitis are typical reactions to many isocyanates. When a person becomes sensitized to an
isocyanate, very small amounts of the substance often provoke a serious reaction similar to an extreme
asthma attack. Isocyanates also present a health hazard to fire fighters. They are subject to a workplace
exposure limit (WEL).

PPE - respiratory protection should be worn.

Use - in printing inks, adhesives, two-pack paints (particularly in vehicle body shops) & in the manufacture
of plastics (polyurethane products).
Asbestos– are in three main forms -crocidolite (blue), amosite
(brown) & chrysotile (white). The blue & brown asbestos are
considered to be the most dangerous & may be found in older
buildings where they were used as heat insulators around
boilers & hot water pipes & as fire protection of structure.
White asbestos has been used in asbestos cement products &
brake linings. It is difficult to identify an asbestos product by its
color alone – laboratory identification is usually required.
Asbestos produces a fine fibrous dust of respirable dust size
which can become lodged in the lungs. The fibers can be very
sharp & hard causing damage to the lining of the lungs over a period of many years. This can lead to one of
the following diseases: (1)asbestosis or fibrosis (scarring) of the lungs (2) lung cancer (3)mesothelioma -
cancer of the lining of the lung or, in rarer cases, the abdominal cavity.
Lead- A heavy, soft & easily worked metal. Enters body via inhalationbut can also enter by ingestion & skin
contact. The main targets for lead are the spinal cord & the brain, the blood & blood production. The effects
are normally chronic & develop as the quantity of lead builds up.

33
Symptoms- Headaches & nausea are the early symptoms followed by anaemia, muscle weakening &
(eventually) coma.
Regular blood tests are a legal & sensible requirement as are good ventilation & the use of appropriate
personal protective equipment. High personal hygiene standards & adequate welfare (washing) facilities are
essential & must be used before smoking or food is consumed. The reduction in the use of leaded petrol
was an acknowledgement of the health hazard represented by lead in the air.
Use- in many industries but is most commonly associated with plumbing & roofing work.
Silica- The main component of most rocks & is a crystalline substance made of silicon & oxygen. It occurs in
quartz (found in granite), sand & flint. Harm is caused by the inhalation of silica dust which can lead to
silicosis (acute & chronic), fibrosis & pneumoconiosis. The dust which causes the most harm is respirable
dust which becomes trapped in the alveoli. This type of dust is sharp & very hard &, probably, causes
wounding & scarring of lung tissue. As silicosis develops, breathing becomes more & more difficult &
eventually as it reaches its advanced stage, lung & heart failure occur. It has also been noted that silicosis
can result in the development of tuberculosis as a further complication. Hard rock miners, quarrymen, stone
& pottery workers are most at risk. Health surveillance is recommended for workers in these occupations at
initial employment & at subsequent regular intervals.
Prevention- is best achieved by the use of good dust extraction systems & respiratory personal protective
equipment

Occupational Health & Hygiene

Health surveillance is needed to protect workers, identify any health changes related to exposure as early as
possible & warn of any lapses in control arrangements. Occupational health & hygiene(OHH) process shall
be the maintenance & monitoring of personnel profile of work men, the WEL ( work place exposure limit
) to hazardous chemicals/gases or other environmental agents, which may badly affect (acute or chronic)
the health of them.
This include, generation of personnel profile
including health history, identification of hazardous
agents in work place through risk assessment
process, identifying the people at risk & action to
mitigate it.The industrial hygiene monitoring
plan(IH monitoring) of Al Magwa shall be covering
the medical surveillance program, for
identification of work place exposure, that requires
ongoing monitoring &surveillance the potentially
affected personnel.
The OHH program covers the following :-
Pre employment medical evaluation:- Medical fitness test of all employee before the commencement of
work ,which include, audiometry, spirometry, RFT) respiratory function test) Blood & urine pathology, BP,
Height weight, BMI, color vision, physical examination & ECG.
Periodical medical examination :- which include the repetition of the above examination on completion of
one year from the last examination.
Confined space entrant examination:- Which is done annually for the fitness to enter & work in confined
space including all the above test & additional chest X ray .
Respiratory protection program- Identify work place respiratory hazards & supply of client approved
respiratory protective devices to the affected employees.
Atmospheric monitoring program:- A comprehensive, site-specific Air Monitoring Program to evaluate
the exposure potential for all identified & suspected chemical contaminants.
There are two types of air monitoring. (1) specific personal exposure monitoring requirements for 23 chemical
substances including asbestos, benzene, lead, & formaldehyde. Sampling techniques such as passive
dosimeters, diffusion tubes, filter cassettes, & charcoal tube sampling with pumps & subsequent laboratory
analysis, plus real time air monitoring using direct reading instruments for each site activity as
appropriate.(2)Indirect sampling methods.
Noise monitoring:- using the calibrated equipment for general noise & personal noise exposure

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Dust monitoring :- :- using the calibrated equipment for atmospheric dust (Fine particles of dust & dirt, once
airborne will settle out on the environment & cause a nuisance through soiling of surfaces, as well as causing
health problems )& personal exposure to it
Chemical hazard management :- Approval from client for all chemicals prior bring in to the workplace, it’s
safe storing handling & transportation.
Chemical hazard communication program:- Communication of hazardous chemical & substances from the
MSDS ( material safety data sheet ) availability if MSDS & records of training.
Ergonomic hazards program:- Identification of all ergonomic hazards , arrangement of work stations , &
training to employees.
For the welfare of employees, all work places shall have adequate supply of cool drinking water, dining
facilities with air condition, rest rooms, changing rooms, washing & cleaning facilities(shower bath) (
especially for hazardous chemical handling places) according to the man strength (one toilet for 20
numbers ). For filed activities, there shall be mobile ablation units in serviceable condition. All the facilities
provided shall be maintained in hygienic condition. First aid(an immediate care for an injury or illness)
stations with trained first aider shall be provided for project with man strength of 100 employees. First aid
kits shall be held under the custody of the trained first aider & shall be administered & record maintained.
No tablets/injections/oral solutions (consumable) shall be administered other than antiseptic & bandages.

Office Safety
Safety at office, we do think working in a comfy, climate-controlled office is safe & hazard-free , but there
are many risks . The main areas are :-
 STP (Slip, Trip & Fall ) unattended spills, wet floors, exposed cords, unstable work surfaces, uneven
floors, loose rugs & cluttered areas.
 Ergonomic- MSDs ( stress & strains, postures, repetitive movement, poor communication etc)
 Eye strain ( long time usage of computer leads to dry, irritation, trouble focusing etc)
 Fire (electrical cords(damaged/overloaded & unearthed) kitchen heaters, smoking (cigarette buds).
 Indoor air quality (inadequate heating &ventilation) leadsto asthma& other respiratory disorders,
allergies from chemical & sensitivities. Increased number of occupants& time spent. Noise etc..
 Risk of violence(threatening behavior, verbal or written threats, harassments, verbal abuse &
physical attacks)
 Alone working.
 Stress.
 Bullying (verbal comments to hurt mentally like rumors, harassing, intruding etc. )
The following safety measures shall be considered :-
 STF hazards from cords running, across an office, wet
floor should be avoided.
 No material boxes stacked near fire fighting
appliances
 Room heaters away fromcombustible materials.
Smoking in designated place & disposing of burnt
buds properly.
 Walk ways clear of boxes& clutters, no frayed or
buckled carpets.
 Never leaving file cabinets open & unattended.
 Paper cutters be guarded & closed when not in use.
 All food be properly stored.
 Keyboards, & computer shall be adjustable to
improve comfort & reduce strain.
 Not overloading an electrical outlet.
 Keeping papers clear from devices such as hot
plates, & never leave them on while out of the office.
 Ergonomically designed Chairs with arm rests & an
adjustable back.
 Adequate lighting & ventilation, cleaning of filtration
of air conditioning unit
 Daily Vacuum cleaning the floor, carpets & disposal of waste including food waste adequately.

35
  Cleaning of kitchen, food room , toilet , fridge, microwave, utensils & disinfecting them.
 No disparity, No color discrimination for cast & creed . Office policy for mutual respect & action for
violating it.

Safety Violations & Infringements

Corrective discipline shall be used to deal with safety violators to achieve acceptable performance.
Employees who habitually or arbitrarily engage in unsafe work practices will be penalized. For any such
safety violations, the following penalty system will be applicable to all violators:-
(a)Minor Violation
 Not wearing personal protective equipment (PPE) at work site.
 Minor traffic violation (wrong parking, over speeding).
 Blocking of emergency equipment or exits.
 Using unapproved scaffolding.
 Not keeping proper housekeeping.
 Not keeping noise level as per EPA limit.
 Not discharging/handling/storing/transporting effluents/wastes as per the guidelines.
 Transporting
(b)Major Violation and disposing the effluents or waste/s without waste transport manifest.
 Smoking in the non-smoking areas, carrying matches or lighter.
 Working without valid work permit.
 Not wearing proper breathing apparatus if instructed.
 Not providing shoring for the excavations.
 Not providing fire extinguisher for hot work.
 Repeating minor violations more than twice.
 Major traffic violation.
 Found guilty negligent driving resulting in a vehicle accident.
 Entering closed area or classified area without permit.
 Not complying with written instruction on the work permit.
 No proper packing/sealing of materials applied while transportation/shifting of wastes, which results in
public complaints.
 Usage of truck/vehicle without good condition for shifting hazardous materials.
 Not meeting EPA and Company requirements as indicated in the guidelines
 Non-adherence to KNPC HSE procedure, guidelines or safe work practices are proven (by incident
investigation) to be direct cause of high potential incidents.

* Note:- In these cases Al Magwa reserves the right to insist on more severe penalties.
Violation First Second Third
Minor KD 300/- KD 600/- KD 1000/-
Major KD 1000/- 1% of Contract Value (subject to 2% of Contract Value (subject to minimum
minimum KD 1000/-) or KD 10000/- KD 1000/-) or KD 50000/- whichever is
whichever is lower * lower *
 In the event of Contractor’s violation as per above stipulations, KNPC reserve the right to exercise the
following remedies, individually or collectively, in addition to any other rights and remedies provided
under the Contract at its sole discretion:
 Suspension of employee(s) involved in violation(s
 Immediate termination of employee(s) involved in violations and such employees shall not be hired in
other KNPC contracts also.
 Termination of the contract.
 Blacklisting of the Contractor from KNPC

Barricading & Signage

Safety signs are a form of communication among the three ways of communication( Visual. Verbal &
Written) & it is a regulatory requirement, used to warn the approached. The safety signs are in five classes
with color codes &, geometric shape as follows:-

36
Mandatory ( Blue) - Signs that indicate a specific
course of action is to be taken( ordering the use of
specific protective equipment ) . The shapes shall
be circular, the wording shall be in white & the
background shall be blue.
Prohibition/ Danger Signs- ( Red)- A regulatory
sign prohibiting an action, which may endanger life
or cause injury. Such ( that certain behavior is
prohibited( smoking) ) . The shape shall be circular,
the symbol shall be in black & the background
should be white with a circular band in red & with
an oblique north-west/south east crossbar in red.

Warning/ Caution Signs( Black/Yellow) – Risk of danger, A signs that warns of hazard present & that
particular care must be taken. . The shape shall be triangular, the wording or symbol shall be in black & the
background shall be yellow with a black triangular band.

Fire Equipment Signs( Red) –A sign Indicate the location of fire-fighting equipment & how it shall be used.
The shape shall be rectangular, the wording shall be in white & the background shall be red.

Safety/Safe Condition (Green )- A sign that indicates safety advises, escape routes & safety equipment.
The shape shall be rectangular, the wording shall be in white & the background shall be green.

General Conditions:
 Always respect safety signs & barricades.
 Don't ignore any such signs .Ignorance is accepted to a level (not knowing the meaning of any safety
sign), ask your supervisor, clarify it & then proceed further. But negligence is punishable.
 Strictly adhere with all traffic signs inside & outside the restricted & Kuwait roads. areas.
 All vivid hazards & Unsafe areas, which has potential for risks to human occupancy (trenches, material
storage/ handling &transport etc) shall be properly signage & barricaded with soft (caution tapes) & or
hard barricading with signboards &warning lights.

Hand & Portable Power Tools

Portable power(electric, pneumatic etc..) & hand tools are the storage of risk, which are being neglected by
the user. Examples- burns, bruise, cuts, strains, electrocution or shock, fire & explosion, STF ( slip trip & fall
) falling a&flying of tools, derbies, WRULD etc. Respect all the tools while working with them.
Safety Requirements .
 All tools (irrespective of portable electrical, pneumatic or
hand ) must be of good quality& of sound repair.
 Right tool shall be used for the right job.
 Ferrous & non ferrous tools for the use in hazardous & non
hazardous area shall be distinguished &used.
 No homemade or modified tools shall be used.
 Repair of portable tools (if manufacture recommends) shall be
done by competent person only.
 User check shall be done prior &regular inspection/audit by a
competent supervisor, color coded &records maintained.
 All tools shall be complete, kept clean &free from oil & grease.
 Cutting edges must be kept guarded to avoid inadvertent
contact.
 Never carry sharp tools in pockets. Tool boxes shall be used.
 Carrying of tools to elevated places shall be securely in carry
bags to avoid falling hazards.
 Tools shall be controlled in a store, all for daily issue & return
to store after work & shall be documented.
 Quarterly stock taking audit of the store shall be done.

37
  Only trained & competent employees shall operate power tools.
 Electrical power tools & cords shall be clear off wet surface.
 Entangling / contact with cords of electrically operated power tools shall be avoided.
 Knot in power tools shall be forbidden.
 Never carry electrical tools on its power cord, use handles provided for the purpose.
 Work place shall be arranged in such a manner to avoid STF hazards.
 Correct type of personal protection shall be worn to protect from risks mentioned above.
 No loose clothing/jewelry, when exposed to unguarded rotating equipment.
 Ergonomically acceptable environment shall be held.
 For pneumatically operable portable tools, the hose connection shall be sound & secured with whip
check arresters.
 Pneumatic hammers(Chippers) Concrete Hilties shall have silencer fitted&adequate ear muffs worn by
the operator.
Hazard Risk Control measures
Inspection & color coding, dead man switches, braided / industrial
sockets, no octopus connection, isolate for repair/ maintenance /
Electricity Shock (fatal/ severe)
when not in use. Ground wire for all except double insulated. ELCB,
training, competency, supervision & PPE
Flammable /
Fire/ explosion PTW, gas test, intrinsically safe gadgets, safe distance & FR blankets,
explosive
Guards, no hand gloves, loose sleeves, cotton rags, jewelry& long
Moving parts Entanglements
hair, firm holding & training.
PTW, Correctly rated equipment & accessories, ring testing, safe
Flying debris, distance from plane of rotation, eye/face protection & other PPE,
Eye, hand & face injury
swarf guards, work piece secured, no excess force applied, notification,
isolation, barricading, screening & supervision.
Silencer/ muffler, hearing protection, job rotation, health monitoring
Noise Hearing damage
& notification.

Hand / Arm Vibration

Procedure & operating manual, TBT, selection of low vibrating tools,
Syndrome (HAVS) &
Vibration vibration absorbing handles, job rotation, supervision, health
Carpal Tunnel
monitoring & PPE.
Syndrome
Muscular-skeletal
Ergonomics Work space, job rotation, mechanical aids, health monitoring & PPE.
injury (MSD)
PTW, procedures, housekeeping, sound work platform, better
Slips, trips &
Injury or fatality footing, fall arrest system & work practice, cable management,
falls (STF)
Training, competency & supervision.
Respiratory illness,
PTW, procedures, respiratory, hearing & eye protectors, ventilation,
Dust reduced visibility &
work planning, housekeeping training & supervision.
skin irritation.
Airline PTW, safe work procedure, inspection, supervision, whip checks,
Injury to eye/ face. hit
detaching or isolation from busy routes, barricading, signage, training &
by & distraction
bursting. competency.
Tool jamming Inspection, supervision, competency, information, instructions,
Wrist/hand injury
or bending training, proper handling & storage.
Inappropriate All of the above, right tool for right job, inspections, audit, motivation
All of the above
use & penalty.

Excavation, Trenching& Drilling

Behavior of earth & its condition depends upon nature of soil, weather condition, size & method of
excavation etc.
Excavation- Is a man made cut, cavity or depression in an earth surface formed by cutting, scooping, or
digging out of soil.
Trench- An excavation that is narrow in relation to its length (depth/height) shall be more than the length
& breadth in LBH.

38
Manual Excavation- The excavation
without using any powered equipment or
excavating machinery such as backhoe,
loader, jack Hammer etc.
Mechanical Excavation- The excavation
using powered equipment or excavation
machinery such as backhoe, loader, jack
hammer, etc.
There are potential significant hazards
associated with excavation & trenching.
That are :-
 Lack of situational awareness
 Underground utilities( water, fuel &
sewage etc)
 Electrical cables
 Ammunitions & Explosives
 Cave ins
 Oxygen deficiency
 Flammable & or toxic gasses
 Drowning
 Excavating equipment
 Reptiles
Safety Measures
 Find, is there a safer way to complete the job without working in the excavation/trench or near heavy
equipment.
 Comply with work permit requirement & conditions. Availability of valid excavation notification
highlighting all the underground utilities.
 Informing rescue team about the job to be performed with clear spotting of location.
 Availability of supervisory staff throughout the work.
 Assess the condition of the soil by a competent personal in order to select the shoring, slopping ,
benching or shielding shall be adopted .
 Atmospheric monitoring for toxic gases especially for process facilities.
 Pit lower than 1.2 meters shall be considered as confined space & necessary entry permit & working
conditions hall be adhered.
 No excavation shall be permitted within the 05 meter radius of underground facilities.
 Provision of adequate PPE especially goggles.
 Forbidden use of pick axe & modified tools.
 Provision of appropriate access & egress to & fro the pit. All excavations of 01M or deeper shall have
access provided in the means of benching the edges or ladder access. For excavations for lateral distance
ladder shall be securely placed at & every 25 feet.
 Edges of the pit shall be cleared 01 meters to avoid cave ins.
 Excavation equipment shall be certified & operated by a qualifies & competent personal, movement of
the equipment shall be directed by a flag man.
 Equipment having internal combustion engines shall not be used inside excavations & exhaust gases shall
be kept clear of excavation.
 Secure & barricade & signage the work site for un authorized access of men , vehicle & equipment.
Provision of hard barricading & warning lights (for night) at all vulnerable points.
 Prohibition of standing/ working under excavating equipment & load.
 Maintenance of Safe distance of equipment from facilities & buildings.
 Provision of make shift cross over at important points.
 Inspection of work site at shifts after any rain, thunder or earth quake.

Micro tunneling & HDD(Horizontal directional Drilling) are the best &safest way to perform the excavation
jobs to install pipes or cables under roads,rivers, railways, buildings…etc. without disturbing the flow. It is
most innovative excavation/ construction method with low risk, low cost& highly safest &fastest method of
drilling.

39
 Hot Work
Any work which involves ignition or which can produce ignition shall be considered as hot work.
 Flammable Gas Test (LEL 0%) within 15 Meter (radius) is compulsory prior to any hot work. This include
vehicle &use of any battery operated instruments.
 All sewers, drains, vents or other gas escaping points within the 15 meter ( radius) shall be covered.
 Barricade the work point using approved flame retardant blankets. Especially when over head hot works
are performing, prevent falling of spark/ hot slag onto people or flammable materials below.
 The adjacent area shall be wetted for smolderingdebris.
 Only experienced & properly trained & authorized persons shall perform hot works jobs.
 Combustible material shall be cleared of 8 meters( radius) from the vicinity of the hot work.
 Personnel engaged in hot work shall wear proper
protective equipment such as welding helmet, ear
plug, safety goggles, high safety boots, fire retardant
coverall, fire resistant gloves, apron, leggings,
shoulder cover etc., as per requirement.
 02 Numbers of fire extinguisher shall be available at
7.5 meter (radius) to the hot work & charged water
hose or steam hose shall be immediately available at
all locations where hot work is performed.
 A trained "fire-watch" shall be stationed during all
hot work locations. All other work men of the hot
work team shall be trained in use of portable fire
extinguishers.
 Continuous supervision shall be maintained where
hot work is performed .
 A fire check shall be made of the area not more than one half hour after completion of hot work, mark the
hot metal or provide means of warning other workers.
 Personnel operating are welding or cutting equipment shall be protected from possible shock. Once the
work is completed the machine/ equipment shall set off & moved to a safer place .
 Provide natural & / or mechanical ventilation/ extractors to clear the fumes from welding area.
 Check the welding machine, terminals, cables, cable laying & earthing before work. Welding hose shall not
be repaired with tape. It should be clamped or ferruled. Welding cable, hoses & other equipment shall be
placed clear of passage ways, ladders & stairways.
 The safety certificate & color coding for the equipment shall be ensured.
 Ensure grounding & that the welding return lead is clamped properly as close as possible to work piece.
 Always keep the welding cables & gas hoses as short as possible.
 Approved backflow check valves & flash arrester shall be used on both gas & oxygen lines.
 Welding torch shall not be lighted by matches or by a hot object / surface. A friction lighter or approved
device shall be used.Always check the condition of hoses & torches before lighting.
 Oxygen or fuel gas cylinders shall not be taken into confined space.
 Machinery, tanks, equipment, shafts, pipes etc., that could contain explosive or highly flammable
material, shall be thoroughly cleaned & decontaminated prior to the application of heat.
 In gaseous spaces where there is a possibility for explosion, welding or cutting equipment shall not be
used until the space is adequately ventilated.

Hazards Risk Control

Wrong
Fire &explosion, Fatality, injury& Detailed drawing& identified line, WPS &
Identification of
damage to property Client Emergency Services
line.
Quality/thickness test, line pressure &
operating temperature maintained ,
Fire &explosion, Fatality, injury&
Burn Through item on atmospheric pressure,
damage to property
Competent welder, certified welding
equipment, Supervision
Radioactivity Invisible injury to internal organs WPS, Safe work action(TDS),

40
 including genital disorders,
Cancer,un intended shut down of
UV/IR detectors &plant shut down.
Fall from height Fatality & injury &or damage to
Men , material property
Spill hazard Environment pollution,fire
Notification, Certified Radiographers,
Medical evaluation , PPE&EAP
WPS & Training,Safe work platform,
Safety harness, barricading&confining
material at height.
WPS, Certification of valve, Approved
work method statement. Breathing sets,
Gas monitoring, Spill Containment
procedure.

Hot Tapping
In certain circumstances, welding is allowed on live lines & tanks due to difficulty in depressurizing&getting
freed of flammable material. Welding on live equipment like stubs welding on lines or vessels, prior to
drilling for hot tap, welding brackets on tanks&patchwork for require extra precautions in addition to
normal hot work precautions.

Safety requirements
Velocity of liquid or gas flow in the item to be welded shall be above the minimum of 10 m/s during
welding of the stub.
The liquid level shall be at least 01 M above the point of welding while welding brackets or stubs to tanks
containing hydrocarbons. Welding on the roof above liquid level is prohibited. The flash point of the
content shall not less than 68.6° C. with temperature not less than 10° C below its flash point & the tank
should be at atmospheric pressure.

Compressed Gas Cylinders

 The name of the gas & chemical formula or symbol shall be clearly marked on the neck of the cylinder.
 For shifting compressed gas cylinders, use a cart or other mechanical device especially designed for
transporting the gas cylinders.
 Cylinders shall never be used for any purpose other than to contain gas for which the cylinder was
designed.
 Cylinders shall not be dropped, thrown about or allowed to strike violently with each other.
 Empty cylinders shall be marked or labeled "EMPTY". Valves shall be tightly closed & the valve protection
caps replaced.
 Hazard warning labels shall be displayed on
the cylinder.
 All liquefied gas cylinders shall be kept
upright & secured against by using suitable
cylinder stands or chains.
 Cylinders shall not be subjected to contact
with direct flame, electric arc, molten metal
or other sources of heat or corrosive
material / environment.
 Oxygen or any oxidizing agent cylinders
shall not be stored indoors within 20 feet
from flammable gas cylinders.
 Valve protection caps must protect
cylinder valves when the cylinder is not in
use or when it is being transported.
 Cylinders shall not be misused as rollers,
supports or for any such purposes.
 The cylinder valve shall always be closed before attempting to stop leaks.
 Magnets, slings or chains shall not lift cylinders. A properly designed cradle shall be used for lifting.
 Cylinder valves shall be opened slowly for use. A cylinder not provided with a hand wheel shall be opened
with a standard spindle key to avoid damage to the spindle.

41
 The key shall be kept in place for quick emergency shut down when needed. If the valve cannot be
opened with usual force, it shall be returned to the vendor.
 Regulators & pressure gauges shall not be interchanged' between cylinders of different gases.
 Before opening or closing a regulator or cylinder valve, note' the direction of rotation indicated.
 Oxygen shall never be used as a substitute for compressed air.
 When an oxygen cylinder is in use, its valve should be opened fully in order to prevent leakage around the
valve stem.
 Acetylene cylinder valve shall not be opened more than one & one half turns of the spindle & preferably
no more than three-fourth of a turn.
 Acetylene cylinders shall not be used at pressures higher than 15 psi,
 Oil or grease shall never be used as a lubricant on valves or attachments to oxygen cylinders, since oil &
oxygen under pressure can be a fire hazard. Also, oxygen regulators shall not be handled with oily or
greasy hands or gloves.
 Acetylene cylinders shall be properly secured & always used, transported or stored in a vertical position.
Cylinders shall be protected from sparks, flames & contact with energized electrical equipment.

Radiation/ Radiography works

The process of emitting energy in the form of waves or particles .
Ionizing radiation(IR) using rays(X rays & Gama rays ) &
particles(alpha & beta) &Non ionizing radiation (NIR) optical (UV
)Visible lights & IR &electromagnetic fields (EMFs) (power
frequencies, microwaves , radio frequencies, lasers & power lines )

Risk from Radiation

Radioactive rays or particles are color less, odorless, tasteless &
invisible can harm human cells. Radiation is carcinogen, can cause
cancer. Can cause other adverse health effects, including genetic
defects in the children of exposed parents or mental retardation in
the children of motors exposed during pregnancy.
Safety Measures
 All radiation sources shall be stored, handled, transported
& disposed of by approved & authorized personal under
regulations( radiation protection manual, MOH, Kuwait regulations & client regulations ) &
stringent safety measures.
 Inspection record( monthly inspection for radiating source & six months shield ability test for
container) shall be maintained.
 Permit to work, prior notification including 30 minutes prior announcement, barricading &
signage(three dimensional) shall be held for commencement of the radiography.
 The work shall be performed preferably at night hours or break hours so that other works are not
halted & safety is not compromised.
 Strict & competent supervision shall be ensured.
 Time, Distance &Shielding (TDS) are the basic concept for radiation protection.This is to be
ensured while dealing with radiography.
 Radiographers shall wear lead apron & positioned with personal dosimeter.
 The dose received shall be recorded & over exposure shall be strictly dealt with.
 Eating, drinking, smoking & the application of cosmetics are forbidden while dealing with
radioactive material.

While storing & transporting of radioactive material, safety of personnel protection of property &
environment shall be assured. Radioactive material shall be stored separately from all other materials or
equipment. The storage place shall be 10 centimeter or more above the ground level & kept under lock &
key. The key shall be strictly with the responsible radiography engineer or supervisor. The material shall be
kept in a case made of lead with ample thickness. Company name , contact personal & number, radiation
sign with safe distance etc.. shall be clearly mentioned
Transportation

42
 Radioactive material shall be transported in an authorized/designated vehicle with adequate
signage(criticality safety index), the same shall be escorted by two trained men including the driver. Escorts
shall wear film badges & in position of pocket dosimeters to identify inadvertent release of radiation during
transport. In the event of accidents or incidents during the transport of radioactive material, emergency
provisions, as established by relevant national &/orinternational organizations, shall be observed to protect
persons, property & theenvironment.

Pressure Testing
Pressure testing (Hydrostatic & pneumatic) of vessels &pipelines brings critical risk, if such risks are not
assessed&mitigated, it can be life threatening one. All such tests shall be done in accordance with
international standards such as API & BS.
 The pressure test shall be planned well, in
line with existing procedures of the client
& company.Work method statement/ safe
work plan shall be prepared on the basis
of it &get approved from the client.
 Empower all personnel with the authority
to “Stop work” when hazardous conditions
exist or potentially hazardous conditions
identified.
 Availability of work permit & provision of
barricading &signage at safe zone(100
feet) to restrict un authorized entry.
 All test equipment( Pressure safety valve,
test gauge &compressor etc.. ) shall be
with valid test /calibration certificate.
 Verify the pressure ratings of hoses, fittings, gaskets &other manifold materials.Verify pressure
rating of facility being tested.
 Whip check arresters at hose joints/ couplings
 Adequacy of lighting
 Trained & competent crew under supervision. Assigning responsibilities to each individual.
 Adequate safety talk prior the test.
 Precautions for potential weather extremes shall also consider.
 Availability of correct PPE, especially ear muffs plus radio communication or other best
communicating method.
 No SIMOPS ( Simultaneous operations ) near pressure testing vicinity.
 Gradual increase in test pressure, No sudden increase is accepted.
 No tightening/ tampering of bots while under pressure.
 Release of water or air to the safe manner on successful completion of test.
 When performing pneumatic tests, the piping shall be inspected to determine if the insidesurfaces
are contaminated with a combustible or flammable material (e.g., iron oxide,condensate). If found,
remove such materials prior to air testing.
 Pressure bleeding shall be done gradually & complete bleeding shall be ensured via gauges before
opening the flanges.

Electrical Safety
Reference to 29 CFR (Code of federal regulations) Subpart “S”1910.301 – 1910.308&1910.331 – 1910.335,
Clients & company procedure, electricity shall be dealt with utmost care.
Electricity are two (1)Static( stationary) & (2)Dynamic (Moving)
Static (stationary)- is electric charge that is built up on a material. eg. the slight electrical shock when we
touch a doorknob during dry weather. It is formed by accumulation of extra electrons (negatively-charged
particles

43
Dynamic- is flow of free electrons ( energy) through
a conductor.
The main hazards of Dynamic electricity are :-
 Electrical Shock
 Electrical Burns
 Arc-Flash /Arc Blast
 Fire & Explosion
 Falls (indirect or secondary injuries)
Shock Severity Depends On :-
 The route the electrical current takes through the
body.
 The type & amount of voltage present.
 The surface where the person is standing. Wet or
dry.
 The Time
 The skin of the person (Wet or dry).
How to prevent electrical accidents:-
OSHA requires to protect live parts of electrical
equipment with 50 volts or more by:
 Insulation
 Electrical Protective Devices
 Guarding
 Grounding
 PPE

 Safe Work Practices including training :-

 Obtain valid permit to work .
 Only trained,competent & authorized shall work with electrical system & its repair.
 Do Lock-Out & Tag-Out( electrical )
 Always use three-prong plugs( industrial ) , double-insulated tools, & safety switches. Be sure machine
guards are in place & that always follow proper procedures.
 Replace damaged cords or plugs ( industrial plugs) immediately on notices .
 No over loading.
 Never run cords under rugs Keep electric cables & cords clean & free from kinks. Never carry equipment
by its cords.
 Always pull an electrical cord from outlet by the plug & never by the cord.
 Make sure electrical connections are tight to avoid loose connections which might lead to sparks & fires.
 Use extension cords only when flexibility is necessary & never use them as substitutes for fixed wiring,
never run them through holes in walls, ceilings, floors, doorways, or windows & never use them where
they are concealed behind walls, ceilings, or floors.
 Always use properly rated fuses & in case of tripping of circuit breakers or melting of fuses check the
reasons before replacing the fuses.
 Avoid overloading an electrical outlets.
 Always maintain good housekeeping clear passage or access around electrical equipment & switch
boards.
 Proper signage to warn unauthorized access.
 Working near overhead power lines of 50 kilo-Volts (kV) or less, or any equipment using must not come
any closer than 10 ft from the lines. Add 4 inches of distance for every 10 kV over 50 kV.
 All electrical faults & breakdowns must be reported immediately to the electrical maintenance supervisor
of the client.

Marine safety
The off shore activities, which need additional safety & accessibility. Those personnel engaged in such
areas shall be physically &medically fit & certified, be with additional personal floatation device (life
jacket) & safety harness other than the mandatory PPE. All the work to be covered under proper work
permit & the procedures of the client & all the time safety standards shall be maintained. Generation of

44
waste shall be minimized & disposal at authorized places in line with the requirements.Staffing &work
load shall be within the safe limit. No overtime work shall be performed. Enough rest breaks shall be
arranged to avoid fatigue. All shall be responsible for personal safety & safety of others.

5 S Strategic tool for performance excellence

An performance excellence tool, which was introduced in Japan & effective for Oil & Gas material
management
The tool generated from five Japanese words, which are
(1)SERI(sweep( sort) remove unnecessary items & dispose off them properly)
(2)SEITON(systematic arrangement(set in order) (straighten /streamline) - arrange all necessary items,
so they can be easily find / picked up & taken for use, label them, so that anyone can find them or put
them away
(3)SEISOU (shine / sweep / sanitize or scrub)-turn the work place in to clean & bright, where everybody
enjoy working. Keep things in good repair so it is easy to be used when needed.
(4)SEIKETSU(standardize) - the best practice in work area via adoption of all three previous pillars)&

(5)SHITSUKE (sustain)(to keep in working order) once, achieving all those 4 previous pillars (sweep, set,
shine & standardize) sustain in it.

Management of Change (MOC)

It addresses, all temporary & permanent
changes in legislation, in the organization,
personnel (organizational change in
management) individual roles & responsibilities,
changes in environmental tolerability, systems,
procedures, equipment, operations, locations,
operating practices, a substantial change in the
conditions of work, the introduction of any
measure or change which may substantially
affect employees’ health & safety, products,
business activities &materials, shall be
evaluated are identified & managed to ensure
HSE risks arising from these changes remain at
an acceptable level. The MOC programs ensures
that changes to hardware, control systems, procedures & the organization are properly reviewed &
approved by the expertise prior to the implementation to eliminate occupational hazards that resulted to
injuries, illness, damage to equipment, loss in production, impact to the environment & impact to the
reputation of the project & the organization are recognized & assessed to ensure that HSE Objectives are
not compromised by the changes. Recommendations for improvement are tracked &close-out.Risk
assessment shall be carried out in all changes to mitigate the risk generated from MOC.

Night Work
Extra care shall be given for night works as it brings additional risks to the employees. Perform it to
essential jobs only if unavoidable. No high risk activities including mechanical lifting & hot works.
Risks - Night work risk assessment shall be completed to manage all risks, such as- disruption of the
internal body clock (circadian rhythms),sleeping difficulties, fatigue, health effects(gastrointestinal
problems (indigestion, abdominal pain, constipation, chronic gastritis, peptic ulcers),increased blood
pressure & heart rate, cholesterol,alterations in glucose & lipid metabolism, menstrual disorders, asthma,
diabetes, epilepsy, drug &alcohol use), cardiovascular problems (hypertension, coronary heart disease)
increased susceptibility to minor illnesses (colds, flu &gastroenteritis)individual factors (slowed physical &
mental reaction time, increased errors, decreased vigilance, increased chronic fatigue, anxiety,
nervousness & depression)) social & family stress, reduced productivity&difficulties in communication.
Preventive actions- Training (on sleep routines, nutrition, exercise),increases environmental comfort
ability (temperature, lighting &comfort levels) to improve alertness.Medical fitness,no lone working,

45
 proper communication, refreshment arrangements(tea making facilities including fridge & microwave
oven, adequate meal( light, nutritious & easy to digest), rest breaks(two short breaks &a meal
break),resting place, job rotations (least three or four days), organizing workloads for toughest &most
dangerous tasks at early in the shift, with less demanding tasks for late in the shift, adjust the workload
to prevent boredom, effectivesupervision, as accidents prone time are between 2:00am & 5:30am,
when performance is at its lowest&safe transportation.
Benefits- Increased morale thus increased work efficiency in turn improves product&quality, decreased
sickness &absenteeism, decreased lost-time incidents, reduced risk of fatigue-related accidents, reduced
likelihood of compensation claims&reduced staff turnover.

Environmental protection & Waste Management

“When the earth is sick & polluted, human health is impossible…. To heal ourselves we must heal our
planet, & to heal our planet we must heal ourselves.”

Protection of the environment is for protection of life.Environment is mostly about trees & plants, which
releases O2. The detrimental impact done by every individual plays its role for the protection or destruction
of the living environment. Eco conscious decisions of awareness, caring & concerning shall be adopted.
Why should we care the environment?
 Essential for healthy living( Air sustains us & water is a basic necessity)
 Protect from Global warming- release of carbon dioxide & green house gases from our activities.
 Protection of biodiversity (inter relation with plants, animals, & other living things),can be negatively
influenced by habitat loss & degradation due to human activity, climate change & pollution, among other
things.
How shall we care the environment ?
That are 3 R’s
Reduction/minimization of waste-The
primary objective of the organizations.
Minimize the quantity required to be
treated & disposed of, achieved usually
through better product design &or process
management.
Reuse-Reuse items as much as possible
before replacing them. For example, it
generally makes more environmental sense
to update your computer rather than get rid of it & buy a new one.
Recycle- Recyclable items or their components are put to some new purpose as much as possible. If your
computer is not fit for reuse as is, you can donate it to one of several organizations, to refurbish it or
recycle its components.
No matter how small or insignificant your actions may seem, they matter. It only takes 1 person to start a
movement that could possibly lead to a major environmental breakthrough.
In common, waste are two types - hazardous & non hazardous, shall be segregated as per KEPA ( Kuwait
Environmental Protection Agency ) law: Article 19, Appendix # 11.1,11.2 & 11.3 & shall be collected in the
labeled containers with color as below :-
Red: Hazardous materialsincluding Bio medical wastes (with bio marking)
Green: Food refuse
Yellow: Paper & Cardboard.
Brown: Plastics
Blue: Glass
All waste shall be properlydisposed in the approved dumping/disposal area only. Waste disposal record shall
be maintained by projects as well as centralized records in Al Magwa Main office (HSE)
Guidelines
 Atmospheric venting of hazardous gases at facilities shall be forbidden & venting to water or other
neutralizing media shall be adopted.

46
 Littering, spoiling the soil shall be forbidden, always maintain a positive behavior to dispose waste
properly.
 Segregate waste in the initial stage itself for proper disposal.
 Spill tray for hazardous oil/liquid shall be provided &spill containment procedure shall be applied by
referring the MSDS of the product.
 Minimize the use of water& electricity & power off the sources&faucet when not in use. Use LED bulbs
than other energy consuming lights.
 Provision of automatic sensors to actuate / shut off lights & air-conditioning system in offices.

Bad weather
Heat related illnesses are:-
Heat stroke (Sun stroke)- occurs when the
body fails to regulate its own temperature &
body temperature continues to rise, often
to 40.6°C(105°F) or higher. It is a medical
emergency. Even with immediate treatment,
it can be life-threatening or cause serious
long-term problems.
Symptoms-dry skin, rapid& strong pulse &
dizziness.
First Aid- Rapid mechanical cooling with
resuscitation, move person to cool area,
remove clothing( passive cooling), apply
hyperthermia vest (if available) immersion in
cold water is the best method, seek
immediate medical attention.
Heat exhaustion (Prostration) -generally
develops when a person is working or
exercising in hot weather & does not drink
enough liquids to replace those lost liquids.
Can be a precursor of heatstroke.
symptoms-heavy sweating, pale or flushed
face, rapid breathing, nausea, dizziness,
irritability, head ache, thirst, weakness or fatigue & weak pulse.
First aid-Move the person to shade or to air conditioned place, elevate feet, remove tight clothing, give non
alcoholic drink, cool down by spraying or sponging with cold water & fanning.
Heat syncope(orthostatic dizziness) - occurs when blood flow to the brain is reduced, resulted to
fainting, dizziness, headache, increased pulse rate, restlessness, nausea, vomiting, brief loss of
consciousness.
First Aid- Lie or sit down in the shade or a cool area. Elevate the feet to increase blood to brain. Drink fluids
containing salt. Refrain from vigorous activity.
Heat edema (swelling)-in the legs & hands, occurs when you sit or stand for a long time in a hot
environment.
First aid- Elevate the leg for a period of time in shaded place& take lots of fluid.
Heat cramps -Occurs in muscles after exercise, because sweating causes the body to lose water,
salt&minerals (electrolytes). Symptoms -Muscle pains experiences during heavy exercise in hot weather.
Heat rash (prickly heat)- occurs when the sweat ducts to the skin become blocked or swell, causing
discomfort & itching.Symptoms -Skin irritation from excessive sweating.
Heat tetany - Usually results from short periods of stress in intense heat. Symptoms may include
hyperventilation, respiratory problems, numbness or tingling, or muscle spasms.
The following safety precautions shall be adopted to prevent heat related illness:-
 Take shower twice a day.
 Wear lightweight, light-colored, loose-fitting clothing & socks,replace cotton innerwear daily.

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 Limit theoutdoor activity to morning & evening hours.Try to rest often in shady areas.
 Use safety hard hat to protect head & sun glasses (UV protected) while working & driving.
 Apply barrier cream to exposed skin. Use limited deodorant but no antiperspirants.
 Cut down on exercise.
 For prescribed medicines (which may affect the blood blow), consult with doctor for correct replacement.
 Drink plenty of water even if you are not thirsty, dehydration starts before you feel thirsty. Avoid hot
drinks &beverages containing caffeine (coffee, tea or soft drinks) check the color of urine regularly.
 Eat lighter meal than usual, especially at lunch. Avoid heavy & fried food. Include green salads like
cucumber& lettuce.
 Increase salt intake to replenish loss of body salts from sweating.
 Go to bed early for a comfortable sleep.
People at risk:- Infants & young children, people over 65, people with mental illness& those who are
physically ill, ( heart disease or high blood pressure) &obese.
Cold related illnesses
Knowing the body mechanisms of heat retention &production are essential to the prevention
&management of cold-related illnesses & injuries, such as-
 Vasoconstriction– Decreasesin blood flow to the periphery to prevent loss of body heat.
 Shivering- While involuntary shivering generates heat through increased muscle activity, it may also
hinder aworker performance& ability to perform behavioral tasks to aid in heat retention.
 Activity increase- Increases heat production through a general increase in metabolic activity. Quick bouts
of intense activity can generate incredible amounts of heat.
 Behavioral responses- Adjusting the number & type of clothing layers will result in heat regulation by
controlling the amount of heat lost by the body.
There are two cold-related pathologies -
hypothermia& frostbite.
1. Hypothermia(mild (shivering, cold
sensation, goose bumps, numb hands),
moderate(intense shivering, muscle
incoordination, slow & labored movements,
mild confusion, difficulty speaking, signs of
depression, withdrawn) (&severe(shivering
stops, exposed skin is bluish & puffy, inability
to walk, poor muscle coordination, muscle
rigidity, decrease in pulse & respiration
rate&unconsciousness) - is decrease in the core
body temperature to at least 95 degrees F. It
occurs when the heat loss is greater than the
metabolic & heat production.

2. Frostbite (frost nip(outer layer of skin is frozen, skin appears white & waxy or possibly gray or mottled. It
may have sensation or may be numb. May be painful), superficial frostbite &deep frostbite(Skin appears
white, mottled or gray. It feels hard or rubbery on the surface, but deeper tissue is still soft. Skin is
insensitive to touch)- thermal injury to the skin from prolonged exposure to moderate cold or brief
exposure to extreme cold. Prone areas are- the hands, feet, nose, ears & cheeks. Factors influencing
susceptibility or risk tocold injury or illness. For example, exposure to 30 degrees - 50 degrees temperature
under wet & windy conditions can be equivalent to sub-zero temperatures with no wind or moisture.

The best method of management of cold related illness is prevention.

Dress in layers (thin & multiple layers of clothing is better than thick one layered sweater). Cover head&
upper extremities to prevent excessive heat loss from such areas. Remain dry by wearing a wicking fabric
next to the body & a breathable, water repellent outer layer, Remain adequately hydrated.Eat regular
meals.Avoid alcohol, caffeine & nicotine.Train employee in recognition of cold-related illnesses.Consider
work planning if weather conditions worsen.

Disclaimer

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This hand book is for ready reference for the user and for further details, respective SWP shall be
referred.

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