DBN-1 HSE TA Site Safety Plan_0

ISSUED FOR CLIENT REVIEW

REVIEWED BY DATE

0 29 NOV 04 ISSUED FOR CLIENT REVIEW PRJ BR

REV DATE DESCRIPTION ORIG CHECKED BY

APPROVED BY (FLUOR)

APPROVED BY (YANPET)

SAUDI YANBU PETROCHEMICAL COMPANY YANBU AL-SINAIYAH, K.S.A.

YEP DBN-1 PROJECT

ITEM NO. REV

9905-02-000 0 DBN-1 SITE SAFETY PLAN

DOCUMENT NO.

9905-02-000 Site Safety Plan FLUOR

Saudi Yanbu Petrochemical Company P.O. Box 30139

Yanbu Al-Sinaiyah 51888 Kingdom of Saudi Arabia

YANPET DEBOTTLENECKING – 1 PROJECT

SITE SAFETY PLAN

FLUOR ARABIA LIMITED P.O. Box 3381

Al-Khobar 31952 Kingdom of Saudi Arabia

® TABLE of CONTENTS DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

PROJECT PRACTICES

Practice No. Title SECTION I. 1 Roles & Responsibilities 2 Subcontractors Responsibilities 3 Work Area Hazard Assessment 4 Safety Education & Training 5 Safety Task Assignment 6 Emergency & Contingency Planning 7 Hazard Communication 8 Safety Violation Notification System 9 Personal Protective Equipment 9-A Personal Protective Equipment – Eye Protection 9-B Personal Protective Equipment – Head Protection 9-C Personal Protective Equipment – Hand Protection 10 Housekeeping 11 Sanitation & Potable Water 12 Illumination 13 Materials Storage & Handling 14 Barricading 15 Ladders 16 Scaffold Safety 17 Powered Aerial Work Platforms 18 Forklifts & Powered Industrial Trucks 19 Fall Protection 20 Steel Erection 21 Hand Tools 22 Power Tools 23 Powdered Actuated Tools 24 Electrical Safety 25 Excavation & Trenching 26 Confined Space Entry 27 Rope Chain & Sling Inspection 28 Mobile, Overhead & Gantry Cranes 29 Rigging / Lifting Plans 30 Personnel Hoisting 31 Welding, Cutting & Heating 32 Fire Protection & Prevention 33 Heat Stress Prevention 34 Operator Licensing 35 Abrasive Blasting 36 Respiratory Protection 37 Control of Hazardous Energy 38 Site Safety Inspections 39 Safety Committee Meeting/Walkthrough 40 Site specific Rigging Inspection 41 Incident Investigation 42 Flagman & Traffic Vest

® TABLE of CONTENTS DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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FORMS

Form No. Title SECTION II.

DBN-F8 Blue Card DBN-F9 Barricade Tag DBN-F10 Ladder Inspection Checklist DBN-F11 Powered Aerial Work Platform Checklist DBN-F12 Forklift Inspection Checklist DBN-F13 Harness Inspection Checklist DBN-F14 Assured Equipment Grounding Inspection Checklist DBN-F15 Excavation Permit DBN-F16 Daily Excavation Inspection Checklist DBN-F17 Rope, Sling & Shackle Inspection Checklist DBN-F18 Monthly Crane Inspection Checklist DBN-F19 Daily Crane Inspection Checklist DBN-F20 Critical Lift Permit DBN-F21 Rigging & Lift Plan DBN-F22 Authorization for Use Of Suspended Personnel Hoisting Platform DBN-F23 Justification for Use of Suspended Personnel Hoisting Platform DBN-F24 Equipment Operator License Record DBN-F25 PPE Training Record DBN-F26 Medical Questionnaire for Respirator Use DBN-F27 Respirator Fit Test DBN-F29 HSE Committee Minutes DBN-F30 Job Hazard Analysis DBN-F31 Safety Task Assignment DBN-F32 Daily Tool-Box Meeting Report DBN-F33 Chemical Inventory DBN-F34 Formal Near Miss/Incident Investigation Report DBN-F40 Daily Safety Report DBN-F41 Green Lift Checklist DBN-F42 Lift Classifications DBN-F43 Safety Violation Notification Form DBN-F44 Rigging Data Sheet DBN-F45 Transportation Drawing


HSE SECTION I.

PROJECT PRACTICE


HSE Practice 1 Roles & Responsibilities

® ROLES & RESPOSIBILITIES PRACTICE 1 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1 PURPOSE

The purpose of this practice is to define the Health, Safety, and Environmental (HSE) requirements that are common to The Yanpet DBN-1 Turnaround Engineering, and Execution activities.

2 SCOPE

This practice provides the minimum HSE company requirements for: • Roles and responsibilities, • Management of change, • Training and education, • Audits, • Accidents and incidents management, • Performance indicators, • Records retention.

3 DEFINITIONS

JHA – Job Risk Analysis (also known as Job Hazard Analysis).

STA – Safety Task Assignment.

1.0 ROLES AND RESPONSIBILITIES

The titles will change from project to project, as will the responsibilities and tasks. The following bullet items are for guidance only.

1.1 Project Director/Managing Director/General Manager

Responsibilities: • Provide an environment that protects all personnel and the general public

using the implementation of the Fluor HSE Policy; • Provide overall direction and support for the implementation of the Fluor

HSE Policy and Management System; and • Provide sufficient resources to support approved Fluor HSE initiatives.

Tasks: • Review proposals and approve the allocation of resources for practical and

effective HSE initiatives and • Verify that specific HSE Procedures are in place for site activities required

by the client.

1.2 Project/Site Manager

Responsibilities: • Accountable for the overall direction and support of the implementation of

the HSE Management system; • Verify that the HSE Policy protects all personnel and the general public;


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• Accountable for the provision of adequate HSE resources, facilities, and initiatives to effectively implement and manage the HSE Management System;

• Accountable for critical review of engineering specifications in terms of HSE standards at the design stage;

• Encourage the proactive involvement of all personnel in managing the HSE program;

• Verify that employees are aware of and understand their HSE responsibilities.

• Provide appropriate skills training to all employees; • Accountable for the effective management of all Workers Compensation

cases; • Accountable for the suitability of contractors to work safely on the project; • Accountable for overall HSE performance on the project; and • Verify that Hazard Analysis Studies 1, 2 and 3 are performed during the

engineering design phase. • Administer day-to-day activities of worker’s compensation program, if

applicable.

Tasks: • Review the Fluor HSE Management system on a regular (at least annually)

basis; • Review incident records and verify that all follow-up action is completed

in a timely manner; • Participate in audits and planned inspections of the site; • Where possible, investigate all incidents where personal injury occurs; • Review all on-site audit reports; • Review proposals and approve the allocation of resources for practical and

effective HSE initiatives; • Provide that all orientations including a HSE overview, are presented by

the HSE Manager or nominated delegate; • Continuously monitor Fluor HSE performance indicators and project

inspection reports; • Monitor the completion of hazard studies against the project schedule; and • Where possible attend/chair the Project HSE Committee meetings. • Expedite the final solution or outcome of recommendations that are

identified in the HSE-related reviews. • Provide and require formal HSE training for all Fluor Supervisors. This

training shall be documented and conducted within thirty (30) days of the employee’s appointment as a Supervisor.

1.3 Line Management

Responsibilities: • Plan and direct the work in such a manner that the Fluor HSE Management

System, together with the client’s HSE Policy and procedures and statutory requirements, are met and

• Implement procedures to eliminate injury to project personnel, the general public, and/or damage to property and the environment.


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• Possess a comprehensive knowledge of all HSE rules pertaining to his/her job.

• Explain all applicable HSE work practices to all employees under his/her direct supervision and verify that each employee understands the rules and regulations.

• Consistently enforce HSE rules and regulations. • Maintain a zero tolerance for unsafe acts.

Tasks: • Supervise the training of new employees, either personally or with the

assistance of experienced craftsmen, until he/she demonstrates the ability to work in a safe and efficient manner.

• Monitor employees’ performance to enforce the use of safe work practices. • Always use JHAs to analyze work activities to identify potential hazards; • Implement work Procedures that incorporate control methods for identified

hazards; • Consult with the HSE Manager on HSE and injury management issues; • Conduct scheduled and unscheduled inspections of their work areas; • Responsibly manage on-site injury treatments and follow up as necessary

with appropriate First Aid; • Report and investigate all incidents that occur in their respective areas of

responsibility; • Apply appropriate Fluor disciplinary procedures to address breaches of the

Fluor HSE Policy and procedures; • Conduct toolbox meetings; • Inspect the workplace and acknowledge good HSE performance; • Take appropriate remedial action on substandard HSE items; • Facilitate HSE and skills training to verify that all personnel are adequately

skilled to undertake their tasks; and • Enforce completion of the Job Start Checklist for each job before work

commences. • Promptly notify his/her direct Supervisor and/or the Project/Site HSE

Representative concerning work areas where unique hazards exist and/or special assistance is required.

• Promptly report to his/her direct Supervisor all cases of employees who, in his/her opinion, are not qualified for the work to which they have been assigned or who engage in unsafe work practices.

• Conduct Toolbox HSE Meetings for all employees under his/her supervision. • Immediately report all incidents that could have resulted in personal injury or

property/environmental damage. • Immediately report all incidents that have resulted in personal injury or

property/environmental damage. • Assist in accident investigation and submit a report promptly on required

forms. • Periodically analyze work methods to establish necessary HSE work

methods and to simplify job processes. • Assist the Project/Site HSE Representative in the preparation of

departmental or Project/Site safe work practices. • Be responsible for housekeeping in his/her department and for the use and

maintenance of all personal protective devices, equipment, and safeguards.


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1.4 Vice President, HSE

Responsibilities: • Report company HSE performance. • Develop and implement a Fluor Accident Prevention Program for use by

all levels of Management in project execution; • Communicate directly with Management to facilitate the timely receipt of

accident prevention and HSE information; • Assist Management in recruiting, training, and evaluating HSE

Professionals; • Develop written plans, programs, and materials as continuous training aids

in accident prevention and HSE; and • Coordinate HSE services furnished by the Company's insurer.

Tasks: • Work with executive management to provide resources to implement HSE

Management System. • Work with executive management to annually review HSE Practices and

Procedures.

1.5 HSE Manager

Responsibilities: • Coordinate the implementation and management of the Fluor HSE

program and Policy; • Through regular fieldwork verify that all personnel are fully conversant

with the corporate and/or project HSE Management System, its procedures, and related HSE instructions;

• Coordinate orientations and other HSE training where necessary for all personnel;

• Distribute material on HSE education, promotion and awareness; • Verify that first aid and emergency procedures are in place within a

project; • Manage and maintain the HSE-related records and documentation; • Verify that Material Safety Data Sheet (MSDS) registers are developed and

maintained; and • Maintain and update HSE Notice Board(s). Tasks: • Coordinate the Fluor HSE Committees; • Coordinate appropriate orientation training for personnel commencing

employment; • Coordinate general Fluor HSE training for all personnel; • Coordinate thorough investigation of all incidents; • Coordinate audits to eliminate conditions and work practices that are

hazardous to the job; • Conduct unscheduled and scheduled inspections of work areas; • Attend Fluor toolbox meetings; • Review and monitor emergency procedures; • Display and disseminate HSE material suitable for Fluor toolbox topics; • Encourage hazard identification and reporting by all site personnel; and


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• Consult with employee and treating physician regarding an employee’s rehabilitation and early return to work.

1.6 HSE Advisor

Responsibilities: • Participate with the area supervisor in area inspections on a regular basis; • Participate in any investigations relating to HSE issues; • Inform personnel in the area of Fluor HSE issues; • Report all hazards to their supervisor or the Project Manager; • Attend meetings of the HSE Committee and consult with the Project

Manager(s) on HSE issues.

Tasks: • Attend HSE Committee meetings and represent work group; • Assist employees with HSE issues; • Undertake regular inspections of the work area with the area supervisor;

and • Contribute to accident/incident investigations and the preparation of

reports.

1.7 HSE Representative

Responsibilities: • Participate with supervisor in area inspections on an as-required basis; • Participate in investigations relating to HSE incidents; • Report all hazards to immediate supervisor; and • Participate in HSE Committee.

Tasks: • Represent work group at HSE Committee meetings; • Assist or represent employees in any other meetings, dealing with HSE

issues; • Undertake regular inspections with area supervisor; and • Contribute to any investigations completed and the preparation of reports.

1.8 All Personnel

Responsibilities: • Co-operate with and constructively participate in the HSE Management

program; • Comply with Fluor HSE requirements that apply to an individual’s work; • Work within competencies held; • Adhere to procedures to protect the safety of you, fellow employees, and

the general public; • Proactively be involved in the HSE program; this involvement may include

some aspects of planning, problem solving, priority setting, training, and improving work practices and


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• Analyze the work scope (i.e., conduct and or assist with JHAs) to identify and assess HSE hazards and to provide for the development of safe work methods.

In compliance with an individual’s “duty of care”, all personnel will: • Be aware of and work for the health and safety of themselves and others in

the workplace; • Comply with all safe-working directions given in the workplace; • Not misuse or damage any equipment; and • Wear all appropriate protective clothing and equipment.

Tasks: • Keep work area in an orderly condition and comply immediately with any

lawful d irective given by Fluor or the Client; • Report all personal injuries, incidents, near misses, and hazards

immediately; • Use correct PPE and equipment as stated by the project and work

requirements; and • Report all breaches of safe working practices.


HSE Practice 2 Subcontractors Responsibilities

® SUBCONTRACTORS RESPONSIBILITIES PRACTICE 2 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1 PURPOSE

The purpose of this Practice is to provide subcontractors a summary of FLUOR ARABIA HSE Procedures/Practices for eliminating accidents and injuries and the minimum requirements for compliance with applicable regulations.

2 REFERENCES

2.1 Title 29 Code of Federal Regulations (CFR) - Part 1926

2.2 American National Standards Institute (ANSI) - Z87, Z89

2.3 National Electric Code (NEC)

2.4 Yanpet Standard H-P-301—Safety & Loss Prevention Department: Safety Regulations for Contractors

3 EXHIBIT E OF CONTRACT

3.1 Definitions

3.2 Flammable Liquid - liquid having a flash point below 140 °F and a vapor pressure not exceeding 40 pounds per square inch (absolute) at 100 °F

3.3 Flammable Material - liquids, solids, or gases that are capable of being easily ignited, burning intensely, or having a rapid rate of flame spread (usually dusts, fine powders, or substances that ignite spontaneously at low temperatures).

3.4 Subcontractor - In this Practice, the term subcontractor shall mean any subcontractor or contractor contracted to FLUOR ARABIA or contracted to a third party but directed in their work by FLUOR ARABIA

4 PROCESS

4.1 General

4.1.1 Each subcontractor shall know and comply with FLUOR ARABIA, Local, State, and Federal HSE Standards and Regulations.

4.1.2 Subcontractors shall submit their company's written Health and Safety Program to the Subcontract Administrator, who shall have the Project HSE Manager/Construction HSE Manager, review it for content and compatibility with the FLUOR ARABIA HSE Program. Deficient programs shall be revised to meet FLUOR ARABIA’s minimum require ments.

4.1.3 The subcontractor shall provide his or her job supervisor's home address and telephone number to the Subcontract Administrator so the supervisor can be contacted after hours in case of an emergency involving the subcontractor's workers or equipment

4.1.4 The subcontractor shall ensure that his or her safety program is in compliance with existing safety and health requirements of Local, State, and Federal regulatory agencies. This shall include, but is not limited to, Fall Protection, Confined Space activities, Hazard Communication Training,


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Personal Protective Equipment Training, and Respiratory Protection Training (including respirator fit testing, required medical examination and clearance).

4.1.5 The subcontractor shall also conduct training specifically addressing the project HSE Program for his/her employees and shall ensure their compliance with the program, including policies that exceed government require ments. The subcontractor shall provide to FLUOR ARABIA documentation verifying that this training has been conducted.

4.1.6 The subcontractor is responsible for employees working for him or her and for other persons calling on or doing business with him or her on a Company project.

4.1.7 Prior to the start of work, the subcontractor shall provide the name of their Manager and documentation of their qualifications to the Subcontract Administrator. This Manager shall be assigned to the project site and be responsible for administering and enforcing the HSE pro gram. The subcontractor’s Manager shall meet with the FLUOR ARABIA Project HSE Manager/Construction HSE Manager to review the safety regulations that must be adhered to on the project.

4.1.8 After award of subcontract, and prior to commencement of any work on an FLUOR ARABIA project, the subcontractor shall ensure that his/her personnel (both supervisory and hourly) receive an initial FLUOR ARABIA HSE orientation the Construction HSE Manager. This shall be the first step in the orientation program.

4.1.9 Contractors and/or subcontractors will be advised of the provisions of the project HSE expectations, of client stipulations, and of contractual obligations in the subcontract documents at the pre-job meeting. The obligation of all contractors and/or subcontractors is to comply with applicable statutory safety, health and environmental laws, regulations and rules. Contractors and/or subcontractors shall be advised that they have the sole and complete obligation to provide a safe and healthful working environment for their employees and for other persons at the project site who may be exposed to their work.

4.1.10 Subcontractor is responsible for the health, safety and environmental (HSE) protection of all persons and property and for compliance with all national, international, state and local laws, Owner’s and Contractor’s rules, regulations and orders applicable to the performance of the Work. Subcontractor shall develop its own HSE Procedures, manage, and supervise the implementation of those procedures during the execution of the Work. Contractor shall review and approve Subcontractor’s HSE Policies and Procedures.

4.1.11 Compliance with the HSE Policies and Procedures is mandatory for all employees on the Project. The responsibility for enforcement of the HSE Policies is delegated to everyone on the Project site; however, Subcontractor’s management has primary responsibility for its personnel and Lower Tier Subcontractor’s to establish and enforce the HSE Policies and Procedures, and to promote safe working conditions on the Project.

4.1.12 The Owner and Contractor require that Subcontractor and its Lower Tier Subcontractors place the highest importance on HSE at all times during the performance of the Work on the Project Site. The Subcontractor shall fully participate in and cooperate with all HSE programs implemented by the Owner, or Contractor to meet the HSE objectives of the Project, and shall provide all statistics, information, training and education in HSE required by such programs. Subcontractor shall provide sufficient staff on the Project Site to provide such information and programs as required by Contractor. The Contractor shall have the right to terminate the Subcontract agreement if, in the sole opinion of the Contractor, the Subcontractor is not cooperating fully with or participating


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fully in any such reporting systems or programs, or Subcontractor has not provided staff or support for such programs, or if the Contractor believes the Subcontractor cannot or will not be able to perform the Work and meet the HSE objectives. This right to terminate shall be in addition to Contractor's right to exclude any individual or firm from the Project for allowing an unsafe condition to exist.

4.1.13 Contractor and/or Owner may inspect the Project Site and appropriate Work records to ascertain Subcontractor’s compliance with the safety and health requirements of the Subcontract. However, neither the existence nor exercise of such right shall relieve the Subcontractor of its responsibility of monitoring and ensuring its own and its Lower Tier Subcontractors compliance with HSE requirements of this Subcontract.

4.1.14 The Subcontractor shall ensure that all of the Subcontractor’s employees engaged in the Work, as well as Subcontractor’s representatives, suppliers, Lower Tier Subcontractors and visitors shall be aware of and be subject to the rules and regulations set by Contractor and Owner for the safe, orderly and efficient conduct of all operations upon the Project Site. Subcontractor shall be responsible for compliance with the most stringent requirements of Owner and Contractor HSE rules and regulations.

4.1.15 Subcontractor warrants that the performance of the Work will comply in all respects with all applicable national and/or international occupational safety and health laws, regulations, acts, rulings, orders and/or standards promulgated there under and agrees to hold Contractor and Owner harmless from any and all liabilities, claims, fines and penalties, including reasonable costs and settlements incurred as a result of Subcontractor’s failure to comply with the requirements of this Subcontract document.

4.1.16 Subcontractor shall take all necessary precautions for the safety of its employees and all other persons on the Project Site and shall comply with all applicable provisions of governmental authorities’ safety laws to prevent accidents or injuries to employees and other persons or damage to property on or about or adjacent to the premises where the Work is being performed.

4.1.17 Subcontractor shall at all times be responsible for HSE and shall protect the Work, workers, the publics, Owner’s, contractor and Other’s property.

4.1.18 The Subcontractor shall, at all times, be responsible for providing all of Subcontractor’s employees, agents or Lower Tier Subcontractors with a safe place of employment. The Subcontractor shall inspect the location where its employees, agents, or Lower Tier Subcontractors may be working, and shall promptly take action to correct conditions that are or may become an unsafe place of employment for them.

4.1.19 Subcontractor shall implement its own HSE program providing training for its employees, providing specific safety instructions on special activities, and providing on-going safety supervision. Subcontractor shall support their safety program with necessary signs, notices, materials, equipment, and incentives. Prior to start of Work in the field, the Subcontractor’s written safety program will have to be approved by the Contractor’s Site Manager or designated Representative. Delay in the Subcontractor’s obtaining approval of this written program will be no justification for changes in completion schedule or price.

4.1.20 Subcontractor shall provide a defined separation of other Work not related to the Project. This defined separation will assist Owner, Contractor, and Subcontractor in maintaining reasonable control of the Project HSE efforts.


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4.1.21 Additional requirements can be found in Contract Exhibit E and its attachments.

4.2 Specific Subcontractor Safety Rules

4.2.1 Some requirements that apply to subcontractors working on a FLUOR ARABIA project include:

4.2.1.1 Medical Facilities - The subcontractor will use Yanpet’s medical facility for treatment of all work related illnesses and injuries.

4.2.1.2 Accident Reporting - A copy of each Incident Report (Near Miss, First-Aid, Doctor’s case, Recordable, Restricted Work Day Case and/or Lost Time, Fire, Release, Vehicle Accident, or Utility Damage) must be provided to the Construction HSE Manager within 24 hours. Copies of the subcontractor's OSHA 300 Log must be furnished upon request.

4.2.1.3 Clothing - The subcontractor and his/her personnel shall comply with requirements for wearing appropriate work clothing, including, but not limited to, work boots, gloves, etc.

4.2.1.4 Personal Protective Equipment - hard hats and safety glasses that comply with ANSI standards (Z87 and Z89) must be worn at times on the jobsite. Hearing protection must be worn in areas of high noise levels. Appropriate respiratory protection equipment must be used when conditions warrant. Suitable protective clothing must be worn when required. Approved safety harnesses and properly attached safety lines must be worn by subcontractor employees working at heights above 6 feet.

4.2.1.5 Inspections - Subcontractors are required to conduct a daily safety check of each of the areas where their employees are working and to correct any unsatisfactory conditions. Subcontractors shall conduct a formal written safety check documenting unsatisfactory conditions and submit solutions within two workdays to the Construction HSE Manager.

4.2.1.6 Daily safety inspections conducted by Company personnel are required on jobsites. In addition, the Subcontract Administrator and a supervisor from each subcontractor shall participate in the weekly supervisor’s Compliance Inspection.

4.2.1.7 Subcontractors are required to correct immediately any unsatis -factory safety conditions resulting from their operations.

4.2.1.8 Violation Procedures - When unsafe conditions or practices in subcontract work are observed by FLUOR ARABIA, the subcontractor supervisor shall be informed by Noncompliance Notice for corrective action. The Construction HSE Manager shall be responsible for ensuring that appropriate action is taken. If the subcontractor takes no action within two workdays, the Construction HSE Manager shall issue a letter to the subcontractor's management outlining the violation and


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appropriate corrective action. If the subcontractor refuses to correct the unsafe condition or practice, FLUOR ARABIA shall take corrective action and shall withhold subcontractor payment. FLUOR ARABIA shall exercise the right to terminate the subcontractor for recurring violations or refusal to correct hazards.

4.2.1.9 If the subcontractor creates a hazard or situation that can cause death or serious injury, work, shall be stopped by FLUOR ARABIA until the hazard is corrected. The subcontractor shall reimburse expenses resulting from a continuing uncorrected hazard to FLUOR ARABIA If the subcontractor refuses to correct the hazard, FLUOR ARABIA shall take corrective action and will withhold subcontractor payment. FLUOR ARABIA shall exercise the right to terminate the subcontractor for recurring violations or refusal to correct hazards.

4.2.1.10 Safety Meetings - Subcontractors shall conduct, as a minimum, weekly safety meeting. Subcontractor supervisory and craft employees shall attend these training sessions, and attendance shall be documented. Topics shall be pertinent to the work the subcontractor is performing.

4.2.1.11 Electrical Equipment - Subcontractors are responsible for maintenance of their extension cords, and shall remove from service immediately those that are defective. Subcontractors shall use ground fault circuit interrupters (GFCIs) or an Assured Equipment Grounding Program. The subcontractor can furnish a copy of their Assured Equipment Grounding Conductor Program to the Construction HSE Manager, but GFCIs shall be the preferred method of protection required in most cases. Electrical wiring, boxes, cords, etc. shall be in compliance with the National Electrical Code (NEC) and OSHA.

4.2.1.12 Prior to working on electrical equipment, a subcontractor must make certain that circuits in the immediate vicinity of his or her work are appropriately protected and either locked out or tagged out of service to ensure that no one can accidentally energize the circuit. Subcontractors are required to follow the FLUOR ARABIA Control of Hazardous Energy Practice, or submit their own Procedure/Practice for approval if it is more stringent.

4.2.1.13 Fire Protection/Prevention - Gasoline and other flammable materials must be kept in approved containers, and storage requirements for quantities and types must comply with local and Federal regulations. Bulk storage of fuels is discouraged. Special permission shall be obtained from the Company prior to storing fuels in bulk volumes.

4.2.1.14 "No Smoking" signs must be posted in areas where flammable materials are stored, and subcontractors must enforce no-smoking areas on the project site. All areas where smoking is permitted shall be designated the by the Yanpet representative.


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4.2.1.15 Subcontractors must furnish the appropriate number, size, and type of portable fire extinguishers required for their work area and must train their personnel in proper use. Fire extinguishers must not be tampered with or removed from their assigned locations.

4.2.1.16 Housekeeping - Good housekeeping practices are extremely important, and subcontractors are responsible for conditions in their respective areas. Refuse and scraps must not be allowed to accumulate, particularly when they interfere with work flow or create fire hazards. Combustible refuse must be placed in appropriate metal containers.

4.2.1.17 Subcontractors shall perform a weekly audit of their work areas. A copy of the audit findings and resolutions shall be submit ted to the Construction HSE Manager each week.

4.2.1.18 A written Safe Work Authorization must be obtained from the production supervisor before any work can be started in any restricted area. All areas within the confines of the fenced area are restricted unless specifically designated otherwise in writing. The Safe Work Authorization is to be obtained from a Yanpet Production Supervisor. Authorization is normally valid for the period stated on the authorization up to a maximum of one shift.

4.3 Subcontractor Security

4.3.1 Subcontractors must take the security measures required to protect their materials, including those furnished to them by FLUOR ARABIA, which is not responsible for subcontractor materials or tools. Subcontractors are responsible for loss or damage they, their workers, or their subcontractors cause to the work, materials, adjacent property, or persons.

5 RECORD RETENTION

5.1 Subcontractor violations shall be documented in letters maintained in the Construction HSE Manager’s files. Copies shall also be forwarded to the FLUOR ARABIA Subcontract Administrator.

5.2 Subcontractor safety meetings shall be documented in reports filed in the Construction HSE Manager’s files.

5.3 A copy of the subcontractor's safety program shall be kept on file in the Construction HSE Manager’s files.

5.4 A copy of the subcontractor’s incident reports as defined in shall be kept on file in the Construction HSE Manager’s file.

5.5 Each subcontractor shall submit a written report at the end of the assignment or at the end of each week (whichever covers the shorter time period) to the Subcontract Administrator and Construction HSE Manager. This report shall provide the number of near-misses, first-aids, doctor cases, recordables, restricted work day cases, lost time cases, fires, vehicle accidents, utility damage


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incidents, spills/releases, etc. the subcontractor had while working for FLUOR ARABIA during that week. The report shall also specify the number of hours the contractor worked for FLUOR ARABIA


HSE Practice 3 Work Area Hazard Assessment

® WORK AREA HAZARD ASSESSMENT PRACTICE 3 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1 Purpose 1.1 The purpose of this Practice is to identify and minimize the risk of occupational and

environmental hazards that may be encountered on projects. 2 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart c (1926.20)

2.2 Form DBN-F30—Job Ha zard Analysis 3 Definitions

3.1 None

4 Process 4.1 The inspections shall be conducted according to the following specifications:

4.1.1 An initial inspection shall be conducted prior to mobilizing employees into a work area under a new contract or work assignment. The initial assessment shall provide information about the site, the process, raw materials, & waste materials, and will serve to provide information useful in the development and/or revision of the project’s site-specific plans.

4.1.2 A monthly compliance inspection shall be led by the Construction Manager. (Practice 2).

4.1.3 A weekly compliance inspection shall be led by each Area or Craft superintendent with the assistance of the Construction HSE Manager (Practice 2).

4.1.4 A work area assessment shall be included in the Safety Task Assignment (STA) conducted by each work group prior to beginning tasks (DBN-F31).

4.2 Items to consider when conducting the assessment include, but are not limited to the following: 4.2.1 Chemical inventory (determine if the site has chemicals that are regulated by

substance specific standards or the process safety management standard)

4.2.2 Asbestos inventory of the site 4.2.3 Lead based paint inventory 4.2.4 Slip, trip and fall hazards

4.2.5 Access to eyewash stations, safety showers, exits, and electrical disconnects 4.2.6 Access to medical facilities 4.2.7 All equipment available for FLUOR ARABIA use

4.2.8 Regulations and Procedures that FLUOR ARABIA is required to follow 4.2.9 Burn hazards 4.2.10 Pinch points

4.2.11 Confined spaces 4.2.12 Anchorage points 4.2.13 Rescue and emergency response capabilities

4.2.14 PPE needs 4.2.15 Weather conditions 4.2.16 Activities of others nearby

4.2.17 Plants and animals in the area 4.3 Contractors shall conduct a Job Hazard Analysis (JHA) on all major work operations

using Form DBN-F30—Job Hazard Analysis, work operations that are particularly


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hazardous by nature, and those operations requiring special planning. The following list of general activities can be used as a guide to help determine when a JHA is required. This list is not meant to be all-inclusive: 4.3.1 Excavation and trenching operations. 4.3.2 Blasting.

4.3.3 Pile driving and drilled pier installation. 4.3.4 Foundation construction. 4.3.5 Concrete work.

4.3.6 Structural steel erection. 4.3.7 Roofing and decking work. 4.3.8 Tower construction.

4.3.9 Transmission line construction. 4.3.10 Tank, vault, basin, and vessel construction. 4.3.11 Building construction.

4.3.12 Metal wall panel and precast panel installation. 4.3.13 Mechanical equipment installation. 4.3.14 Electrical equipment installation.

4.3.15 Insulation work. 4.3.16 Painting, coating, and lining operations. 4.3.17 Heavy rigging and lifting operations.

4.3.18 Chemical cleaning activities. 4.3.19 Pressure testing. 4.3.20 Startup and commissioning activities.

4.3.21 Cofferdam installation. 4.3.22 Tunneling operations. 4.3.23 Hazardous waste remediation.

4.3.24 Work in roadways. 4.3.25 Confined space work. 4.3.26 Prior to the start of a work operation that requires a JHA, the appropriate

personnel shall be assembled. The personnel required to complete a JHA shall be dependent on the complexity of the work operation being evaluated. As applicable, persons shall be included that have knowledge in the following areas, but as a minimum, at least one management and one craft employee shall be involved in the process: 4.3.26.1 Hazards associated with the work operation.

4.3.26.2 Knowledge on the equipment and tools needed to safely perform the work.

4.3.26.3 Procedures to perform the work.

4.3.26.4 Applicable regulatory standards. 4.3.26.5 FLUOR ARABIA HSSE Program requirements. 4.3.26.6 Chemicals and processes involved.

4.3.27 The JHA shall be used as a guide to complete the JHA. The form is broken down into three areas: Sequence of the Job, Potential Hazards, and


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Recommended Action or Safe Procedure. The following shall be considered when completing each section:

4.3.27.1 Sequence of the Job--The job shall be broken down into manageable steps with enough detail to adequately cover the task being evaluated. For example, steel erection can be broken down into several tasks such as steel delivery, offloading, staging, anchor bolt installation, column erection, beam installation, fill-in steel, bolt up, stairs and handrail, grating, etc. These major sections can be broken down into manageable subsections; for example, offloading can be further broken down into the following categories--positioning the truck, setting up the crane, selection of the appropriate rigging, rigging the steel, swinging the load, unhooking the rigging, etc.

4.3.27.2 Potential Hazards--For each task identified in the Sequence of the Job section of the JHA form, the hazards associated with the task shall be identified. Typically, each task will have more than one potential hazard listed; for example, hazards created while “positioning the truck” from the example described above would include load shifting and crushing employees; workers being backed over by the truck; truck being positioned under an overhead power line, causing a potential electrical hazard; truck hitting and damaging other equipment and structures, etc.

4.3.27.3 Recommended Action or Procedure--For each hazard identified in the Potential Hazard section of the JHA form, a way to eliminate the hazard shall be described in this section. Emphasis should be placed on time, material, equipment, training, and procedures. For example, the hazard listed in the above example, “workers being backed over by the truck,” could be eliminated by the following: ensuring all trucks are equipped with a backup alarm, assigning someone to act as a signal person (that person will need to be trained), the signal person being required to wear an orange reflectorized vest, etc.

4.3.28 Upon completion of the JHA but prior to the start of the work operation, the contractor shall submit the JHA to FLUOR ARABIA for review.

4.3.29 Upon approval by FLUOR ARABIA, the contractor shall use the form as a guide for completion of the STA and to ensure the elements listed are in place prior to the start of the work operation. The contractor shall also use the form as a training tool to ensure each employee involved in the work operation is adequately trained on each element of the JHA.

4.3.30 If a situation arises during the work operation that has not been addressed by the JHA, or if a situation occurs that requires an existing element of the JHA to be modified, the contractor shall modify the JHA as appropriate to address the issue. The contractor shall ensure affected employees are trained on any changes or additions made to the JHA.

5 Record Retention 5.1 None


HSE Practice 4 Safety Education & Training

® SAFETY EDUCATION & TRAINING PRACTICE 4 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to define the requirements for the education and training of personnel in the recognition of work hazards and the methods used to control or eliminate those hazards.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926

3.0 Definitions

3.1 None

4.0 Process

4.1 Training shall be conducted in accordance with the requirements of this Practice and applicable Federal, State, Local, and client requirements.

4.2 Each project shall prepare a training plan based upon the following checklist:

4.2.1 Assign someone to coordinate the training program development.

4.2.2 Identify training needs.

4.2.2.1 Review Federal, local, Client, and Company requirements for training programs.

4.2.2.2 Consult Material Safety Data Sheet’s (MSDS) for materials used on the project.

4.2.2.3 Check OSHA 300 Logs and incident investigations.

4.2.2.4 Review indicators of training needs: lack of knowledge, unfamiliarity with equipment, and careless or incorrect project performance.

4.2.2.5 Review new equipment, procedures.

4.2.2.6 Review Project Safety Planning and Safety Analyses.

4.2.3 Determine whether there are other Company training programs that contain the same types of training.

4.2.4 Identify who needs each type of training.

4.2.5 Develop objectives for each training program.

4.2.6 Determine how much training is needed.

4.2.7 Identify the best format/delivery mode for the training.

4.2.8 Schedule the training.

4.2.9 Decide who is to conduct the training.

4.2.10 Verify the skills and knowledge in the subject matter if the training is to be conducted by in-house personnel.

4.2.11 Confirm the credentials in the subject matter for consultants who will conduct training.

4.2.12 Establish a formal outline for the training.

4.2.13 Establish a method of measuring the effectiveness of the training.

4.2.14 Plan how to institute improvements in the training.


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4.3 Training shall be documented.

4.4 Employee education and training shall be accomplished through, but not be limited to, the following:

4.4.1 Orientation

4.4.1.1 Each person, upon assignment to a Project, shall attend an orientation conducted by the FLUOR ARABIA Training Supervisor prior to the commencement of work. A written test shall be conducted.

4.4.1.2 The orientation shall include, but shall not be limited to:

• FLUOR ARABIA Health, Safety and Environmental Procedure

• Client and project specific requirements

• Job Planning and Safety Analysis

• Work area hazard assessments

• Safe work practices

• Reporting unsafe acts and conditions

• Fall prevention procedures

• Scaffolds, ladders, and work platforms

• Barricades and perimeter guards

• Housekeeping

• Fire protection and prevention

• Work permit system

• Control of hazardous energy sources (lock-out/tag-out/try)

• Signs and tags

• Emergency Procedures

• Trenches and excavations

• Material storage and handling

• Electrical safety

• Rigging and cranes

• Welding and cutting operations

• Operation and use of mobile equipment

• Minimum dress requirements

• Personal protective equipment

• Reporting near-misses and accidents

• First aid services and facilities

• Bloodborne pathogens awareness

• Material suspected of containing asbestos or lead

• Note: Refresher courses for orientation and other FLUOR ARABIA specified training will be required for all employees who have been absent from YANPET operations for a period of three months or longer.


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4.4.2 Supervisor Safety Orientation

4.4.2.1 Each supervisor shall attend a safety orientation upon employment. This orientation shall be based upon site specific requirements and shall include at a minimum:

• Safe work practices - When making work assignments, the supervisor must include instructions regarding Safe Work Practices, and use of Personal Protective Equipment. The supervisor is responsible for ensuring employees have the proper PPE and employees under their supervision use suitable tools.

• Auditing for safety - In following the progress of the work assigned, the supervisor shall ensure that safe Procedures/Practices are followed and initiate corrective action as necessary.

• Positive reinforcement and disciplinary action

• Supervisor Safety Meetings - Supervisor safety meetings must be attended weekly

• Emergency Procedures

• Accident Investigations

• First-aid

• Fire Protection and Prevention

• Weekly safety meetings

4.4.2.2 Supervisors shall also attend the FLUOR ARABIA Supervisory Development Course consisting of a minimum of 10 hours of health and safety training (may be reduced on Turnaround Projects).

4.4.3 Craft Supervisor Safety Meeting

4.4.3.1 The site shall have weekly craft Supervisor’s Safety Meetings (can be part of the regular staff meeting) that shall be attended by the craft supervisors or a representative of each craft and shall follow these guidelines:

• The Construction Manager (or Project Superintendent) and Construction HSE Manager shall be responsible for establishing the agenda prior to the meeting.

• The Construction Manager shall lead the discussion in at least one of the weekly meetings for each area on a monthly basis. The Project (Area) Superintendent or General Foreman shall be responsible for conducting the remaining meetings each month.

• Encouragement shall be given for a group discussion on methods of correction, improvement, etc. for health and safety concerns.

• Any upcoming project with particular or inherent hazards is to be reviewed.

• The following items shall also be discussed at each meeting:

⇒ Identify principal accident causes


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⇒ Crafts involved in accidents

⇒ Accident prevention measures to be initiated by responsible individuals

• Review weekly safety statistics

• Revie w the most frequently noted serious, non-serious, and repeated safety violations, including corrective action required by the responsible individual.

• A written record of the meeting shall be maintained.

• Attendance is mandatory.

4.4.4 Weekly HSE Meeting

4.4.4.1 A weekly safety meeting shall be held at a time and place specified for each project.

4.4.4.2 The material covered shall be relevant to the work and employees must be able to hear/see the presentation.

4.4.4.3 The meeting shall provide the opportunity for employees to ask questions, make suggestions, and voice safety concerns.

4.4.4.4 The meeting shall also be used to review recent incidents and refresh employee training on health and safety issues.

4.4.4.5 The HSE Professional shall be responsible for the management of the safety meeting program.

4.4.4.6 The Construction Manager, Project Superintendent, and line supervisors shall actively participate in selecting topics and conducting meetings.

4.4.4.7 The Construction Manager shall conduct at least one meeting per month.

4.4.4.8 Vice-presidents and Home Office Construction Managers are required to attend and participate in these meetings when they visit the site.

4.4.5 Project Planning and Safety Analysis

4.4.5.1 Prior to beginning a work assignment, the supervisor shall discuss the proper Procedures, equipment operation, the hazards involved, and the safety techniques required so that employees will be aware of the hazards, including those that are inherent to the work assigned.

4.4.6 Subcontractor Safety Coordination Meetings

4.4.6.1 Weekly subcontractor safety coordination meetings shall be held. The attendees shall include:

• Construction Manager (or designee)

• Subcontract administrator(s)

• Subcontractor management personnel

• Construction HSE Manager

• Subcontractor HSE representative

• Client representatives as desired


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• Guests as desired.

4.4.6.2 The agenda of the meeting shall include upcoming critical operations, project Procedures, safety statistics and performance, and other items pertinent to the Safety and Health program and the execution of work assignments.

4.4.7 Daily Tool Box Meetings

4.4.7.1 Tool Box Meetings are conducted on a daily basis with craft personnel. The foreman or general foreman utilizing materials prepared in coordination with the site HSE department conducts these 15-minute meetings. Craft foremen and superintendents shall attend these meetings and actively participate and support safety. The Tool Box Meetings are utilized as primary channels of two-way communications between the Company and employees regarding project safety.

4.4.7.2 On a weekly basis, the site HSE department will issue a subject for discussion. The subject may be:

• Discussion of current safety problems and the required corrective actions.

• New safety rules, procedures, or regulations.

• Safety educational items. 7.4.7.3 The subject for discussion must be current and related to actual

items or problems on the project. Viewed in retrospect, the subject matter must provide an impression of reinforcement and defining safety standards to be implemented on the project, frequent violations of safety standards observed and the corrective actions required. In addition:

7.4.7.4 Supervisors are encouraged to discuss current and future work plans as well as the safety aspects of the same.

7.4.7.5 Craftsmen are encouraged to participate fully, to voice their recommendations for improvement or constructive criticism of current practices.

7.4.7.6 Items raised at Tool Box Meetings are recorded and channeled back through the appropriate supervisors for corrective actions. High priority is assigned to items raised and reported from these meetings. Craft supervisors and superintendents are required to respond items that fall into their area of responsibility.

7.4.7.7 It is important that feedback or answers to items or questions raised are returned to the craftsmen. Once action has been decided upon or actions taken, a summary of action items along with the imposed solution must be posted on the bulletin boards, and returned to supervision so that actions can be discussed at the next Tool Box Meeting.

7.4.7.8 The Tool Box Meeting shall be documented with the subject attached. See “Weekly Tool Box Meeting Report” (DBN-F32).

5.0 Record Retention

The Construction HSE Manager shall maintain records of training, orientations, and safety meetings in the Project Safety Department file for the duration of the project.


HSE Practice 5 Safety Task Assignment

® SAFETY TASK ASSIGNMENT PRACTICE 5 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of the Safety Task Assignment (STA) Practice is to assist employees and supervisors in identifying and minimizing hazards prior to beginning tasks.

2.0 References


3.0 Definitions

3.1 None

4.0 Process

4.1 Development of the STA will be based on an approved Job Hazard Analysis (JHA) for that major activity. The STA will be reviewed before beginning each task or, if the task is continuous over a period of more than one day, that a STA will be conducted or reviewed at the start of the shift or before beginning the task. A properly executed STA will help employees recognize hazards, identify training needs, and plan their work; thereby ensuring a safe and efficient work process. STA’s are designed to focus on a single task/element within an overall JHA.

4.2 The analysis shall include, but shall not be limited to, the following questions with a written Plan for addressing these issues:

4.2.1 Is there adequate lighting?

4.2.2 Could people trip over materials on the floor?

4.2.3 Are there exposed live electrical wires?

4.2.4 Are tools, machines, and other equipment in good repair?

4.2.5 Do machines have guards in place?

4.2.6 Are noise levels too high to allow clear communication?

4.2.7 Are fire alarms and portable extinguishers readily available?

4.2.8 Are emergency exits clearly marked?

4.2.9 Is personal protective equipment available, in good condition, and used when necessary?

4.2.10 Is the work area adequately ventilated?

4.3 The STA form (DBN-F31) shall be used to meet the requirements of this Practice.

4.4 At a minimum, the STA process should list specific job steps and create a checklist to identify possible hazards:

4.4.1 Include each step

4.4.2 Describe each step in adequate detail

4.4.3 Include inspection and use of protective equipment

4.4.4 Detail job set-up procedures

4.4.5 Include the condition, use, and HSE of equipment and machinery

4.4.6 Identify any machine parts or exposures that could create risk of injury

4.5 Detail actual steps to be followed while performing the job to identify any movements or positions that could create risk of injury.

4.6 Note procedures/steps to follow when it is necessary to shut down equipment.

® SAFETY TASK ASSIGNMENT PRACTICE 5 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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4.7 Include organization and placement of materials, parts, tools, etc.

4.8 Identify hazards created while performing the job (dust, chemicals, heat, excessive noise, falls, cave-ins, falling objects, f loor openings, etc.).

4.9 Determine the best way to eliminate/reduce identified hazards:

4.9.1 Fix clear-cut problems, such as replacing missing machine guards.

4.9.2 Seek ways to eliminate, combine, or rearrange job steps to eliminate or reduce hazards.

4.9.3 Identify equipment that could be used to reduce the hazard(s).

4.9.4 Change tools, add ventilation, or make other physical changes to reduce the hazard(s).

4.9.5 Detail new job steps to follow after changes are made.

4.9.6 Identify hazards that cannot be reduced and seek ways to eliminate the job or do it less often.


5.1 A copy of each completed STA shall be maintained on file in the Project HSE office for the duration of the Project.


HSE Practice 6 Emergency & Contingency Planning

® EMERGENCY & CONTINGENCY PLANNING PRACTICE 6 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to define the criteria for a site specific Emergency Preparedness and Contingency Plan designed to contain damage and limit loss and downtime.

2.0 References


2.2 Project Emergency Action Plan—15019-9905-01

3.0 Definitions

3.1 Health, Safety, and Environment (HSE)

4.0 Process

4.1 Requirements

4.1.1 Since dealing effectively with any type of emergency situation depends upon preplanning, prompt notification, coordinated mobilization, quick implementation of specific duties and assignments, and the optimum use of FLUOR ARABIA’s emergency resources, these plans must be coordinated with project-wide emergency planning.

4.1.2 The Emergency Preparedness and Contingency Plan must be location specific, it must be in writing, and it must be displayed for employee review at the Project site.

4.1.3 The Emergency Preparedness and Contingency Plan must provide response actions to anticipated emergency situations that may result from fire and/or explosion, the release of toxic gases or chemicals, natural disasters, civil disorders, or any other condition which has the potential to cause injury or death.

4.1.4 The Emergency Preparedness and Contingency Plan must address in detail the routing to be designated for access and egress for the necessary emergency equipment and personnel to the scene of an incident. At a minimum it must address the following:

4.1.4.1 Designated personnel to respond to emergencies.

4.1.4.2 Designated on site equipment and vehicles to be used by emergency personnel.

4.1.4.3 Designated personnel to direct emergency vehicles.

4.1.4.4 Designated routes to be followed by emergency vehicles.

• Consider the ongoing construction activities and provide adequate means of access and egress.

• Consider if there are railroad tracks in the vicinity and how long and when they are blocked and provide for alternate means of access and egress.

4.1.5 If the customer location in which Company personnel are working has an active emergency action and/or evacuation plan, elements of the customer plan that affect Company personnel must be reflected in the Project Emergency Preparedness Plan.

4.1.6 The Plan must describe:

4.1.6.1 The method by which all types of emergency situations are announced.


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4.1.6.2 Emergency escape procedures, emergency escape routes, wind direction and emergency evacuation route assignments, and safe distances and places of refuge.

4.1.6.3 Procedures to be followed by employees who must remain in place to shut down any critical equipment before they can evacuate.

4.1.6.4 Personnel roles, lines of authority, and communication.

4.1.6.5 Emergency recognition and prevention.

4.1.6.6 Site security and control.

4.1.6.7 Procedures to account for all employees when an emergency evacuation is necessary, including location of assembly areas.

4.1.6.8 Critique of response and follow-up.

4.1.6.9 Identities of personnel or agencies who will provide rescue and/or medical duties as required.

4.1.6.10 Personal Protective Equipment and emergency equipment.

4.1.6.11 The method of reporting fires and other emergencies to local, state, and federal agencies, facility personnel, public response agencies, additional offices as provided for in the contract documents, and other workers, including published telephone numbers.

4.1.6.12 Site topography, layout, and prevailing weather conditions.

4.1.6.13 Names and/or job titles, as well as telephone numbers, of persons who can be contacted for additional information about the Emergency Preparedness and Contingency Plan.

4.1.6.14 Procedures to be used to assure that all Company personnel understand the Emergency Preparedness and Contingency Plan and the part they play in its execution.

4.1.6.15 Decontamination procedures not covered by the site health, environmental and safety plans.

4.2 Training

4.2.1 Before implementing the Emergency Preparedness and Contingency Plan, the Construction Manager must designate and train a sufficient number of workers to assist in the safe and orderly emergency evacuation of all other employees. The Plan must be reviewed with and signed and dated by each employee at the following times: (a) when the Plan is initially developed; (b) whenever responsibilities or designated actions under the Plan change; and (c) whenever the Plan itself is changed.

4.2.2 An aggressive disaster drill is probably the most important feature of any project's Emergency Preparedness and Contingency Plan, therefore an attempt should be made to schedule at least one unannounced evacuation drill during each project. When it is not feasible to actually hold a surprise evacuation drill, at least one drill should be scheduled at the beginning of a work shift. During this drill, a "walk-through" of the notification alarm and the evacuation routes can be accomplished.


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4.3 Response planning

4.3.1 Fire and explosion

4.3.1.1 It has been demonstrated that personnel who have been intensively drilled in the proper procedures to follow in a fire emergency, react swiftly and correctly to minimize danger to themselves and their fellow employees, and are better prepared to take fire control measures until local fire authorities arrive on the scene. Information on each of these steps should be included in the Emergency Preparedness and Contingency Plan.

• Discovering The Fire - Any person discovering a fire, should quickly and carefully remove anyone who is injured or in immediate danger. This person must be careful not to risk injury to themselves, as it is most important that he remain conscious and able to report the fire.

• Reporting The Fire - When possible, the nearest telephone should be used to report the fire, with the individual reporting the fire providing the following information: that there is a fire; what is on fire; the specific location of the fire; and the name, phone number, and location of the person reporting the fire. If there is a manual pull fire alarm reporting system in operation at the fire location, this system should be used in addition to the telephone reporting. Emergency telephone numbers for fire department, hospital, ambulance, doctor, police, and HSE office, must be posted through-out the jobsite and at each telephone location.

• Sounding The Alarm - It will also be necessary to establish a system for alerting workers of the emergency and of the need to evacuate the work area. Ideally this would be some type of sound system that could be heard through-out the work area This sound system can be anything from a loud bell to a hand-held compressed air horn of the type used on small boats. The object is to have some type of blaring sound that can be heard by all of the workers and immediately identified as an alarm indicating there is an emergency situation in the work area. When working on a site or in a facility that has its own emergency announcement system, elements of this existing alarm system should be a part of the Emergency Preparedness and Contingency Plan, however the use of the customer's site alarm does not necessarily relieve the Project of the necessity of having its own alarm system.

• Evacuation - When evacuation is necessary, there must be no hesitation in requiring personnel to immediately vacate the area. Emergency exits and other means of egress from the area must be noted prior to the start of the job and located on an emergency exit plan, which is then made a part of the Emergency Preparedness and Contingency Plan. Both primary and secondary routes must be selected in case the emergency situation makes it perilous to use one or the other routes. Copies of this emergency exit plan must be posted in numerous locations throughout the project. A staging area must be preselected and all personnel required to report there


9905-02-000.doc 12/8/2004 4

immediately for a roll call to assure that all are present and accounted for. Once out of the area, no one s hould be allowed to re-enter until the emergency is declared over.

• NOTE: Wherever possible, develop more than one evacuation route. Emergency evacuation routes for a fire may not necessarily be the same evacuation routes to use during some other type of emergency situation. Be certain to analyze the entire Emergency Preparedness and Contingency Plan and take into consideration the type of emergency, the possible wind directions, fences, closed off areas, buildings, etc., and then physically label the escape routes with signs, markers, barriers, etc.

4.3.2 Emergency Spills Or Release

4.3.2.1 Even in a well planned and executed job, the possibility exists that an accident may occur and an emergency spill or toxic chemical release may take place. Recognition of this fact requires that suitable emergency procedures be prepared in advance and be made known to all persons potentially involved. Each project must give consideration to the nature of possible accidents resulting in an emergency spill or a toxic chemical release and must design methods for dealing with them as part of their Emergency Preparedness and Contingency Plan.

4.3.2.2 The following steps must be carried out in the event of a hazardous substance spill:

• Immediately notify site management and safety personnel, Corporate Director HSE, the customers’ representatives, or other personnel designated on the incident notification schedule.

• Clear the location of all persons except those trained to deal with the incident;

• Determine the nature and source of the spill/release. Use Material Safety Data Sheets to determine the characteristics of the material and what type of precautions are necessary in dealing with the material;

• Depending upon the classification and the amount of the spill, it may be necessary to notify the local police and/or fire department, and a specific agency of the Federal, State or Local authority; contact the Corporate Director HSE for assistance.

• Clean up shall be performed by qualified personnel.

• Notify appropriate personnel when the spill has been successfully cleaned up.

•

4.3.3 Natural Disasters

4.3.3.1 Floods, hurricanes, tornadoes, earthquakes, severe thunderstorms, and blizzards, are but a few of the natural disasters that occur each year throughout the country, for which we must be prepared if we are to provide the type of protection necessary for our employees and our property. Most of these conditions are usually forecast sufficiently in


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advance for emergency action to be initiated before the problem becomes serious.

4.3.3.2 In most cases, merely advising our personnel of the coming danger and seeing to it that they are in a safe location will be sufficient, should the incident occur during normal work hours. For example, if a Tornado Warning is broadcast while our personnel are working in a location that does not provide the degree of protection necessary, they should be advised of the warning and moved to a structurally sound interior location that would provide adequate protection from the weather, wind blown objects, and broken glass.

4.4 Contingency Plan

4.4.1 A description of the facility/project site must be developed:

4.4.1.1 An up-to-date map of the area to include key thoroughfares, nearby cities and towns to be marked with the facility and any other sister companies or auxiliary or owned properties.

4.4.1.2 A site layout that includes :

• the property perimeter

• fence lines and gates

• buildings with locations of exterior doors

• water and sewer connections, sprinkler shut-offs, gas line shut-offs, electric transformers, storage of combustible and flammable material.

4.4.1.3 Interior layouts of all buildings.

4.4.1.4 A description of the principal functions of the facility and hours of operation and staffing.

4.4.2 Inventory

4.4.2.1 An inventory of assets, resources, risks and vulnerabilities will contribute direction and priorities to the emergency planning process. The following areas should be researched and fully listed in the Site Plan:

• Critical Areas - What sorts of losses could be the most harmful or costly? Examples include:

⇒ personnel (by injury or death)

⇒ vital records (see below)

⇒ cash or negotiable instruments

⇒ reputation or competitive advantage by spill or release

• Vulnerabilities - what is most likely to be encountered as an emergency? Examples include:

⇒ fuel storage

⇒ tornado

• Local Contractor Resources - List telephone numbers of contractors who may provide essential support during an emergency. Note their 24 hours per day availability. Examples include suppliers of:

⇒ medical care/hospital


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⇒ safety equipment

⇒ security guards

⇒ temporary lighting

⇒ office supplies

• Employee Primary & Secondary skills - Research and list relevant skills of site personnel that may include:

⇒ CPR and other first aid or medical skills

⇒ mechanical and repair abilities

⇒ licenses for and knowledge of operating trucks or heavy equipment

⇒ fire fighting training and experience

⇒ any other skills that may be useful during an emergency or during recovery.

• The degree of competence in each skill should be determined and added training should be provided where necessary. Appropriate and current licenses or their copies should be kept on file.

• Vital Records - Those records and data that are considered vital or essential for reconstitution or continuation of operations should be identified. Such records warrant careful handling to include fireproof storage or off-site back-ups. Examples may include:

⇒ insurance certificates

⇒ accounts receivable

⇒ payroll and personnel data

⇒ customer contracts, prices and profiles

⇒ environmental records

⇒ legal documents

⇒ leases

⇒ licenses and permits

4.4.3 ALTERNATE LOCATIONS

4.4.3.1 Where appropriate, a list may be developed with addresses, contact names, phone numbers and other relevant information for obtaining alternate locations for:

• office space

• garage space

• fenced truck yards

• apartments

4.5 CRITIQUE OF RESPONSE

4.5.1 Whenever the Emergency Preparedness and Contingency Plan is implemented in response to an incident, a critique of the response shall be conducted and documented.


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5.0 Record Retention A copy of the Project specific Emergency Preparedness and Contingency Plan shall be maintained on file in the Project Safety Office files for the Duration of the project. All associated documentation for this plan shall be maintained with the plan.


HSE Practice 7 Hazard Communication

® HAZARD COMMUNICATION PRACTICE 7 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of the Hazard Communication Practice outlines the means by which the project will develop a site specific Hazard Communication Program.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart D (1926.59)

3.0 Definitions

3.1 ACGIH - American Conference of Governmental Industrial Hygienists is an organization of industrial hygienists devoted to the administrative and technical aspects of occupational and environmental health. Each year, ACGIH publishes the Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices.

3.2 Carcinogen - a substance or agent producing or inciting cancer. These substances are listed by the National Toxicology Program (NTP) in its Annual Report on Carcinogens, the International Agency for Research on Cancer (IARC) in its Monographs, and by the Occupational Safety and Health Administration in 29 CFR Part 1926 Subpart Z, Toxic and Hazardous Substances.

3.3 Chemical - any element, chemical compound or mixture of elements and/or compounds. Examples: cleaning compounds, lubricants, paints, fuels, welding rods, and base metals.

3.4 Consumer Products - any product or hazardous substance meeting the definition of the Consumer Product Safety Act (15 U.S.C. 2051 et seq.) and Federal Hazardous Substances Act (15 U.S.C. 11261 et seq.) respectively, where the employer can show that it is used in the workplace for the purpose intended by the chemical manufacturer or importer of the product, and the use results in a duration and frequency of exposure which is not greater than the range of exposures that could reasonably be experienced by consumers when used for the purpose intended.

3.5 Hazardous Chemical - any chemical that is a physical hazard or a health hazard.

3.6 MSDS - Material Safety Data Sheet - a document required by the Hazard Communication Standard by which information concerning the hazards of materials and chemicals is supplied to employees who may come into contact with those materials. The content of the MSDS is specified in section (g) (2) of Title 29 CFR Part 1926.59.

3.7 OSHA - The Occupational Safety and Health Administration. A division within the Department of Labor charged with implementing the provisions of The Occupational Safety and Health Act of 1970.

3.8 PEL - Permissible Exposure Limit. Limit established by the Occupational Safety and Health Administration (OSHA) concerning the airborne concentration of a contaminant to which an employee may be exposed legally during the work shift or some portion of that shift.

3.9 TLV - Threshold Limit Values (and Biological Exposure Indices) are guidelines developed by the ACGIH to assist in the control of health hazards. The TLV's refer to airborne concentrations of substances, and it is believed represent conditions under which nearly all workers may be repeatedly exposed, day after day, without adverse effect.

4.0 Process

4.1 Written Plan

4.1.1 Each project shall develop, implement a written site specific Hazard Communication Plan for their workplace.


9905-02-000.doc 12/8/2004 2

4.1.2 The plan shall describe how:

4.1.2.1 The project will maintain labels and other forms of warnings on hazardous chemicals in the workplace.

4.1.2.2 The project will obtain Material Safety Data Sheets (MSDS's), how the information will be used, how employees will be trained on the information, and how the MSDS file will be maintained. How employees will be provided access to MSDS’s will also be covered in their written program.

4.1.2.3 The project will provide information and training to employees concerning the Hazard Communication Program and the hazards in their work place.

4.1.2.4 Communication of information and training for non-English speaking employees will be evaluated on a project by project basis, as needs arise.

4.1.3 The Plan shall also contain:

4.1.3.1 A chemical inventory. That is a list of the hazardous chemical known to be present in the workplace using an identity that is referenced on the appropriate MSDS. (DBN-F33)

4.1.3.2 The methods the employer will use to inform employees of the hazards of non-routine tasks and the hazards associated with chemical contained in unlabeled pipes and vessels in their work areas.

4.1.3.3 A detailed method for making chemical information available to other employers and their employees on multi-employer work sites, including:

• The methods used to make sure MSDS’s are either stored in a central location or copied and provided to other employers;

• The methods used to inform the other employers of any precautionary measures that need to be taken to protect employees during the workplace’s normal operating condition and in foreseeable emergencies; and

• The methods used to inform the other employers of the labeling system used in the workplace.

4.2 Labeling

4.2.1 Containers of hazardous chemicals in the workplace shall be labeled, tagged, or marked with the following information:

4.2.1.1 The identity of the hazardous chemicals contained therein; and,

4.2.1.2 The appropriate hazard warnings

Note: The diamond symbol (developed by the National Fire Protection Agency, NFPA) alone provides a limited amount of information and does not satisfy the full requirements of this section. Other types of labeling systems, i.e., the HMIS label (Hazardous Materials Information System), are similar to the NFPA diamond; however, these have space on the label to include the identity of the hazardous chemical and a section where


9905-02-000.doc 12/8/2004 3

target organ information, special warnings and Personal Protective Equipment (PPE) requirements may be listed.

4.2.2 The manufacturer's labels and warning symbols shall not be removed or defaced unless a new label with the appropriate information is immediately affixed to the container.

4.3 MSDS File

4.3.1 An MSDS shall be requested from the manufacturer or distributor prior to ordering a chemical product. The purchasing agent (or individual responsible for ordering a material) shall forward a copy of the MSDS to the Construction HSE Manager (if there is no Construction HSE Manager on site, the MSDS shall be forwarded to the Corporate Manager of Safety for review). The purchasing agent (or receiving department) shall also maintain a copy of the MSDS in a binder or file of MSDS's being reviewed.

4.3.2 An Construction HSE Manager shall review the MSDS prior to ordering the material.

4.3.3 If the Construction HSE Manager provides approval for the material, then the material shall be ordered. The Construction HSE Manager will supply the MSDS/Product Evaluation memo (DBN-F34) to the purchasing agent stating that the material has been approved and the Construction HSE Manager shall place the MSDS in a file or binder of approved MSDS's.

4.3.4 If, based on the information in the MSDS, the Construction HSE Manager feels the product should not be used on the site, Project Management shall be advised to find an alternative material. If an alternative material is selected then the rejected MSDS shall be placed in a file or binder for rejected MSDS's. If no suitable alternative is available, then the Construction HSE Manager shall provide conditional approval for the material with the understanding that the material will require special training, engineering controls, protective equipment, etc. as appropriate.

4.3.5 A request for an MSDS shall also appear on the purchase order for any hazardous chemicals other than those excluded by Title 29 CFR Part 1926.59 (b)(6) (i-xii).

4.3.6 When a material arrives on site, the MSDS shall be reviewed to ensure that it is the most recent issue. The MSDS shall be marked with the date that the material was received. A copy of the MSDS shall be maintained in the Construction HSE Manager’s master MSDS file.

4.3.7 Chemical products ordered/received by the project shall not be distributed into the workplace until receipt of the accompanying MSDS has been confirmed by the Purchasing Department.

4.3.8 Manufacturers and distributors who fail to supply MSDS's will be notified that they will no longer be considered for purchases by the project.

4.3.9 MSDS's shall be reviewed to ensure that they contain the required information:

4.3.9.1 The identity used on the label, except as provided for in trade secret exemptions; and,

4.3.9.2 The chemical and common name of the hazardous components which comprise 1% or greater of the composition except that chemicals identified as carcinogens shall be listed if the concentrations are 0.1% or greater; and,


9905-02-000.doc 12/8/2004 4

4.3.9.3 Chemical and common names of ingredients which have been determined to be health hazards and which comprise less than 1% (0.1% for carcinogens) of the mixture, if there is evidence that the ingredients may be released from the mixture in concentrations which would exceed OSHA PEL's or ACGIH TLV's or could present a health hazard to employees; and,

4.3.9.4 The chemical and common names of ingredients which have been determined to present a physical hazard when present in the mixture

4.3.9.5 Physical and chemical characteristics of the hazardous chemical

4.3.9.6 Physical hazards of the hazardous chemical

4.3.9.7 The health hazards of the hazardous chemical

4.3.9.8 The primary routes of entry

4.3.9.9 The OSHA PEL and/or the most current ACGIH TLV and any other exposure limits established

4.3.9.10 Whether the hazardous chemical is listed in the National Toxicology Program (NTP) Annual Report on Carcinogens or has been found to be a potential carcinogen in the International Agency for Research on Cancer (IARC) Monographs or by OSHA

4.3.9.11 Any generally applicable precautions for safe handling and use

4.3.9.12 Any generally applicable control measures

4.3.9.13 Emergency and first aid procedures

4.3.9.14 Date of preparation of the MSDS or the last change to it

4.3.9.15 The name, address, and telephone number of the chemical manufacturer, importer, employer, or other responsible party preparing or distributing the MSDS, who can provide additional information on the hazardous chemical and appropriate emergency procedures, if necessary.

4.3.9.16 If the material is no longer being used on the site, the MSDS shall be marked with the date the material was removed from service and filed or bound with other "MSDS's for materials no longer in use". These MSDS's are viewed as exposure records and shall be maintained for 30 years following completion of the project.

4.3.9.17 MSDS quality review: If an MSDS is illegible or has pages or portions of pages missing, the MSDS must be replaced.

4.3.9.18 Trade Secret

• Manufacturers are allowed to withhold some information concerning the identity of chemicals on the MSDS if that information is classified as a Trade Secret. However, medical personnel and health care professionals have steps by which they may request the information for emergency or evaluation purposes. If assistance is required due to the trade secret provision being used on an MSDS, contact the Corporate Director HSE.


9905-02-000.doc 12/8/2004 5

4.4 Training

4.4.1 Employees shall be provided training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard is introduced into their work area. Employees shall be informed of:

4.4.1.1 The requirements of the Hazard Communication standard

4.4.1.2 Any operation in their work area where hazardous chemicals are present; and

4.4.1.3 The location and availability of the written Hazard Communication Program, including the required list of hazardous chemicals and MSDS's.

4.4.2 Employee training shall include at least:

4.4.2.1 Methods and observations that may be used to detect the presence or release of a hazardous chemical in the workplace;

4.4.2.2 The physical and health hazards of the chemicals in the work area;

4.4.2.3 The measures employees can take to protect themselves from these hazards including specific procedures implemented to protect employees from exposure to hazardous chemicals; and

4.4.2.4 Specific details from the project's written Hazard Communication plan, including labeling information, MSDS's, and how to use the appropriate hazard information.

4.4.3 Training must be documented.

4.4.4 A written examination following the training shall serve as documentation that the employee understood the information provided during the training session.

4.5 Non-Routine Tasks

4.5.1 Prior to performance of non-routine tasks, a hazard assessment shall be conducted. Management personnel are responsible for contacting the Project HSE Manager before any non-routine task is undertaken in their respective work area or anywhere else that employees have the potential for exposure to a hazardous material. This is necessary to evaluate and communicate hazards to the affected employees.

4.5.2 Non-routine tasks will vary from project to project; therefore, the details of the hazard assessment to be conducted shall be specified in the site specific written program. The written program shall also indicate the method of transmitting the information concerning the hazards to the employees involved.

4.6 Coordination With Other Contractors

4.6.1 Arrangements shall be established with contractors on multi-employer sites for the transfer of information concerning chemicals. The details of this arrangement shall be specified in the site specific written program.

4.6.2 Where the Company is the Construction Manager on a project, subcontractors will be required to prepare and implement their own Hazard Communication Program that meets the requirements of Title 29 CFR Part 1926.59. In addition, a copy of each contractor's chemical inventory and the MSDS for each material or chemical on the inventory shall be submitted to the HSE Office. This will provide a centralized location from which an MSDS may be obtained. This


9905-02-000.doc 12/8/2004 6

requirement, however, in no way substitutes for the contractor's maintenance of his own Program or MSDS file.


5.1 MSDS's will be treated as medical/exposure records and shall be maintained for the duration of the project plus 30 years.

Employee training records shall be maintained in the Project Safety Office for the duration of the project plus 30 years .


HSE Practice 8 Safety Violation Notification System

® SAFETY VIOLATION NOTIFICATION SYSTEM PRACTICE 8 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to provide uniform disciplinary actions to ensure that project personnel and persons associated with FLUOR ARABIA project adheres to the Safety Procedures/Practices.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926.20

3.0 Definitions

3.1 None

4.0 Process

4.1 HSE Procedures/Practices apply without exception to FLUOR ARABIA employees and others associated with the project when an employee is identified as violating a safety Procedure/Practice, disciplinary action SHALL be taken as follows: (see Safety Violation Notification Form DBN-F29):

4.1.1 Safety Violation System (Not Immediately Dangerous to Life and Health Violation)

4.1.1.1 First Safety Violation - Oral warning (must be documented)

4.1.1.2 Second Safety Violation - Written warning

4.1.1.3 Third Safety Violation - Termination from the project

4.1.2 Safety Violation System (Immediately Dangerous to Life and Health Violation (I.D.L.H.))

4.1.2.1 IDLH situations (i.e., not tied off at an elevated work location), must be handled in the following manner:

• The employee is to be removed from the project IMMEDIATELY.

• The employee's supervisor is to receive a written reprimand.

4.1.3 Work Stoppage

4.1.3.1 When an FLUOR ARABIA Construction HSE Manager notes safety violations, the work will be immediately stopped until the safety violation has been corrected. An HSE representative shall inspect the work/area before it is resumed.


A copy of the Safety Violation form and documentation shall be maintained on file in the Project Safety Office for the duration of the project. Associated documentation in response to any incidents shall be maintained with the files.


HSE Practice 9 Personal Protective Equipment

® PERSONAL PROTECTIVE EQUIPMENT PRACTICE 9 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to specify the minimum requirements for basic work clothing, eye protection, foot protection, head protection and hand protection.

2.0 References


2.2 SASO 322/1994 Industrial Safety and Health Regulations—Personal Protective Equipment

2.3 Yanpet Safety Regulations for Contractors—H-P-0301

3.0 Definitions

3.1 None

4.0 Basic Clothing

4.1 Requirements

4.1.1 Minimum acceptable work clothing for all employees working on project sites includes long pants, safety toed boots/shoes, and a long sleeve shirt that completely covers the worker's shoulders and provides adequate protection against such hazards as concrete splash, abrasions to the skin, oil or grease spills, and slag from welding or cutting.

4.1.2 Welders should be cautioned against wearing highly flammable clothing, such as polyesters, double-knits, etc. Clothing that has become torn, ragged, or frayed is not acceptable, since it presents a hazard of catching on rough corners or machine parts and could cause the wearer to trip or fall.

4.1.3 Clothing soaked with grease, oil, paint, thinners, solvents or similar materials should not be worn where exposed to a heat source.

4.1.4 For the most part, construction and maintenance workers should wear clothing that is reasonably snug—particularly about the neck, wrists, and ankles. Workers shall be cautioned against wearing loose clothing, rings, watches, necklaces, etc.—all of which may catch in power-driven equipment.

4.1.5 Hair, which extends beyond the collar of a shirt, shall be contained above the shirt collar.

4.1.6 In some instances and certain facilities Fire Retardant Clothing must be worn. When Fire Retardant Clothing is required it shall be worn as the outer most garment.

5.0 Eye Protection

5.1 Requirements

5.1.1 Personnel on the project shall wear approved protective eyewear during working hours. Protective eyewear shall meet the minimum requirements of ANSI Z87.1, latest edition.

5.1.2 Eye protection is required in all work areas except offices. Eye protection shall also be worn in office settings when the work conducted therein creates the potential for eye injuries.

5.1.3 Approved eye and face protection must be worn whenever warranted by the work exposure.


9905-02-000.doc 12/8/2004 2

5.1.4 ANSI-approved safety glasses with full side shields must be worn in all circumstances. Employees requiring corrective lenses must have glasses in which the frames and lenses meet ANSI specifications or they shall be required to wear protective eyewear over their corrective lenses. The addition of side shields to non-safety glasses shall not be permitted.

5.1.5 Goggles and Full-face shields shall be worn when performing grinding, chipping, or similar activities. Other employees in the area (that is in any area in which grinding dust is falling/flying) shall be protected by screens or shall wear goggles and face shields.

5.1.6 Goggles shall also be worn in areas where dusty operations are conducted or where windy conditions result in greater potential for flying particles.

5.1.7 Welders must wear a welder's hood with lenses that have the correct color density for the type of welding involved.

5.1.8 Welder's helpers and other employees exposed to the welding flash must wear the same level of eye protection, or shall wear burning goggles or filtered safety glasses with the correct color density lenses.

5.1.9 Safety eyewear must be worn in front of and behind the welder's shaded lenses.

5.1.10 Employees who wear contact lenses shall wear safety glasses in addition to the contact lenses where safety glasses are required.

5.1.11 Operators of vehicle and equipment must wear protective eyewear wh ile operating such equipment unless they are in enclosed cabs.

5.1.12 Safety eyewear shall be capable of being disinfected.

5.1.13 Safety eyewear shall be easily cleaned.

6.0 Head Protection

6.1 Requirements

6.1.1 All workers must wear Company-issued hard hats at all times when working in construction areas/projects or areas of an existing facility that have been designated as a "Hard Hat Area." This includes visitors, subcontractors, engineers, inspectors, and anyone else who is authorized to be on the project. When FLUOR ARABIA activities require establishment of a hardhat area in an area that typically does not require hard hats; signs shall be posted to inform others that hard hats are required.

6.1.2 Hard hats shall meet the specifications of ANSI Z89.1 - 1969 as required by OSHA.

6.1.3 Bump Caps and metallic hard hats are prohibited on FLUOR ARABIA projects.

6.1.4 All personnel on the project are required to have their Company logo and their name prominently displayed on their hard hat. The name shall be applied above the brim of the hat using block letters.

6.1.5 Hard hats that have been altered by drilling or cutting will not be permitted, nor will those hats that have been altered by the addition of any items on the outside of the hat other than safety or Company issued stickers. When it is necessary to use additional personal protective equipment that must be attached to the hard hat, only those hard hats designed for this purpose may be used.


9905-02-000.doc 12/8/2004 3

6.1.6 Hard hats shall be inspected regularly for signs of chalking (loss of surface gloss), cracking, chips or other visible defects and replaced when damaged. Headband assemblies must be in good condition and should be exchanged whenever they become broken or weakened. The area between the top of the headband and the top of the hard hat should never be used for storage.

6.1.7 Welders are required to wear hard hats when in a hardhat area. Soft cap welding is not permitted.

6.1.8 Operators of vehicles and equipment are required to wear protective headgear during the operation of such equipment except in enclosed cabs.

6.1.9 Hard hats shall also be required in areas that typically would not require the use of a hard hat (offices, break areas, barracks, etc.) when the work activity creates an overhead hazard.

6.1.10 Hard hats shall be worn with the bill facing forward.

6.1.11 Hard hats complete with suspension and headband shall weigh not more than 425 g.

6.1.12 Hard hats shall be capable of withstanding the impact of a 3.6 kg steel ball dropped 1.5 meter upon its crown at minus 18ºC and plus 48ºC.

6.1.13 Hard hats shall be capable of meeting the following electrical test:

6.1.13.1 Immerse the helmet in tap water with the top down so the water covers both the inside and the outside, and so the brim protrudes 2 cm above the water surface. The brim should remain dry.

6.1.13.2 Place electrodes in the water, one inside and one outside the hard hat.

6.1.13.3 Connect the electrodes to a source of 2,200 volts (rms), 60 hertz alternating current. The current flow through the hard hat shall not exceed 3 milliamperes.

7.0 Hand Protection

7.1 Requirements

7.1.1 Workers shall wear leather, work gloves during all work activities, UNLESS the gloves would increase the hazard potential of the task. The employee shall select gloves that are suited to the type of work involved.

7.1.2 Employees who are required to operate drill presses, power saws, bench grinders, and similar rotating machinery shall not wear gloves.

7.1.3 Gloves such as neoprene, nitrile, butyl rubber, polyvinyl alcohol, “Silver-Shield”, or “Black Knight” may be required when handling specific chemicals.

7.1.4 Cut resistant gloves or Kevlar gloves may be required when working around sharp edges or hot surfaces.

7.1.5 When a hazard assessment indicates that specialized gloves are required, they shall be issued to the employee(s) assigned to the task.

7.1.6 Welders shall wear gloves during all welding operations.


9905-02-000.doc 12/8/2004 4

8.0 Foot Protection

8.1 Requirements

8.1.1 Construction HSE Managers shall conduct a detailed, documented hazard assessment of the site and the work activities conducted on the site and determine if additional foot protection is required beyond the protection specified in this Practice. When additional foot protection is necessary to protect employees from the hazards identified, the employees assigned to those areas and/or tasks shall be required to wear the specified protection that provides the necessary protection and that meets the specifications of the latest version of ANSI Z.41.

8.1.2 Personnel in the process area, process plant, laydown yard, warehouse, or any other work area were foot protection is required will wear protective (safety or steel toe) footwear.

8.1.3 Open toe shoes, high heel shoes, sandals, hush puppies, tennis shoes, jogging or athletic shoes and other such footwear is prohibited on construction projects.

8.1.4 Personnel who perform work within the confines of an office and will periodically leave their work area and conduct business where field activities are taking place.

8.1.5 When working with wet concrete, workers must wear rubber boots.

8.1.6 Protective footwear shall be kept in good repair, and those with worn heels or thin or worn soles shall not be permitted.

8.1.7 Additional protective footwear, which covers the toes and metatarsal area of the foot, shall be worn when there is a potential for foot injury. (i.e., operating a ground compactor, pneumatic drill to break concrete, jack hammers, etc.)

8.1.8 The toe protection shall an integral part of the footwear and must be able to withstand a compression load of 2,268 kg on a bearing surface of not less than 76 mm diameter.


HSE Practice 9-A Personal Protective Equipment – Eye Protection

® EYE PROTECTION PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to define the minimum requirements for eye and face protection.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart E (1926.102)

2.2 ANSI 287.1—Practice for – Occupational and Educational Eye and Face Protection



3.0 Definitions

3.1 None

4.0 Practices

4.1 Requirements

4.1.1 Personnel on the project shall wear approved protective eyewear during working hours. Protective eyewear shall meet the minimum requirements of ANSI Z87.1, latest edition.

4.1.2 Eye protection is required in all work areas except offices. Eye protection shall also be worn in office settings when the work conducted therein creates the potential for eye injuries.

4.1.3 Approved eye and face protection must be worn whenever warranted by the work exposure.

4.1.4 ANSI-approved safety glasses with full side shields must be worn in all circumstances. Employees requiring corrective lenses must have glasses in which the frames and lenses meet ANSI specifications or they shall be required to wear protective eyewear over their corrective lenses. The addition of side shields to non-safety glasses shall not be permitted.

4.1.5 Goggles and Full-face shields shall be worn when performing grinding, chipping, or similar activities. Other employees in the area (that is in any area in which grinding dust is falling/flying) shall be protected by screens or shall wear goggles and face shields.

4.1.6 Goggles shall also be worn in areas where dusty operations are conducted or where windy conditions result in greater potential for flying particles.

4.1.7 Welders must wear a welder's hood with lenses that have the correct color density for the type of welding involved.

4.1.8 Welder's helpers and other employees exposed to the welding flash must wear the same level of eye protection, or shall wear burning goggles or filtered safety glasses with the correct color density lenses.

4.1.9 Safety eyewear must be worn in front of and behind the welder's shaded lenses.

4.1.10 Employees who wear contact lenses shall wear safety glasses in addition to the contact lenses where safety glasses are required.

4.1.11 Operators of vehicle and equipment must wear protective eyewear while operating such equipment unless they are in enclosed cabs.

4.1.12 Safety eyewear shall be capable of being disinfected.

® EYE PROTECTION PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 2

4.1.13 Safety eyewear shall be easily cleaned.

4.1.14 Design, construction, testing, and materials of devices of eye protection shall be in accordance with relevant Gulf standards approved by GSMO.


None


HSE Practice 9-B

Personal Protective Equipment – Head Protection

® HEAD PROTECTION PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to define the minimum requirements for head protection wherever a hazardous condition exists and a need is indicated for using such equipment to adequately reduce the hazard to personnel, visitors, and/or subcontractors.

2.0 References


2.2 ANSI Z89.1—Head Protection

2.3 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart I



3.0 Definitions

3.1 Occupational Safety and Health Administration (OSHA)

3.2 American National Standards Institute (ANSI)

4.0 Practices

4.1 Requirements

4.1.1 All workers must wear Company-issued hard hats at all times when working in construction areas/projects or areas of an existing facility that have been designated as a "Hard Hat Area." This includes visitors, subcontractors, engineers, inspectors, and anyone else who is authorized to be on the project. When FLUOR ARA BIA activities require establishment of a hardhat area in an area that typically does not require hard hats; signs shall be posted to inform others that hard hats are required.

4.1.2 Hard hats shall meet the specifications of ANSI Z89.1 - 1969 as required by OSHA.

4.1.3 Bump Caps and metallic hard hats are prohibited on FLUOR ARABIA projects.

4.1.4 All personnel on the project are required to have their Company logo and their name prominently displayed on their hard hat. The name shall be applied above the brim of the hat using block letters.

4.1.5 Hard hats that have been altered by drilling or cutting will not be permitted, nor will those hats that have been altered by the addition of any items on the outside of the hat other than safety or Company issued stickers. When it is necessary to use additional personal protective equipment that must be attached to the hard hat, only those hard hats designed for this purpose may be used.

4.1.6 Hard hats shall be inspected regularly for signs of chalking (loss of surface gloss), cracking, chips or other visible defects and replaced when damaged. Headband assemblies must be in good condition and should be exchanged whenever they become broken or weakened. The area between the top of the headband and the top of the hard hat should never be used for storage.

4.1.7 Welders are required to wear hard hats when in a hardhat area. Soft cap welding is not permitted.

® HEAD PROTECTION PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 2

4.1.8 Operators of vehicles and equipment are required to wear protective headgear during the operation of such equipment except in enclosed cabs.

4.1.9 Hard hats shall also be required in areas that typically would not require the use of a hard hat (offices, break areas, barracks, etc.) when the work activity creates an overhead hazard.

4.1.10 Hard hats shall be worn with the bill facing forward.

4.1.11 Hard hats complete with suspension and headband shall weigh not more than 425 g.

4.1.12 Hard hats shall be capable of withstanding the impact of a 3.6 kg steel ball dropped 1.5 meter upon its crown at minus 18ºC and plus 48ºC.

4.1.13 Hard hats shall be capable of meeting the following electrical test:

4.1.13.1 Immerse the helmet in tap water with the top down so the water covers both the inside and the outside, and so the brim protrudes 2 cm above the water surface. The brim should remain dry.

4.1.13.2 Place electrodes in the water, one inside and one outside the hard hat.

4.1.13.3 Connect the electrodes to a source of 2,200 volts (rms), 60 hertz alternating current.

4.1.13.4 The current flow through the hard hat shall not exceed 3 milliamperes.


None


HSE Practice 9-C Personal Protective Equipment – Hand Protection

® HAND PROTECTION PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to define the minimum requirements for hand protection wherever a hazardous condition exists and a need is indicated for using such equipment to adequately reduce the hazard to personnel, visitors, and/or subcontractors.

2.0 References




3.0 Definitions

3.1 None

4.0 Process

4.1 Requirements

4.1.1 Workers shall wear leather, work gloves during all work activities, UNLESS the gloves would increase the hazard potential of the task. The employee shall select gloves that are suited to the type of work involved.

4.1.2 Employees who are required to operate drill presses, power saws, bench grinders, and similar rotating machinery shall not wear gloves.

4.1.3 Gloves such as neoprene, nitrile, butyl rubber, polyvinyl alcohol, “Silver-Shield”, or “Black Knight” may be required when handling specific chemicals.

4.1.4 Cut resistant gloves or Kevlar gloves may be required when working around sharp edges or hot surfaces.

4.1.5 When a hazard assessment indicates that specialized gloves are required, they shall be issued to the employee(s) assigned to the task.

4.1.6 Welders shall wear gloves during all welding operations.


None


HSE Practice 10 Housekeeping

® HOUSEKEEPING PRACTICE 10 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to establish the minimum requirements for housekeeping on FLUOR ARABIA. projects.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart C (1926.25)

2.2 Yanpet Standard H-P-0301—Safety & Loss Prevention Department: Safety Regulations for Contractors

3.0 Definitions

3.1 None

4.0 Process

4.1 The poor housekeeping practices are a primary leading HSE indicator of inadequate supervision and will result in disciplinary action up to and including termination.

4.2 Work areas, passageways, stairways, and other areas shall be kept free of debris and materials.

4.3 There shall be unobstructed access at all times to such areas as electrical panels, safety disconnect switches, fire extinguishers, emergency exits, etc.

4.4 Containers shall be provided for the collection and separation of waste, trash, oily and used rags, and other refuse. Containers used for garbage and other oily, flammable, or hazardous wastes, such as caustics, acids, harmful dusts, etc. shall be equipped with covers. Garbage and other waste shall be disposed of at frequent and regular intervals.

4.5 Trash, which does not contain any hazardous waste, shall not be stored or disposed in bags or containers marked for hazardous waste.

4.6 Trash disposal cans shall be provided with covers and emptied daily.

4.7 Lunch and eating areas shall be kept clean and free of all food scraps, wrappers, cups, and other disposable items.

4.8 Glass bottles are not allowed on any FLUOR ARABIA project.

4.9 Work areas shall be cleaned as often as necessary to eliminate tripping and fire hazards. Particular attention shall be paid to the area around scaffolds, ladders, ramps, stairs and electrical and mechanical equipment. Tools and loose materials that create a hazard will be removed.

4.10 Cords, wires, and electrical cables shall be kept in an elevated position to prevent damage by activities or equipment and to eliminate potential hazards to personnel.

4.11 Spills of oil, grease, or other liquid shall be removed immediately or sprinkled with an absorbent material and disposed in accordance with the United States Environmental Protection Agency (US EPA) requirements.

4.12 Protruding nails shall either be removed or bent over in such a way that they no longer present a hazard. This activity will be performed immediately as the protruding nails are identified.

4.13 Cleaned lumber shall be stacked in orderly piles. Workers performing this task shall wear heavy gloves and hard-soled shoes.

4.14 When nails are removed from lumber, the nails shall be collected and disposed properly to eliminate puncture hazards.

4.15 Storage and lay down areas shall be kept clean and materials neatly stacked or placed.

® HOUSEKEEPING PRACTICE 10 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 2

4.16 Combustible scrap and debris will be removed at regular intervals during the course of the work shift. Safe means shall be provided to facilitate such movement.

4.17 All work areas will be left in a clean condition at the end of each working day.


None


HSE Practice 11 Sanitation & Potable Water

® SANITATION & POTABLE WATER PRACTICE 11 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice establishes the minimum requirements for providing adequate sanitary facilities and potable water on project sites.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart C 1926.27

2.2 Title 29 CFR Part 1926 Subpart D 1926.51)

2.3 American National Standards Institute (ANSI) Z4.1—Sanitation in Places of Employment-Minimum Requirements

2.4 ANSI Z4.3—Sanitation-Non-sewered Waste-Disposal Systems – Minimum Requirements

2.5 ANSI Z4.4—Sanitation in Fields and Temporary Labor Camps – Minimum Requirements

2.6 Title 42 - Code of Federal Regulations (CFR) Part 72

3.0 Definitions

3.1 Potable Water - Water that meets the quality standards prescribed in the US Public Health Service Drinking Water Standards, published in 42 CFR Part 72, or water that is approved for drinking purposes by the State or local authority having jurisdiction.

4.0 Process

4.1 Potable Water

4.1.1 An adequate supply of potable water shall be provided in all places of employment. As a general guide, supervisors should estimate minimum water consumption at 6 liters per day per person.

4.1.2 Portable containers used to dispense drinking water shall be capable of being tightly closed, sealed, and equipped with a tap. Water shall not be dipped from containers.

4.1.3 Any container used to distribute drinking water shall be clearly marked as to the nature of its contents and shall not be used for any other purpose.

4.1.4 The common drinking cup is prohibited.

4.1.5 Where single service cups (disposable) are supplied, both a sanitary container for the unused cups and a receptacle for disposing of the used cups shall be provided.

4.1.5.1 Drinking Water containers shall be cleaned and sanitized on a daily basis according to the following steps:

4.1.5.2 The individual assigned to the task of cleaning the containers shall wash his/her hands with soap and water and put on disposable or rubber gloves.

4.1.5.3 The outside of the container shall be rinsed off prior to opening the container.

4.1.5.4 Containers are to be washed with a detergent daily. Hot water shall be used when available. Dishwashing liquid and a scrub brush or sponge shall be used to clean the containers.

4.1.5.5 Containers are to be rinsed with clean water to remove all soap residues.


9905-02-000.doc 12/8/2004 2

4.1.5.6 Containers are to be sanitized using the following method:

4.01.5.6.1. Rinse containers in a solution of 2 tablespoons of chlorine bleach in one gallon of water.

4.01.5.6.2. Rinse containers in clean water.

4.01.5.6.3. When a location is available, the containers shall be allowed to air dry prior to refilling.

4.01.5.6.4. Containers should be cleaned on an elevated, grated, platform to keep them from being subjected to dirt and grime.

4.2 Nonpotable Water

4.2.1 Outlets for nonpotable water, such as water for industrial or firefighting purposes only, shall be identified by signs to indicate clearly that the water is unsafe and is not to be used for drinking, washing or cooking purposes.

4.2.2 There shall be no open or potential cross-connection between a potable water system and a nonpotable water system.

4.3 Toilets at Construction Projects

4.3.1 Temporary toilets shall be maintained in accordance with Federal, State, or Local ordinances.

4.3.2 Toilets shall be constructed to shield the occupants from view and protect against weather and falling objects.

4.3.3 Toilets shall be ventilated and all windows and vents screened.

4.3.4 Adequate tissue shall be provided.

4.3.5 All toilet facilities shall be cleaned and emptied on a regular basis according to project needs.

4.3.6 All toilet facilities shall be located on the project so that clear access is provided for cleaning and servicing.

4.3.7 The following table provides the minimum number of toilet facilities to be provided for employees:

Number of employees Minimum number of facilities

20 or less 1

20 or more 1 toilet seat and 1 urinal per 40 workers

200 or more 1 toilet seat and 1 urinal per 50 workers

4.4 Washing Facilities

4.4.1 Lavatories shall be made available in all places of employment.

4.4.2 The washing facilities shall be maintained in a sanitary condition.

4.4.3 Each lavatory shall be provided with running, potable water.

4.4.4 Hand soap or similar cleansing agents shall be provided.

4.4.5 Individual hand towels or sections thereof, of cloth or paper, warm air blowers or clean individual sections of continuous cloth toweling, convenient to the lavatories shall be provided.


9905-02-000.doc 12/8/2004 3

4.4.6 Whenever showers are required by a particular standard, the showers shall meet the following requirements:

4.4.6.1 One shower shall be provided for each 10 employees of each sex, or numerical fraction thereof, who are required to shower during the same shift.

4.4.6.2 Body soap or other appropriate cleansing agents shall be provided.

4.4.6.3 Showers shall be provided with hot and cold water feeding a common discharge line.

4.4.6.4 Employees who use showers shall be provided with individual clean towels.

4.5 Eating and drinking areas

4.5.1 No employees shall be allowed to consume food or beverages in a toilet room or in any area exposed to a toxic material.

4.5.2 Eating and drinking will be allowed only in designated areas.

4.6 Vermin Control

4.6.1 Every enclosed workplace shall be so constructed, equipped, and maintained so far as reasonable to prevent the entrance or harboring of rodents, insects, and other vermin. A continuous, effective extermination program shall be instituted where their presence is detected.

4.7 Change rooms

4.7.1 Whenever employees are required by a particular standard to wear protective clothing because of the possibility of contamination with toxic materials, change rooms equipped with storage facilities for street clothes and separate storage facilities for the protective clothing shall be provided.

5.0 Record Retention A record of tests performed on potable water at the beginning of, and during the life of, a project shall be maintained in the Project Safety Department files for the duration of the project.


HSE Practice 12 Illumination

® ILLUMINATION PRACTICE 12 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose 1.1 The purpose of this Practice is to establish requirements for illumination

of work areas. 2.0 References


2.2 29 CFR Part 1926 Subpart C (1926.26) 2.3 SASO 335—Industrial Safety and Health Regulations, Electrical Part 4:

Illumination 3.0 Definitions

3.1 A foot-candle is a unit of illumination. It is the illumination at a point on a surface, which is one foot from, and perpendicular to, a uniform point source of one candle.

4.0 Process 4.1 Construction areas, ramps, runways, corridors, offices, shops, and storage

areas shall be lighted to not less than the minimum illumination intensities listed below while any work is in progress.

4.2

For areas not listed above, refer to the latest revision of Illumination Engineering Society (IES) RP-7 that supercedes ANSI A11.1 Practice for Industrial Lighting and SASO 335 Table 2—Illumination levels for Construction Safety (whichever is more stringent).

4.3 Where the use of artificial light is required, it shall be maintained until workmen have had an opportunity to leave the area.

Construction areas, ramps, runways, corridors, offices, shops, and storage areas shall be lighted to not less than the minimum illumination intensities listed below while any work is in progress.

Foot-candles Area or operation

5 General construction area lighting

3 General construction areas, concrete placement, excavation and waste areas, accesses, active storage areas, loading platforms, refueling, and field maintenance areas.

5 Indoors: warehouses, corridors, hallways, and exits.

10 General Construction plant and shops (e.g., batch plants, screening plants, mechanical and electrical equipment rooms, carpenter shops, rigging lofts and active storerooms, barracks or living quarters, locker or dressing rooms, mess halls, and indoor toilets and workrooms.

30 First-aid stations, infirmaries, and offices.


HSE Practice 13 Materials Storage & Handling

® MATERIALS STORAGE & HANDLING PRACTICE 13 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to provide the requirements for the safe handling and storage of materials.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart C (1026.34)

2.2 Title 29 CFR Part 1926 Subpart H (1926.250)

2.3 Title 29 CFR Part 1926 Subpart F (1926.152)

2.4 Title 29 CFR part 1926 Subpart F (1926.153)

2.5 SSA 337 Industrial Safety and Health Regulations Parts 9, 10, 11, 12, 13, and 14 – Building and Construction

2.6 Yanpet Standard H-P-0301—Safety and Loss Prevention Department: Safety Regulations for Contractors

3.0 Definitions

3.1 Combustible Liquid - liquid having a flash point at or above 140 °F (60 °C)

3.2 Combustible Material - liquids, solids, or gases that are relatively difficult to ignite and that burn relatively slowly (such as paper, wood, etc.)

3.3 Flammable Liquid - liquid having a flash point below 100 °F and a vapor pressure not exceeding 40 pounds per square inch (absolute) at 140 °F

3.4 Flammable Material - liquids, solids, or gases that are capable of being easily ignited, burning intensely, or having a rapid rate of flame spread (usually dusts, fine powders, or substances that ignite spontaneously at low temperatures)

4.0 Process

4.1 General

4.1.1 Both temporary and permanent storage shall be neat and orderly. When planning material storage, a minimum of 36 inches of clearance must be allowed under sprinkler heads. Automatic sprinkler controls and electrical panel boxes must be kept free and unobstructed.

4.1.2 There must be unobstructed access to fire hoses and extinguishers. Clear access to emergency exits and aisles shall be maintained. Areas immediately outside emergency exits shall be left clear for egress.

4.1.3 Materials shall be separated based on the type, size, and length of the material. The material shall also be placed in neat, orderly piles that will not fall. The piles shall be stepped back as the height increases and shall be secured by cross piling or cross tying. Piles of material shall be arranged to allow for clear access and egress.

4.1.4 Storage bins and racks that are in good condition shall be used to make storing materials easier and reduce hazards. Storage racks shall be secured to the wall and/or floor as well as to each other. Damaged racks shall not be used for storage. Employees shall not be allowed to climb racks. Racks and bins shall have a weight limit and shall be prominently labeled. Elevated floors shall also be labeled indicating their load capacities.

4.1.5 All materials stored in tiers shall be stacked, racked, blocked, interlocked, or otherwise secured to prevent sliding, falling, or collapse.


9905-02-000.doc 12/8/2004 2

4.1.6 Material shall be stacked as low as practical and in no case higher than 6 meters.

4.1.7 Materials shall not be stored on scaffolds or runways in excess of supplies needed for immediate operations.

4.2 Lumber Storage

4.2.1 Lumber shall be stacked on solid, level sills. Cross-strips or cross-pilings shall be used where the pile is more than 4 feet high. The top of each pile shall be kept as level as possible when lumber is being removed. Used lumber shall have nails removed before it is piled. Employees shall wear gloves when handling lumber.

4.2.2 Lumber to be handled manually shall not be stacked more than 4.8 meters high.

4.2.3 Lumber shall be stacked on level and solidly supported sills.

4.3 Steel Storage

4.3.1 Reinforcing steel shall be stored in separate piles according to size and length. Corrugated and sheet steel must be stacked in flat piles. Spacing strips shall be placed between each bundle.

4.4 Pipe Storage

4.4.1 Pipe shall be stored on pipe sills or racks and shall be blocked to prevent rolling. When removing pipe, employees shall work from the end of the pile as much as possible. Pipe larger than 2 feet in diameter should be handled using mechanical equipment

4.4.2 Pipe, unless racked, shall not be stacked higher than 1.5 meters.

4.5 Petroleum Product Storage

4.5.1 Petroleum products delivered to the jobsite and stored in drums shall be protected during handling to prevent loss of identification through damage to drum markings, tags, etc. Unidentified petroleum products may result in improper use, with possible fire hazard, damage to equipment, or operating failure. Barrels shall be protected to prevent any physical damage or weather deterioration.

4.5.2 Bulk delivery and storage of petroleum products requires care in identification and particular attention to fire hazards during handling and storage. Legible D.O.T. labels shall remain on the bulk containers until the container is empty or removed. Appropriate fire extinguishers must be easily accessible between 25 feet and 75 feet of the storage location, and warehouse personnel must be trained in their use. The storage area is to be diked to prevent the spread of accidentally released material (outside storage of bulk material). The dike and diked area shall be able to contain 110% of the contents of the largest container and must prevent the petroleum product from being absorbed into the soil. Spills shall be cleaned up and removed.

4.5.3 The storage area for flammable materials shall be posted as a "No Smoking" area. Any open flame work in the area shall be under a Hot-Work/Flame permit.

4.6 Flammable Liqui d and Gas Storage

4.6.1 All gases and liquids should be considered flammable unless the label clearly indicates that no such hazard exists. Conditions change so rapidly that extreme care is necessary whenever flammable liquids or gases are being used. Open flames, sparks, or excessive heat can ignite flammable liquids and gases. It is necessary to consider each of these factors when setting up safe storage facilities


9905-02-000.doc 12/8/2004 3

for these items. Oxygen cylin ders shall be separated from all fuel gases by a distance of 20 feet (or a five-foot, 1/2 hour firewall) and stored outside of buildings.

4.6.2 No other equipment or materials should be contained in the area where flammable or combustible liquids or gases are stored. This is especially true for compressed gases and petroleum products.

4.6.3 All areas for storing of flammable liquids and gases shall be designated as such, and "No Smoking" signs must be posted. DOT labels are required on all shipping/transporting containers. Combustible or flammable materials shall not be stored within 20 feet of any fuel gas or oxygen cylinder storage area.

4.6.4 The "No Smoking" rule must be vigorously enforced. These areas shall always be located so that local fire protection will always have access to the material.

4.6.5 Only approved containers shall be used for storing flammable liquids, and each container must have an emergency-venting device. All bulk containers from which flammable liquids are dispensed shall be grounded. When transferring flammable liquids, the dispensing container shall be bonded to the receiving container.

4.6.6 On-site bulk storage of liquid fuels should be avoided whenever possible.

4.7 Material Handling

4.7.1 Supervisors shall give advance consideration to the size, shape, and weight of materials to be handled and plan the most efficient and safest method to accomplish the task. Proper tools shall be provided for the job, and alternate methods should be considered.

4.7.2 Supervisors shall ensure that the work fits the employee in terms of knowledge and physical abilities. When unusual or hazardous operations are required, before beginning the work, employees shall be warned about all possible hazards and given specific safety instructions by their immediate supervisor.

4.7.3 Special precautions shall be taken to prevent hernias and back injuries. Employees will be instructed in proper manual lifting techniques.

4.8 Temporary Buildings

4.8.1 Buildings located within another building or structure shall be constructed of either non-combustible material or combustible material having a fire resis tance of not less than 1 hour.

4.9 Safe Practices

4.9.1 The following general safety material storage and handling practices will be followed:

4.9.1.1 Chock and block tires of trucks during loading and unloading

4.9.1.2 Provide proper personal protective equipment

4.9.1.3 Ensure that only properly trained personnel are used to handle hazardous materials and to oversee material handling methods

4.9.1.4 Report any unsafe condition or practice that cannot be corrected within the scope of your authority

4.9.1.5 Label floors and storage racks with maximum capacities

4.9.1.6 Train warehouse and craft personnel responsible for storing and handling material


9905-02-000.doc 12/8/2004 4

4.9.1.7 Loose or light material shall not be stored or left on roofs or floors that are not closed in, unless it is safely secured.

4.9.1.8 The storage area shall be kept from the accumulation of unnecessary combustible materials.


None


HSE Practice 14 Barricading

® BARRICADING PRACTICE 14 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice establishes the requirements for the use of barricades to restrict access to areas. It is intended as a general statement of good practice that will apply under typical circumstances. Non-routine activities may require additional measures to ensure employee safety. Several methods of barricading to limit access to areas may be used.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart G (1926.200, 1926.201, 1926.202, and 1926.203)

2.2 Title 29 Code of Federal Regulations (CFR) Part 1910 Subpart J (1910.144 and 1910.145)

2.3 SSA 315 Industrial Safety and Health Regulations Part 3 – Occupational Health and Environmental Control

3.0 Definitions

3.1 A barricade can be a sign, a barrier, orange traffic cones, highly visible tape, painted ground markings, etc. Barricades are used to signify warning, caution, and danger and to prevent or restrict access to the area. Barricades may be permanent or temporary barricades.

3.2 Permanent barricades are fixed, painted structures or barriers such as gates, chains, concrete firewalls, or toe-walls. They are intended to convey a permanent warning or caution regarding entering the area. They shall indicate if specific authorization, control measures, and/or protective equipment are required to enter the area.

3.3 Temporary barricades are generally erected for a specific purpose and intended for quick and easy removal. Examples are colored tape, a sign, sawhorses, safety cones, etc.

4.0 Process

4.1 Barricade means an obstruction to deter the passage of persons or vehicles.

4.2 Signs are the warnings of hazard, temporarily or permanently affixed or placed, at locations where hazards exist.

4.3 Signals are moving signs, provided by workers, such as flaggers, or by devices, such as flashing lights, to warn of possible or existing hazards.

4.4 Barricades shall be used in order to alert employees to potential hazards and indicate if authorization, protective measures, or protective equipment is required.

4.5 A tag shall be affixed to the barricade. (DBN-F35). The tag shall be in a conspicuous location and shall contain the following information:

4.5.1 The date the barricade was erected.

4.5.2 The reason for the barricade.

4.5.3 The name of the FLUOR ARABIA contractor Supervisor responsible for the barricaded area.

4.6 Signs shall be placed on barricade stands, posts, or other suitable surfaces.

4.7 Signs must be placed in visible locations, before work starts and must be removed to proper storage areas when they are no longer needed.

4.8 Signs must be legible and maintained in a usable condition.

4.9 Employees must obey posted signs.

4.10 Barricades shall be a minimum of 42 inches high, neat, uniform, and level.

® BARRICADING PRACTICE 14 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 2

4.11 Barricades shall be a minimum of 6 feet back from the edge of excavations, holes, platforms, and roofs unless a protective barricade is used.

4.12 Barricades must have blinking lights when used on roadways or walkways after dark.

4.13 Barricades must have an entrance, opening, or gate whenever possible.

4.14 Barricades are required around:

4.14.1 Excavations.

4.14.2 Floor and roof openings.

4.14.3 Edges of roofs and elevated platforms.

4.14.4 Around overhead work areas.

4.14.5 Wherever necessary to warn employees of the potential for falling in, through, or off.

4.15 Barricades for protection of employees shall conform to the following:

4.15.1 Barricades shall consist of an “A” frame portable structure,

4.15.2 The barricade minimum height is 1 meter.

4.15.3 The barricade maximum length is 2.4 meters.

4.15.4 The top rail shall be 20 to 30 cm wide painted with 15 cm stripes inclined at 45 degrees.

4.15.5 Colors shall be orange and white or black and white.

4.16 Use of Yellow-black barricade tape

4.16.1 Yellow-black tape is used to indicate caution or warning. An employee may enter such an area only after reviewing the tag and taking the necessary precautions.

4.17 Use of Yellow-magenta barricade tape

4.17.1 Yellow-magenta tape is used to restrict access to a work area where a radioactive material is present or where X-raying is being done. Entry is prohibited without the authorization of the supervisor of the radiation work.

4.18 Use of Red barricade tape

4.18.1 Red barricade tape is used to indicate danger. No one may enter a red barricaded area unless the supervisor signing the barricade tag specifically authorizes entry and the entrant has met the requirements indicated on the tag.

4.18.2 When a supervisor feels that a red barricade is necessary, the Construction HSE Manager will be contacted to assess the situation. When it is not possible to eliminate or control the hazard, the Construction HSE Manager shall authorize the use of the red barricade and establish the requirements for entering the barricade.

4.19 Removal of temporary barricades

4.19.1 Temporary barricades shall be removed promptly by the supervisor who installed them once they are no longer needed.


None


HSE Practice 15 Ladders

® LADDERS PRACTICE 15 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for selecting, constructing, maintaining, inspecting, and using ladders.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart X (1926.1050 - 1926.1060)

2.2 ANSI A14.1-1982—Ladders-Portable Wood-Safety Requirements

2.3 ANSI A14.2-1982—Ladders-Portable Metal-Safety Requirements

2.4 ANSI A14.4-1992—Safety Requirements for Job-Made Wooden Ladders

2.5 ANSI A14.5-2000—Safety Requirements for Portable Reinforced Plastic Ladders

2.6 SASO 313 Industrial Safety and Health Regulations Buildings Part 1: Building Facilities

2.7 Yanpet Standard H-P-0411—Ladders & Stairways Procedure

3.0 Definitions



4.0 Process

4.1 Ladder Selection

4.1.1 Great care should be taken in selecting the proper size and design of the ladder for the use intended.

4.1.2 Ladders shall have non-skid surfaces on each cleat.

4.1.3 Ladders shall be capable of supporting four times their intended load.

4.2 Straight Ladders

4.2.1 Ladders must be of sufficient length to extend not less than 36 inches above any platform or landing, which they serve.

4.2.2 All portable straight ladders must be equipped with approved safety shoes.

4.2.3 Metal ladders shall not be used when doing electrical work or around open electrical circuits.

4.2.4 A rope should be spliced onto one of the top rungs of a ladder to provide a ready method of securing the ladder.

4.3 Step Ladders

4.3.1 Stepladders (sometimes referred to as "A" frame ladders) shall have positive locking spreaders that will be fully spread and locked when the ladder is in use.

4.3.2 Stepladders shall not be used as straight ladders. Workers shall not be allowed to work from the top two steps of a stepladder.

4.3.3 Stepladders shall be firm and well constructed. Care shall be taken when setting a ladder on grating. Often the feet of a stepladder will slip through the grating causing the ladder to fall. Stepladders shall be tied off, or a worker shall hold the ladder.

4.3.4 Stepladders longer than 6.1 meters shall not be permitted.


9905-02-000.doc 12/8/2004 2

4.4 Ladder Usage

4.4.1 A stairway or ladder shall be provided at all personnel points of access where there is a break in elevation of 19 inches (48 cm) or more, and no ramp, runway, sloped embankment, or personnel hoist is provided.

4.4.2 A double-cleated ladder or two or more separate ladders shall be provided when ladders are the only mean of access or exit from a working area for 25 or more employees, or when a ladder is to serve simultaneous two-way traffic.

4.4.3 Ladders shall be capable of supporting the following loads without failure:

4.4.3.1 Each self-supporting portable ladder: At least four times the maximum intended load, except that each extra-heavy-duty type 1A metal or plastic ladder shall sustain at least 3.3 time the maximum intended load. The ability of a ladder to sustain the loads indicated in this paragraph shall be determined by applying or transmitting the requisite load to the ladder in a downward vertical direction. Ladders built and tested in conformance with the applicable provisions of appendix A of this subpart will be deemed to meet this requirement.

4.4.3.2 Each portable ladder that is not self-supporting: At least four times the maximum intended load, except that each extra-heavy-duty type 1A metal or plastic ladders shall sustain at least 3.3 times the maximum intended load. The ability of a ladder to sustain the loads indicated in this paragraph shall be determined by applying or transmitting the requisite load to the ladder in a downward vertical direction when the ladder is placed at an angle of 75-1/2 degrees from the horizontal. Ladders built and tested in conformance with the applicable provisions of appendix A will be deemed to meet this requirement.

4.4.4 Ladder rungs, cleats, and steps shall be parallel, level, and uniformly spaced when the ladder is in position for use.

4.4.5 Rungs, cleats, and steps of portable ladders (except as provided below) shall be spaced not less than 10 inches (25 cm) apart, nor more than 14 inches (36 cm) apart, as measured between center lines of the rungs, cleats and steps.

4.4.6 Rungs, cleats, and steps of step stools shall be not less than 8 inches (20 cm) apart, nor more than 12 inches (31 cm) apart, as measured between center lines of the rungs, cleats, and steps.

4.4.7 Rungs, cleats, and steps of the base section of extension trestle ladders shall be not less than 8 inches (20 cm) nor more than 18 inches (46 cm) apart, as measured between center lines of the rungs, cleats, and steps. The rung spacing on the extension section of the extension trestle ladder shall be not less than 6 inches (15 cm) nor more than 12 inches (31 cm), as measured between center lines of the rungs, cleats, and steps.

4.4.8 The minimum clear distance between the sides of individual-rung/step ladders shall be 16 inches (41 cm).

4.4.9 The minimum clear distance between side rails for all portable ladders shall be 11 1/2 inches (29 cm).

4.4.10 The rungs of individual-rung/step ladders shall be shaped such that employees' feet cannot slide off the end of the rungs.


9905-02-000.doc 12/8/2004 3

4.4.11 The rungs and steps of portable metal ladders shall be corrugated, knurled, dimpled, coated with skid-resistant material, or otherwise treated to minimize slipping.

4.4.12 Ladders shall not be tied or fastened together to provide longer sections unless they are specifically designed for such use.

4.4.13 A metal spreader or locking device shall be provided on each stepladder to hold the front and back sections in an open position when the ladder is being used.

4.4.14 Except when portable ladders are used to gain access to fixed ladders (such as those on utility towers, billboards, and other structures where the bottom of the fixed ladder is elevated to limit access), when two or more separate ladders are used to reach an elevated work area, the ladders shall be offset with a platform or landing between the ladders. (The requirements to have guardrail systems with toe boards for falling object and overhead protection on platforms and landings are set forth in subpart M of this part.)

4.4.15 Ladder components shall be surfaced to prevent injury to an employee from punctures or lacerations, and to prevent snagging of clothing.

4.4.16 Wood ladders shall not be coated with any opaque covering, except for identification or warning labels which may be placed on one face only of a side rail.

4.4.17 Individual-rung/step ladders, except those used where their access openings are covered with manhole covers or hatches, shall extend at least 42 inches (1.1 m) above an access level or landing platform either by the continuation of the rung spacing as horizontal grab bars or by providing vertical grab bars that shall have the same lateral spacing as the vertical legs of the rungs.

4.4.18 The following requirements apply to the use of all ladders, including job-made ladders, except as otherwise indicated:

4.4.18.1 When portable ladders are used for access to an upper landing surface, the ladder side rails shall extend at least 3 feet (.9 m) above the upper landing surface to which the ladder is used to gain access; or, when such an extension is not possible because of the ladder's length, then the ladder shall be secured at its top to a rigid support that will not deflect, and a grasping device, such as a grab rail, shall be provided to assist employees in mounting and dismounting the ladder. In no case shall the extension be such that ladder deflection under a load would, by itself, cause the ladder to slip off its support.

4.4.18.2 Ladders shall be maintained free of oil, grease, and other slipping hazards.

4.4.18.3 Ladders shall not be loaded beyond the maximum intended load for which they were built, or beyond their manufacturer's rated capacity.

4.4.18.4 Ladders shall be used only for the purpose for which they were designed.

4.04.18.4.1. Non-self-supporting ladders shall be used at an angle such that the horizontal distance from the top support to the foot of the ladder is approximately one-quarter of the working length of the ladder (the distance along the ladder between the foot and the top support).


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4.04.18.4.2. Wood job-made ladders with spliced side rails shall be used at an angle such that the horizontal distance is one-eighth the working length of the ladder.

4.4.19 Ladders shall be used only on stable and level surfaces unless secured to prevent accidental displacement.

4.4.20 Ladders shall not be used on slippery surfaces unless secured or provided with slip-resistant feet to prevent accidental displacement. Slip-resistant feet shall not be used as a substitute for care in placing, lashing, or holding a ladder that is used upon slippery surfaces including, but not limited to, flat metal or concrete surfaces that are constructed so they cannot be prevented from becoming slippery.

4.4.21 Ladders placed in any location where they can be displaced by workplace activities or traffic, such as in passageways, doorways, or driveways, shall be secured to prevent accidental displacement, or a barricade shall be used to keep the activities or traffic away from the ladder.

4.4.22 The area around the top and bottom of ladders shall be kept clear.

4.4.23 The top of a non-self-supporting ladder shall be placed with the two rails supported equally unless it is equipped with a single support attachment.

4.4.24 Ladders shall not be moved, shifted, or extended while occupied.

4.4.25 Ladders shall have nonconductive side rails if they are used where the employee or the ladder could contact exposed energized electrical equipment, except as provided in 1926.951(c)(1) of this part.

4.4.26 The top or top step of a stepladder shall not be used as a step.

4.4.27 Cross-bracing on the rear section of stepladders shall not be used for climbing unless the ladders are designed and provided with steps for climbing on both front and rear sections.

4.4.28 Ladders shall be inspected by a competent person for visible defects on a periodic basis and after any occurrence that could affect their safe use.

4.4.29 Portable ladders with structural defects, such as, but not limited to, broken or missing rungs, cleats, or steps, broken or split rails, corroded components, or other faulty or defective components, shall either be immediately marked in a manner that readily identifies them as defective, or be tagged with "Do Not Use" or similar language, and shall be withdrawn from service until repaired.

4.4.30 Ladder repairs shall restore the ladder to a condition meeting its original design criteria, before the ladder is returned to use.

4.4.31 Single -rail ladders shall not be used.

4.4.32 When ascending or descending a ladder, the user shall face the ladder.

4.4.33 Each employee shall use at least one hand to grasp the ladder when progressing up and/or down the ladder.

4.4.34 An employee shall not carry any object or load that could cause the employee to lose balance and fall.

4.4.35 The feet of the ladder shall be placed approximately one quarter of its supported length away from the vertical plane of its top support. (That is, set the ladder at a 4:1 slope.)

4.4.36 Only light, temporary work should be performed from ladders.


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4.4.37 Workers should be cautioned frequently about the danger of trying to reach too far from a single setting. In most ladder applications, the weight of the worker is unevenly distributed over an area of approximately 3 inches long by 3 inches wide, any effort that tends to shift the balance of the worker shall be discouraged. This includes activities such as pulling, pushing, prying, etc.

4.4.38 Ladders shall not be placed in front of doors that open toward the ladder unless the door is locked or otherwise guarded.

4.4.39 Ladder feet shall be placed on a firm base, and the area at the top and bottom of the ladder shall be kept clear.

4.4.40 When using straight ladders, both the top and bottom of the ladder shall be secured to prevent displacement. Use ladder shoes, stakes, or other means to secure the ladder.

4.4.41 Ladders leading to landings, walkways, platforms, etc., must extend 36 inches above the point of contact and must be securely fastened to prevent moving. If the ladder is not long enough to extend 36 inches above the landing, suitable grab-rails shall be installed. Long ladders must be braced at intermediate points as necessary to prevent springing.

4.4.42 When ascending or descending ladders, workers are to face the ladder and use both hands to hold onto the side rails. If material must be moved from one level to another, a rope, block and tackle, or other means must be used. Materials are not to be hand carried on ladders.

4.4.43 Ladders shall not be used horizontally as runways or scaffolds.

4.4.44 Barricades or guards are required if the ladder is set up in a congested/crowded area. The area at the base of the ladder must always be kept uncluttered.

4.5 Job-Built Ladders

4.5.1 When it is necessary to build a ladder at the project site, the ladder must comply with the following requirements:

4.5.1.1 OSHA and ANSI requirements regarding job-made ladders.

4.5.1.2 All materials must be thoroughly seasoned, straight-grained, and free from knots, decay, and other defects. All surfaces must be planed and free of splinters, and edges where handrails are used should be beveled.

4.5.1.3 Rung spacing must be uniform and not over 14 inches or less than 10 inches on centers. The wood for the rungs must be clear, straight-grained, and entirely free of knots. The slope of the grain in the cleats shall not be less than 1 in 15. Preferably, the cleats should be straight-grained. Single cleat ladders shall not exceed 30 feet in length.

4.5.1.4 Rungs or cleats should be recessed ½ inch into the rails, or filler strips of the same thickness as the cleats shall be inserted between the cleats and nailed to the side rails.

4.5.1.5 Portable ladders shall support four times the intended load.

4.5.1.6 Ladders shall be at least 16 inches wide at the base.

4.6 Ladder Inspection


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4.6.1 All ladders shall be inspected before each use and monthly for deterioration and damage by the designated competent person(s). Close visual inspection is recommended.

4.6.2 No employee shall be allowed to use (for any reason) any ladder that has broken, loose, or cracked rungs, side rails, or braces. Any ladder found in this condition shall be removed from service immediately. All inspections shall be documented (LGH SFOR 6404-06.001), and ladders shall be color coded for each month.

4.7 Ladder Maintenance

4.7.1 Wooden ladders may be periodically treated with a clear preservative such as varnish, shellac, or linseed oil. Ladders shall not be painted because painting covers up structural defects.

4.7.2 All ladders should have the rungs cleaned to prevent accumulation of materials that might destroy their non-slipping properties, and all metal fittings should be carefully checked for rust and corrosion.

4.7.3 When not in use, ladders should be protected from the weather. Ladders stored horizontally should be supported at both ends and at intermediate points to prevent sagging of the middle section that tends to loosen the rungs and warp the rails.


A copy of all ladder inspection records as specified in this Practice shall be maintained in the project Safety Department files for the duration of the project.


HSE Practice 16 Scaffold Safety

® SCAFFOLD SAFETY PRACTICE 16 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice provides the minimum requirements for erecting and dismantling elevated work platforms.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart L (1926.450 - 1926.452)

2.2 ANSI/SIA A92.2-1990—Vehicle-Mounted Elevating and Rotating Platforms

2.3 ANSI/SIA A92.3-1990—Manually Propelled Elevating Aerial Platforms

2.4 ANSI/SIA A92.5-1990—Boom Supported Elevating Work Platforms

2.5 ANSI/SIA A92.6-1990—Self-Propelled Elevating Work Platforms

2.6 ANSI/SIA A92.7-1990—Airline Ground Support Vehicle -Mounted Vertical Lift Devices

2.7 ANSI/SIA A92.8-1993—Vehicle-Mounted Bridge Inspection and Maintenance Devices

2.8 ANSI/SIA A92.9-1993—Mast-Climbing Work Platforms

2.9 Saudi Aramco Scaffold Safety Handbook

3.0 Definitions

3.1 Fixed Scaffolds – includes the following: tubular welded frame scaffolds, bracket scaf-folds, tube and coupler (Tube-lox) scaffolds, wood-pole scaffolds, and trestle scaffolds.

3.2 Suspended Scaffolds - includes the following: two-point suspended scaffolds, multilevel suspended scaffolds, floats, needle-beam scaffolds, boatswain's chair, and electric hoist platforms.

3.3 Competent person - One who is capable of identifying existing and predictable hazards in the surroundings or working conditions related to scaffolding which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.


3.5 Qualified – means one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated their ability to resolve problems related to the subject matter, the work, or the project.

4.0 Exception to Standard Practice

4.1 General

4.1.1 Scaffolds will be erected, maintained, and dismantled in accordance with the Saudi Aramco Scaffold Safety Handbook with the following exceptions:

• Fall protection requirements will still comply with Practice 17.

• Scaffold inspection will be on a daily basis in accordance with Section 5.1.14 of this practice.

• Competent persons will be designated in writing in accordance with Section 5.1.1 of the practice.

• Any erection, maintenance, or dismantling activities or requirements not specifically addressed in the Saudi Aramco Scaffold Safety Handbook will be required to follow this practice.

• Prior to scaffold erection and dismantling a valid Yanpet Cold Work Permit is required.


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5.0 Process

5.1 General

5.1.1 Each project shall designate a scaffold Competent Person(s). This designation shall be made in writing and the individual’s qualifications shall be documented.

5.1.2 Each project shall conduct training regarding the safe erection and dismantling of scaffolds for all employees involved in those activities. The training shall comply with the current version of OSHA’s scaffolding standards.

5.1.3 Each project shall conduct safety training for all users of scaffolds in accordance with the latest version of OSHA’s scaffolding standards. Training shall include at a minimum:

• Fall Hazards

• Electrical Hazards

• Falling Objects

• Fall Protection

• Scaffold Use

• Scaffold Load Capacity

5.1.4 Employees shall be retrained when conditions for the work involving the scaffold change or the scaffold is modified.

5.1.5 All working platforms shall be capable of sustaining a minimum-working load of 75 psf on 6-foot spans or have a safety factor of 4 to 1 for the intended load.

5.1.6 Posts shall be plumb and scaffold platforms shall be level.

5.1.7 A stationary scaffold shall be secured to the building or a fixed structure vertically every 25 feet starting at the base of the scaffold and horizontally every 30 feet. This rule shall also apply to rolling scaffolds at their working stations. Outriggers may be used in lieu of tying off, or scaffolds may be clamped together, so that the height does not exceed three times the smallest bas e dimension without additional stabilization.

5.1.8 A qualified engineer shall determine the structural integrity of structural steel, reinforcing steel, and concrete or building members before attachment of scaffolds by bracing or tying off.

5.1.9 Where persons are required to work or walk under scaffolding, a screen guard of No. 18 gauge ½-inch wire mesh or equivalent shall be provided between the toe board and handrail.

5.1.10 All workers shall use a personal fall arrest system when there is no (or an incomplete) handrail, when there are openings over 12 inches in the working platform, or when on suspended working platforms.

5.1.11 Swinging stages, floats, and boatswain's chairs shall be tested before using. (Test by applying a dead load with the unit close to the floor or ground.)

5.1.12 Crews requiring scaffolds shall requisition them well in advance as part of the work planning activities to avoid delays and work stoppages.

5.1.13 Scaffold erection crews shall inspect all components for defects as the erection proceeds. Any components found to be defective shall be set aside and tagged for repair or disposal.


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5.1.14 The Competent Person(s) shall perform daily inspections of the scaffolds. All defects shall be corrected at once or the scaffold shall have a "red" tag attached. (See 4.07)

5.1.15 Scaffold handrails shall be about 42 inches above the platform. The minimum distance between the handrail and the platform is 38 inches. The 38 inches allows for overlap of the scaffold planks.

5.1.16 Handrail posts shall be installed at intervals not to exceed 8 feet and shall be a minimum of 2” x 4” lumber or equivalent.

5.1.17 Only only qualified personnel shall modify scaffolds. Non-qualified personnel who modify scaffold will receive disciplinary action, up to and including termination.

5.2 Fixed Scaffold Requirements

5.2.1 Tubular Welded-Frame Scaffold Requirements

5.2.1.1 Scaffolds of 10 feet or more in height shall include diagonal braces, handrails, mid-rails, toe boards, and 2- x 10-inch or 2- x 12-inch scaffold planks or manufactured scaffold decking to provide a complete working deck without gaps or openings. Corner posts shall have the metal feet in place. On soft ground, wooden sills of at least 2- x 10-inch lumber or equivalent shall be provided. Scaffold planks shall be painted on each end to designate them as inspected planks to be used only for scaffolding and as marking for overhang limits.

5.2.1.2 When scaffold sections are erected, only scaffold pins or equivalent are to be used for the corner-post connections. (Do not use tie-wire or welding rods.) All scaffold posts shall be pinned together.

5.2.1.3 When casters are used for a rolling scaffold, they shall be locked except when the scaffold is being moved. No one shall be permitted on a scaffold while it is being moved. Casters shall be designed to carry the intended load of the scaffold.

5.2.1.4 Scaffold screw jacks shall be extended in accordance with manufacturers' recommendations, but in no case shall they be extended in excess of 12 inches. Whenever screw jacks and caster wheels are not used, metal base plates must be used for adequate base support. All supports are to be pinned and secured.

5.2.1.5 Scaffolds shall have solid footing and shall be erected so that vertical members are plumb and the platform is as horizontal as practical. Scaffold planks are to be cleated, wired down, or otherwise secured against accidental displacement.

5.2.1.6 Wedge shims shall not be used.

5.2.1.7 Work from incomplete scaffolds, when approved by the competent person, requires that the employee take added precautions.

5.2.1.8 Personal fall arrest system shall be used if handrails are missing, mid-rails are missing, the platform is incomplete, if other fall hazards exist, or if the scaffold in any way does not meet OSHA’s definition of a complete scaffold.

5.2.1.9 Horizontal braces of 2- x 4-inch lumber or equivalent shall be secured across corner posts when it is necessary to remove the


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diagonal braces. Diagonal braces shall not be removed from more than one section in a series of sections unless there are four braced sections between them.

5.2.1.10 Ladders shall be used if access to the scaffold platform is blocked or if the scaffold -climbing devices are more than 16 inches apart.

5.2.1.11 Before use, every scaffold higher than 125 feet must be inspected and approved by a registered professional engineer (trained in scaffolding) and the Construction HSE Manager. This inspection shall be documented and filed at the Project HSE office.

5.2.1.12 Toe boards shall be secured in a firm manner by interlocking at the corner posts with notches, wiring, nailing, U-clamping to the bearing members, or by use of approved commercial toe-board systems.

5.2.1.13 Employees gaining access to scaffolds shall have both hands free at all times and shall use the hand-over-hand method of climbing on the rungs. Employees shall not use toe boards as handholds or footholds to gain access to the platform.

5.2.2 Bracket Scaffold Requirements (on reinforcing steel wall installations):

5.2.2.1 Where more than one layer of horizontal bars has been placed, and conditions permit, the scaffold shall be secured to an inside horizontal bar.

5.2.2.2 If conditions do not permit attaching the bracket scaffold to an inside horizontal bar, the scaffold shall be secured with a minimum of three 3/8-inch diameter U-bolts attached to each end and the middle of the outer horizontal or vertical bar.

5.2.2.3 The horizontal reinforcing bar shall be secured to a vertical reinforcing bar that is either embedded in concrete or has been spliced by an approved method.

5.2.2.4 Each scaffold shall have a 4-foot x ¼-inch safety chain attached to the ends of the scaffold and secured to an inner rebar other than the bar that is supporting the scaffold.

5.2.2.5 Guardrails and toe boards shall be installed on all open sides and ends of scaffolds.

5.2.2.6 No more than three persons plus the necessary tools and equipment shall be permitted on a single scaffold section at any time. The load is not to go beyond the scaffold's designed capacity. Bracket scaffolds shall be constructed to support 1,550 pounds, and the capacity shall be posted on the scaffold.

5.2.2.7 Workers with safety harnesses shall have the lanyard secured above the point of operation, but under no circumstances shall it be attached to the scaffold.

5.2.2.8 Scaffolds may be painted "caution yellow" to give adjacent crane operators a better perspective when working close to scaffolds during the day or night.

5.2.3 Tube and Coupler (Tube-lox) Scaffolds

5.2.3.1 Posts shall be erected on required bases and maintained plumb.

5.2.3.2 Diagonal cross-bracing shall be provided as follows:


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• Horizontally every third section

• Vertically every fourth section

• Whenever posts are farther apart then 7 feet, the braces shall be at a 45-degree angle.

5.2.3.3 Runners shall be erected along each side versus the scaffold at the bottom and top of each section.

5.2.3.4 Bearers and braces shall extend past the posts a minimum of 4 inches but not more than 12 inches. Extensions of these shall not protrude into walking or climb ing areas.

5.2.4 Wood-Pole Scaffolds

5.2.4.1 Wood-pole scaffolding shall be designed and erected so that the load capacity is at least 75 psf on 6-foot spans or the safety factor is at least four times the intended load.

5.2.4.2 Before use, every wood pole scaffold higher than 60 feet shall be inspected and approved by a registered professional engineer (trained in scaffolding) and the Construction HSE Manager. This inspection shall be documented and filed at the Project HSE Office.

5.2.4.3 Foundations for pole scaffolds shall be capable of sustaining the pole loads without sinking or shifting. Wood sills must be a minimum of 2- x 10-inch lumber.

5.2.4.4 When poles are spliced, 4-foot wood splice plates or better shall be installed on at least two adjacent sides at the same height and length.

5.2.4.5 Pole scaffolds shall be secured at intervals of 25 feet vertically.

5.2.4.6 Diagonal and cross bracing of sufficient quantity and strength shall be used for scaffold erection to prevent any scaffold movement.

5.2.4.7 Where there is concern for combustible material in a work area, fire-resistant materials shall be used.

5.2.5 Trestle Scaffolds

5.2.5.1 Trestle scaffolds shall have at least a 6-inch ridgepole and should be limited to one level only.

5.3 Suspended Scaffold Requirements

5.3.1 Two-Point Suspended Scaffolds

5.3.1.1 These scaffolds shall have standard toe boards, mid-rails, and handrails.

5.3.1.2 A lifeline for each worker shall be provided and secured independently from the scaffold support lines.

5.3.1.3 Workers shall be tied off at all times when on the scaffold, using a triple sliding hitch or catch hardware.

5.3.1.4 Workers must be provided with a safe method of moving to and from the scaffold.

5.3.1.5 When moving the scaffold roof supports, workers must remain behind the guardrail or, if there is no guardrail, be tied off with a safety harness to an independent support.


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5.3.1.6 Protection for areas below the work shall be provided by using signs and barricades and screened staging, when applicable.

5.3.1.7 Workers shall not lower the scaffold below the point of three turns of the supporting cables on the drum of a swinging stage scaffold. Supporting cables shall be marked or painted to include limits.

5.3.1.8 Workers shall check the loading on the stage one foot off the ground before using it.

5.3.1.9 Outrigger beams, when required, should extend from 1 foot to 6 feet beyond the edge of the building, and the inboard length from the fulcrum should be at least 1½ times the outboard length from the fulcrum. A mechanical stop to retain the supporting cables shall be secured at the outer end of the outrigger.

5.3.1.10 If cornice hooks are used, each hook must be tied back to something solid. All hooks must be latched or moused.

5.3.2 Multilevel Suspended Scaffolds Requirements

5.3.2.1 Multilevel suspended scaffolds are used primarily for large-area vertical work such as installation of siding.

5.3.2.2 The rules listed for two-part suspended scaffolds apply here, except those rules for tie-off:

• Multilevel suspended scaffolds shall have two lifelines attached to the scaffold, independent of the supporting lines.

• Workers on the top stage will tie off with a safety harness to an independent lifeline.

• Workers on the lower stages will tie off with a safety harness to the scaffold itself.

5.3.3 Floats

5.3.3.1 Floats shall be installed in accordance with standard rigging practices, using a 1-inch manila rope, or equivalent. The supporting ropes shall be run diagonally under the platform from corner to corner.

5.3.3.2 Workers on floats shall secure themselves with a personal fall arrest system before getting on a float and untie after getting off a float.

5.3.3.3 Floats are to be constructed to the standard 4- x 6-foot size, and additional support shall be given to the platform with diagonal 1- x 4-inch braces on the bottom.

5.3.3.4 The platform shall be of ¾-inch plywood or equivalent, with 4- x 1-inch minimum edging on top to prevent items from rolling off.

5.3.4 Needle-Beam Scaffolds

5.3.4.1 Needle-beam scaffolds shall be supported by 1-inch manila rope, ½-inch wire rope cable, ¼-inch or high-test chain or equivalent, using a standard scaffold hitch or eye splice. Supports on the beam shall not to be more than 8 feet apart for the 4- x 6-inch timbers.

5.3.4.2 Needle-beams shall be at least 4- x 6-inch construction-grade lumber, with a minimum of 1,500-psi fiber stress.


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5.3.4.3 The platform span between needle-beams shall not exceed 8 feet when 2-inch scaffold plank is used. The overhang of scaffold planks shall not be less than 6 inches nor more than 12 inches.

5.3.4.4 Handrails and toe boards shall be used, and workers shall use a personal fall arrest system.

5.3.5 Boatswain's Chairs

5.3.5.1 Seats shall be a minimum of 12 inches x 24 inches and 2 inches thick. Splitting the board shall be prevented by cleats fastened on the underside.

5.3.5.2 Boatswain's chairs shall be suspended with the standard 5/8-inch nylon rope boatswain's sling through four corner holes.

5.3.5.3 The worker shall be tied off to an independent lifeline with a personal fall arrest.

5.4 Electric Hoist Platforms

5.4.1 When working platforms are suspended from electric hoist mechanisms and used to raise and lower workers, personal fall arrest system shall be used and attached to an independently secured lifeline. Such platforms shall have sides 42 inches in height above the platform. Before each use, the hoist mechanism shall be visually inspected and the load support checked at 1 foot off the ground. The cable and the lay of the cable on the spool shall be checked constantly.

5.5 Scaffold Erection and Dismantling Requirements

5.5.1 Pockets, pouches, and tool belts shall be used to carry the necessary tools for the work.

5.5.2 Scaffold members shall be hoisted or lowered with a hand line or passed from hand to hand. Throwing items up to coworkers or dropping them is not per-mitted.

5.5.3 Constant fall prevention measures must be main tained. Provisions shall be established for using a safety harness and working on firm scaffold decks when this can be done safely.

5.5.4 Scaffold feet shall be established on a firm and level base of support.

5.5.5 When scaffolds are to be secured to fixed structures or outriggers are to be used, they shall be installed as soon as possible. When dismantling a scaffold, these should be left on as long as practical.

5.5.6 The coordination of this activity with surrounding operations and environment shall be given prior consideration.

5.6 Mounting and Dismounting Scaffold Requirements

5.6.1 Do not carry objects in hands, but keep both hands empty for climbing handholds.

5.6.2 Step only on secured ladder or access rungs.

5.6.3 Give full attention to stability while getting on and off the working platform. Do not use the toe board as a handhold or foothold.

5.6.4 Pay attention to each step and handhold; most falls occur near the top of the ladder or near the bottom.


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5.7 Scaffold Tagging

5.7.1 General Scaffold Tagging Requirements

5.7.1.1 A green scaffold tag (DBN-F4—Sample Complete Scaffold Tag) designates a complete scaffold as defined by the manufacturer and/or OSHA.

5.7.1.2 A yellow scaffold tag (DBN-F4—Sample Modified Scaffold Tag) designates a scaffold that is safe to use but has been altered to suit a specific job. A yellow scaffold tag shall detail any hazards (incomplete handrail, incomplete decking, low-overhead, limited climbing clearance, etc.) and the necessary protective measures.

5.7.1.3 If a scaffold is in the process of being erected, modified, or disman-tled, it shall have a red tag (DBN-F4—Sample Scaffold Erected, Modified, or Dismantled Tag). A scaffold that has a red scaffold tag shall be considered unsafe and shall not be used.

5.7.1.4 If a scaffold has been damaged or is defective, a red tag must be attached.

5.7.2 Installation and Removal of Scaffold Tags

5.7.2.1 A competent person shall determine whether a usable scaffold receives a yellow or a green tag. The Competent Person shall be responsible for completing all pertinent information on the tag and affixing the tag.

5.7.2.2 The scaffold tag shall be affixed to each scaffold access ladder approximately 5 feet, 6 inches from its base, where it will not interfere with normal access.

5.7.2.3 Anyone may remove a green or yellow scaffold tag if the scaffold does not meet the requirements, i.e., a scaffold which has been damaged, has been improperly modified, is missing components, or is deficient in any safety aspect. A red tag will be used in these circumstances. Only a competent person in scaffold erection may place a yellow or green scaffold tag on a scaffold.

5.7.2.4 After a scaffold has been repaired, a scaffold competent person shall inspect it and re-tag it accordingly.

5.7.2.5 Daily inspections shall be performed by a Competent Person to ensure that all scaffolds are in safe condition and tags are legible.

5.8 Inspection and Testing - Scaffold Planks

5.8.1 Scaffold planks shall be inspected and tested by a designated competent person upon receipt and before use as a platform. Users shall examine planks visually before each use.

5.8.2 Examine planks for knots, excessive grain slope, shakes, decay, dry rot, and other defects.

5.8.3 Density of lumber should be equivalent to Douglas fir and capable of supporting four times the intended load. Moisture content should not exceed 20 percent.

5.8.4 All scaffold planks shall be scaffold grade or equivalent as recognized by approved grading rules.


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5.8.5 Planks shall be 2- x 10 inch or 2- x 12-inch heavy- duty (75 psi on 6 foot span lumber).

5.8.6 Discard the plank as a scaffold plank if evidence of a defect is noted.

5.8.7 Requirements 4.8.3 and 4.8.5 above should be specified on the purchase requisition.

5.9 Special Scaffolding

5.9.1 Any scaffold that must be specially adapted to the work place where the requirements above cannot be met must be approved by a qualified registered professional engineer, the Construction Manager, the Construction HSE Manager and the designated Competent Person.

5.10 Storage of Scaffolding

5.10.1 Scaffold materials shall be temporarily stored in a manner that will protect and prevent damage to them.

5.10.2 Scaffold materials shall not be left in work areas where they obstruct traffic and/or cause fire hazards.


None


HSE Practice 17 Powered Aerial Work Platforms

® POWERED AERIAL WORK PLATFORMS PRACTICE 17 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice provides requirements for operating and using aerial lifts, vehicle-mounted work platforms, or powered platforms.

2.0 References

2.1 ANSI/SIA A92.2-1990—Vehicle-Mounted Elevating and Rotating Platforms

2.2 ANSI/SIA A92.3-1990—Manually Propelled Elevating Aerial Platforms

2.3 ANSI/SIA A92.5-1990—Boom Supported Elevating Work Platforms

2.4 ANSI/SIA A92.6-1990—Self-Propelled Elevating Work Platforms

2.5 ANSI/SIA A92.7-1990—Airline Ground Support Vehicle -Mounted Vertical Lift Devices

2.6 ANSI/SIA A92.8-1993—Vehicle-Mounted Bridge Inspection and Maintenance Devices

2.7 ANSI/SIA A92.9-1993—Mast-Climbing Work Platforms

2.8 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart L (1926.453)

2.9 SASO 328/1988—Industrial Safety and Health Regulations: Equipment—Powered Platforms and Vehicle -Mounted Work Platforms

3.0 Definitions

3.1 Competent Person - a person capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

3.2 Powered Aerial Work Platforms - a mechanical work platform for taking workers to their work location. These can include scissor lifts, boom lifts, single person lifts, multi- person lifts, boom trucks, etc. These do not include suspended manbaskets.

4.0 Process

4.1 Requirements

4.1.1 Employees who work with aerial lifts, vehicle-mounted work platforms, or powered platforms shall follow safe practices established by this Practice, as well as those established by the manufacturer of the equipment.

4.2 Inspection

4.2.1 Inspection of powered aerial work platforms will be made in accordance with manufacturers' recommendations and Company, State, and Federal inspection require ments and regulations and documented.

4.2.2 Each aerial lift, vehicle-mounted work platforms, or powered platform will be inspected prior to being allowed on-site.

4.2.3 Lift controls shall be tested each day prior to use to determine that such controls are in safe working condition.

4.3 Operation

4.3.1 Employees shall not be permitted to use or operate lifts or platforms unless they have been trained and licensed by the designated competent person in the use and operation of such equipment.

4.3.2 Copies of all training and licensing shall be maintained on-site in the Project HSE files in accordance with Section 4.4 of this Practice.

4.3.3 Powered aerial work platforms being used near electrical distribution or


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transmission lines shall comply with standards set forth in OSHA 29 CFR 1926. The following clearances will be made at a minimum:

4.3.3.1 For lines rated at 50 kv or less, the minimum clearance between the lines and any part of the aerial lift shall be at least 3 meters.

4.3.3.2 When the lines are rated in excess of 50 kv, the minimum clearance between the lines and any part of the aerial lift shall be at least 3 meters plus 10 mm for each kilovolt in excess of 50 kv, or twice the length of the line insulator, but never less than 3 meters.

4.3.4 Equipment shall not be moved when the boom is elevated in a working position with workers in the basket or on the platform unless equipment was manufactured to perform these functions as stated in writing by the manufacturer.

4.3.5 Manufacturers' specifications and limitations shall be followed.

4.3.6 Employees working from the basket with the lanyard attached to the equipment shall wear safety harnesses. Under no circumstances shall the lanyard be attached to a pole, the structure, or other equipment.

4.3.7 Employees who tamper with controls and/or bypass safety devices (such as dead-man switches, etc.) are subject to termination.

4.3.8 Mobile and self-propelled lifts and platforms shall not be used in outside work activities when severe wind conditions exist.

4.3.9 Extended boom aerial work platforms shall not be exposed to "wind loading" while elevated and fully extended.

4.3.10 Work activities from aerial lifts or work platforms in outside areas are prohibited during electrical storms.

4.3.11 Outriggers must be used when available with equipment.

4.3.12 No work may be performed from handrails of platforms. No alterations may be made to the equipment unless the manufacturer approves them in writing.

4.3.13 Aerial lifts may be "field modified" for uses other than those intended by the manufacturer provided the modification has been certified in writing by the manufacturer or by any other equivalent entity, such as a nationally recognized testing laboratory, to be in conformity with all applicable provisions of ANSI A92.2-1969 and this section and to be at least as safe as the equipment was before modification.

4.3.14 Lift controls shall be tested each day prior to use to determine that such controls are in safe working condition.

4.4 Operator Certification and Training

4.4.1 The operator's knowledge of operating and safety procedures and requirements for this equipment must be verified by a practical test and by observation of his or her performance during the first month of operation.

4.4.2 A competent person (such as an equipment superintendent) shall be designated at each project by the Construction Manager (CM). The competent person shall administer the practical test to determine an applicant's/employee’s operating ability and if deemed competent in the safe operation of the equipment a license will be issued to the employee.

4.4.3 A practical test shall be used to determine an applicant's/employee’s operating ability on each type and model of equipment to be operated.


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4.4.4 Training will be provided for each operator in compliance with equipment operator training Procedures that are specified by the Company.

4.5 Specific requirements 4.5.1 Ladder trucks and tower trucks. Aerial ladders shall be secured in the lower

traveling position by the locking device on top of the truck cab, and the manually operated device at the base of the ladder before the truck is moved for highway travel.

4.5.2 Extensible and articulating boom platforms 4.5.2.1 Lift controls shall be tested each day before use to determine that

such controls are in safe working condition. 4.5.2.2 Only authorized persons shall operate an aerial lift. 4.5.2.3 Belting off to an adjacent pole, structure, or equipment while

working from an aerial lift shall not be permitted. 4.5.2.4 Employees shall always stand firmly on the floor of the basket, and

shall not sit or climb on the edge of the basket or use planks, ladders, or other devices for a work position.

4.5.2.5 Boom and basket load limits specified by the manufacturer shall not be exceeded.

4.5.2.6 The brakes shall be set and when outriggers are used, they shall be positioned on pads or a solid surface. Wheel chocks shall be installed before using an aerial lift on an incline, provided they can be safely installed.

4.5.2.7 An aerial lift truck shall not be moved when the boom is elevated in a working position with men in the basket, except for equipment that is specifically designed for this type of operation.

4.5.2.8 Articulating boom and extensible boom platforms, primarily designed as personnel carriers, shall have both platform (upper) and lower controls. Upper controls shall be in or beside the platform within easy reach of the operator. Lower controls shall provide for overriding the upper controls. Controls shall be plainly marked as to their function. Lower level controls shall not be operated unless permission has been obtained from the employee in the lift, except in case of emergency.

4.5.2.9 Climbers shall not be worn while performing work from an aerial lift.

4.5.2.10 The insulated portion of an aerial lift shall not be altered in any manner that might reduce its insulating value.

4.5.2.11 Before moving an aerial lift for travel, the boom(s) shall be inspected to see that it is properly cradled and outriggers are in stowed position.

4.5.3 Electrical tests. All electrical tests shall conform to the requirements of ANSI A92.2-1969 section 5. However equivalent d.c.; voltage tests may be used in lieu of the a.c. voltage specified in A92.2-1969; d.c. voltage tests which are approved by the equipment manufacturer or equivalent entity shall be considered an equivalent.

4.5.4 Emergency Communication 4.5.4.1 Communication equipment for use in an emergency shall be

provided for each powered platform. 5 Record Retention Training and testing record of each employee designated as a Competent Person and as an equipment operator shall be kept on file in the project's HSE office until project closeout.


HSE Practice 18 Forklifts & Powered Industrial Trucks

® FORKLIFTS & POWERED INDUSTRIAL TRUCKS PRACTICE 18 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice establishes requirements for safe operation of forklifts and other powered industrial trucks.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart N (1926.600)

2.2 Title 29 Code of Federal Regulations (CFR) Part 1910 Subpart N (1910.178) 2.3 SSA 325 Industrial Safety and Health Regulations Part 6 – Equipment-Material Handling

3.0 Definitions


4.0 Process

4.1 General Requirements

4.1.1. All new powered industrial trucks shall meet standards established by ANSI.

4.1.2. All nameplates and markings shall remain in place and shall be legible.

4.1.3. All forklifts shall be inspected daily using DBN-F12 - Forklift Inspection Report.

4.1.4. Only trained and authorized operators shall be permitted to operate powered industrial trucks. (Operators shall be trained in the safe operation of each powered industrial truck used at the project or facility.)

4.1.5. No person shall ride on the lifting mechanism of a forklift or use the forklift as a work platform. Manufacturer-approved personnel baskets may be used if all manufacturer's specifications and limitations are met.

4.1.6. If a powered industrial truck is found to be in need of repair, is defective, or is unsafe in any way, the truck shall be taken out of service until it has been restored to safe operating condition. (All repairs shall be made by authorized personnel.)

4.1.7. All equipment left unattended at night, adjacent to a highway in normal use, or adjacent to construction areas where work is in progress, shall have appropriate lights or reflectors, or barricades equipped with appropriate lights or reflectors, to identify the location of the equipment.

4.1.8. Heavy machinery, equipment, or parts thereof, which are suspended or held aloft by use of slings, hoists, or jacks shall be substantially blocked or cribbed to prevent falling or shifting before employees are permitted to work under or between them. Bulldozer and scraper blades, end-loader buckets, dump bodies, and similar equipment, shall be either fully lowered or blocked when being repaired or when not in use. All controls shall be in a neutral position, with the motors stopped and brakes set, unless work being performed requires otherwise.

4.1.9. Whenever the equipment is parked, the parking brake shall be set. Equipment parked on inclines shall have the wheels chocked and the parking brake set.

4.1.10. All cab glass shall be safety glass, or equivalent, that introduces no visible distortion affecting the safe operation of any machine.

4.1.11. All equipment shall comply with the requirements of 29 CFR 1926.550(a)(15) when working or being moved near power lines or energized transmitters.

4.1.12. All vehicles shall have a service brake system, an emergency brake system, and a parking brake system. These systems may use common components, and shall be maintained in operable condition.


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4.1.13. Whenever visibility conditions warrant additional light, all vehicles, or combinations of vehicles, in use shall be equipped with at least two headlights and two taillights in operable condition.

4.1.14. All vehicles, or combination of vehicles, shall have brake lights in operable condition regardless of light conditions.

4.1.15. All vehicles shall be equipped with an adequate audible warning device at the operator's station and in an operable condition.

4.1.16. No motor vehicle equipment having an obstructed view to the rear shall be used unless:

4.1.16.1. The vehicle has a reverse signal alarm audible above the surrounding noise level or:

4.1.16.2. The vehicle is backed up only when an observer signals that it is safe to do so.

4.1.17. All vehicles with cabs shall be equipped with windshields and powered wipers. Cracked and broken glass shall be replaced. Vehicles operating in areas or under conditions that cause fogging or frosting of the windshields shall be equipped with operable defogging or defrosting devices.

4.1.18. All haulage vehicles, whose payload is loaded by means of cranes, power shovels, loaders, or similar equipment, shall have a cab shield and/or canopy adequate to protect the operator from shifting or falling materials.

4.1.19. Tools and material shall be secured to prevent movement when transported in the same compartment with employees.

4.1.20. Vehicles used to transport employees shall have seats firmly secured and adequate for the number of employees to be carried.

4.1.21. Seat belts and anchorages meeting the requirements of 49 CFR Part 571 (Department of Transportation, Federal Motor Vehicle Safety Standards) shall be installed in all motor vehicles.

4.1.22. Trucks with dump bodies shall be equipped with positive means of support, permanently attached, and capable of being locked in position to prevent accidental lowering of the body while maintenance or inspection work is being done.

4.1.23. Operating levers controlling hoisting or dumping devices on haulage bodies shall be equipped with a latch or other device that will prevent accidental starting or tripping of the mechanism.

4.1.24. Trip handles for tailgates of dump trucks shall be so arranged that, in dumping, the operator will be in the clear.

4.1.25. All rubber-tired motor vehicle equipment shall be equipped with fenders

4.1.26. Mud flaps may be used in lieu of fenders whenever motor vehicle equipment is not designed for fenders.

4.1.27. All vehicles in use shall be checked at the beginning of each shift to assure that the following parts, equipment, and accessories are in safe operating condition and free of apparent damage that could cause failure while in use: service brakes, including trailer brake connections; parking system (hand brake); emergency stopping system (brakes); tires; horn; steering mechanism; coupling devices; seat belts; operating controls; and safety devices. All defects shall be corrected before the vehicle is placed in service. These requirements also apply


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to equipment such as lights, reflectors, windshield wipers, defrosters, fire extinguishers, etc., where such equipment is necessary.

4.1.28. Each forklift of powered industrial truck will be inspected prior to being allowed on-site.

4.1.29. Controls shall be tested each day prior to use to determine that such controls are in safe working condition.

4.1.30. Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturer’s prior written approval. Capacity, operation and maintenance instruction, plates, tags, or decals shall be changed accordingly.

4.1.31. Concentration levels of carbon monoxide gas created by powered industrial truck operations shall not exceed the levels specified in Industrial Safety and Health Regulation – Part 4: Hazardous Materials —Toxic and Hazardous Substances.

4.2 Earthmoving equipment

4.2.1. Seat belts

4.2.1.1. Seat belts shall be provided on all equipment covered by this section and shall meet the requirements of the Society of Automotive Engineers, J386-1969, Seat Belts for Construction Equipment. Seat belts for agricultural and light industrial tractors shall meet the seat belt requirements of Society of Automotive Engineers J333a-1970, Operator Protection for Agricultural and Light Industrial Tractors.

4.2.1.2. Seat belts need not be provided for equipment that is designed only for standup operation.

4.2.1.3. Seat belts need not be provided for equipment that does not have rollover protective structure (ROPS) or adequate canopy protection.

4.2.2. Access roadways and grades

4.2.2.1. No employer shall move or cause to be moved construction equipment or vehicles upon any access roadway or grade unless the access roadway or grade is constructed and maintained to accommodate safely the movement of the equipment and vehicles involved.

4.2.2.2. Every emergency access ramp and berm used by an employer shall be constructed to restrain and control runaway vehicles.

4.2.3. All earthmoving equipment mentioned in this 1926.602(a) shall have a service braking system capable of stopping and holding the equipment fully loaded, as specified in Society of Automotive Engineers SAE-J237, Loader Dozer-1971, J236, Graders-1971, and J319b, Scrapers-1971. Brake systems for self-propelled rubber-tired off-highway equipment manufactured after January 1, 1972 shall meet the applicable minimum performance criteria set forth in the following Society of Automotive Engineers Recommended Practices:

• Self-Propelled Scrapers—SAE J319b -1971

• Self-Propelled Graders—SAE J236-1971

• Trucks and Wagons—SAE J166-1971


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• Front End Loaders and Dozers—SAE J237-1971.

4.2.4. Pneumatic -tired earth-moving haulage equipment (trucks, scrapers, tractors, and trailing units) whose maximum speed exceeds 15 miles per hour, shall be equipped with fenders on all wheels to meet the requirements of Society of Automotive Engineers SAE J321a-1970, Fenders for Pneumatic-Tired Earthmoving Haulage Equipment.

4.2.5. Audible alarms.

4.2.5.1. All bi-directional machines, such as rollers, compacters, front-end loaders, bulldozers, and similar equipment, shall be equipped with a horn, distinguishable from the surrounding noise level, which shall be operated as needed when the machine is moving in either direction. The horn shall be maintained in an operative condition.

4.2.5.2. No employer shall permit earthmoving or compacting equipment that has an obstructed view to the rear to be used in reverse gear unless the equipment has in operation a reverse signal alarm distinguishable from the surrounding noise level or an employee signals that it is safe to do so.

4.2.6. Scissor points on all front-end loaders, which constitute a hazard to the operator during normal operation, shall be guarded.

4.3 Excavating and other equipment

4.3.1. Tractors shall have seat belts as required for the operators when seated in the norma l seating arrangement for tractor operation, even though backhoes, breakers, or other similar attachments are used on these machines for excavating or other work.

4.3.2. The safety requirements, ratios, or limitations applicable to machines or attachment usage covered in Power Crane and Shovel Associations Standards No. 1 and No. 2 of 1968, and No. 3 of 1969, shall be complied with, and shall apply to cranes, machines, and attachments.

4.4 Lifting and hauling equipment (other than equipment covered under this practice)

4.4.1. Industrial trucks shall meet the requirements of 29 CFR 1926.600 and the following:

4.4.1.1. Lift trucks, stackers, etc., shall have the rated capacity clearly posted on the vehicle clearly visible to the operator. When auxiliary removable counterweights are provided by the manufacturer, corresponding alternate rated capacities also shall be clearly shown on the vehicle. These ratings shall not be exceeded.

4.4.1.2. No modifications or additions that affect the capacity or safe operation of the equipment shall be made without the manufacturer's written approval. If such modifications or changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly. In no case shall the original safety factor of the equipment be reduced.

4.4.1.3. If a load is lifted by two or more trucks working in unison, the proportion of the total load carried by any one truck shall not exceed its capacity.

4.4.1.4. Steering or spinner knobs shall not be attached to the steering wheel unless the steering mechanis m is of a type that prevents road


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reactions from causing the steering hand wheel to spin. The steering knob shall be mounted within the periphery of the wheel.

4.4.1.5. All high lift rider industrial trucks shall be equipped with overhead guards which meet the configuration and structural requirements as defined in paragraph 421 of American National Standards Institute B56.1-1969, Safety Standards for Powered Industrial Trucks.

4.4.1.6. All industrial trucks in use shall meet the applicable requirements of design, construction, stability, inspection, testing, maintenance, and operation, as defined in American National Standards Institute B56.1-1969, Safety Standards for Powered Industrial Trucks.

4.4.1.7. Unauthorized personnel shall not be permitted to ride on powered industrial trucks. A safe place to ride shall be provided where riding of trucks is authorized.

4.4.1.8. Whenever a truck is equipped with vertical only, or vertical and horizontal controls elevatable with the lifting carriage or forks for lifting personnel, the following additional precautions shall be taken for the protection of personnel being elevated.

4.4.1.8.1. Use of a safety platform firmly secured to the lifting carriage and/or forks.

4.4.1.8.2. Means shall be provided whereby personnel on the platform can shut off power to the truck.

4.4.1.8.3. Such protection from falling objects, as indicated necessary by the operating conditions shall be provided.

4.4.1.9. Wheel stops or other recognized positive protection shall be provided to prevent railroad cars from moving during loading or unloading operations.

4.4.1.10. Fixed jacks may be necessary to support a semi-trailer and prevent upending during the loading or unloading when the trailer is not coupled to a tractor.

4.4.1.11. Positive protection shall be provided to prevent railroad cars from being moved while dock boards or bridge plates are in position.

4.5 Forklift Training

4.5.1. Each operator shall be individually responsible for the control of the forklift being used, safety, operation, and maintenance. Each operator shall be trained in the safe operation, inspection, maintenance, and safety features of the forklift used.

4.5.2. The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training.

4.5.3. Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training.

4.5.4. Training program implementation

4.5.4.1. Trainees may operate a powered industrial truck only:


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4.5.4.1.1. Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and

4.5.4.1.2. Where such operation does not endanger the trainee or other employees.

4.5.4.2. Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

4.5.4.3. All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

4.5.5. Training program content

4.5.5.1. Powered industrial truck operators shall receive initial training in the following topics, except in topics that the employer can demonstrate are not applicable to safe operation of the truck in the employer's workplace.

4.5.5.2. Truck-related topics:

4.5.5.2.1. Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;

4.5.5.2.2. Differences between the truck and the automobile;

4.5.5.2.3. Truck controls and instrumentation: where they are located, what they do, and how they work;

4.5.5.2.4. Engine or motor operation;

4.5.5.2.5. Steering and maneuvering;

4.5.5.2.6. Visibility (including restrictions due to loading);

4.5.5.2.7. Fork and attachment adaptation, operation, and use limitations;

4.5.5.2.8. Vehicle capacity;

4.5.5.2.9. Vehicle stability;

4.5.5.2.10. Any vehicle inspection and maintenance that the operator will be required to perform;

4.5.5.2.11. Refueling and/or charging and recharging of batteries;

4.5.5.2.12. Operating limitations;

4.5.5.2.13. Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle that the employee is being trained to operate.

4.5.5.3. Workplace-related topics:

4.5.5.3.1. Surface conditions where the vehicle will be operated;


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4.5.5.3.2. Composition of loads to be carried and load stability;

4.5.5.3.3. Load manipulation, stacking, and unstacking;

4.5.5.3.4. Pedestrian traffic in areas where the vehicle will be operated;

4.5.5.3.5. Narrow aisles and other restricted places where the vehicle will be operated;

4.5.5.3.6. Hazardous (classified) locations where the vehicle will be operated;

4.5.5.3.7. Ramps and other sloped surfaces that could affect the vehicle's stability;

4.5.5.3.8. Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust;

4.5.5.3.9. Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

4.5.6. Refresher training and evaluation

4.5.6.1. Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

4.5.6.2. Refresher training in relevant topics shall be provided to the operator when:

4.5.6.2.1. The operator has been observed to operate the vehicle in an unsafe manner;

4.5.6.2.2. The operator has been involved in an accident or near-miss incident;

4.5.6.2.3. The operator has received an evaluation that reveals that the operator is not operating the truck safely;

4.5.6.2.4. The operator is assigned to drive a different type of truck; or

4.5.6.2.5. A condition in the workplace changes in a manner that could affect safe operation of the truck.

4.5.6.3. An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.

4.5.7. If an operator has previously received training in a topic specified this practice, and such training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.

4.5.8. The employer shall certify that each operator has been trained and evaluated as required by this Practice. The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.


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4.5.9. Operators shall inspect the equipment before each shift’s use. DBN-F12 shall be used to document forklift equipment inspections.

4.5.10. An equipment superintendent or general foreman shall verify that an operator is qualified to operate each piece/type of equipment that s/he is required to operate.

4.5.11. Operators shall adhere to the following basic rules:

4.5.11.1. Keep to the right on roadways and in wide aisles.

4.5.11.2. Drive at a reasonable rate of speed. Do not exceed posted speed limits and operate at lower speeds when necessary due to conditions of the work area.

4.5.11.3. Slow down at intersections, corners, ramps, and other danger points.

4.5.11.4. Use the horn in blind spots.

4.5.11.5. Give pedestrians the right of way.

4.5.11.6. Maintain a clear field of vision.

4.5.11.7. When parking, do not block traffic.


Completed inspection forms shall be filed in the Project HSE office for the duration of the project.


HSE Practice 19 Fall Protection

® FALL PROTECTION PRACTICE 19 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice provides the minimum requirements to ensure the safety of employees performing work in elevated areas.

2.0 References

2.1 Title 29 Code of Federal Regulation (CFR) Part 1926 Subpart M (1926.500 - 1926.503)

2.2 ANSI A10.14-1991—Requirements for Safety Belts, Harnesses, Lanyards, and Lifelines for Construction and Demolition Use.

2.3 SASO 322/1994—Industrial Safety and Health Regulations: Personal Protective Equipment

3.0 Definitions

3.1 100-Percent Fall Protection - Protecting the worker from the possibil ity of a fall at all times. This includes when moving or stationary. 100-percent fall protection includes guardrail systems, nets, tie off, catch platforms, etc.

3.2 100-Percent Tie Off - Using safety harnesses with lanyard(s) tied-off at all times. Usually this means using two lanyards.

3.3 Anchorage - A secure point of attachment for lifelines, lanyards, or deceleration devices. The anchorage shall be capable of withstanding the forces specified in this Practice.

3.4 Approved - For the purpose of this Practice; tested and certified by the manufacturer or any recognized national testing laboratory to possess the strength requirements specified in this section.

3.5 Full Body Harness - A configuration of connected straps to distribute a fall arresting force over at least the thighs, shoulders, and pelvis, with provisions for attaching a lanyard, lifeline, or deceleration device.

3.6 Fall Arrest System- A full body harness and lanyard that, is attached to a horizontal or vertical lifeline that is properly secured to an anchorage(s).

3.7 Catch Platform - A platform with guardrails set up next to a fall edge to "catch" fallen employees. The platform shall be within six vertical feet of the edge with no openings an employee could fall through.

3.8 Catenary Line - see 3.019. - Horizontal Lifeline, below.

3.9 Competent Person - An individual knowledgeable of fall protection equipment. This knowledge includes the manufacturer's recommendations and instructions for proper use, inspection, and maintenance; and who is capable of identifying existing and potential fall hazards. A Competent Person has the authority to take prompt corrective action to eliminate those hazards and is knowledgeable of the rules contained in this section regarding the erection, use, inspection, and maintenance of fall protection equipment and systems.

3.10 Control Zone - The area between the warning line and the unprotected sides and edges of a building/structure floor or roof surface.

3.11 Deceleration Device - Any mechanism, such as a rope grab, rip-stitch lanyard, or automatic self-retracting life line, which serves to dissipate more energy during fall arrest than a standard line or strap-webbing lanyard.

3.12 Drop Line - An independent lifeline secured to an upper anchorage for the purpose of attaching a lanyard or a fall protection device. This line must be at least a ¾-inch manila rope or a ½-inch nylon rope.


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3.13 Fall Hazard - Where the potential for an employee to fall, (i.e., to a level 6 feet or more below, 6 feet or more on the same level or into hazardous machinery or equipment).

3.14 Fall Protection Work Plan - A written document in which the employer identifies all areas on the jobsite where a fall hazard exists. The Plan describes the method or methods of fall protection to be used to protect employees, and includes the procedures governing the installation, use, inspection, and removal of the fall protection methods that are selected by the employer.

3.15 Fall-Restraint System - An approved device and any necessary components that function together to restrain an employee in such a manner as to prevent that employee from falling to a lower level. When standard guardrails are selected, compliance with applicable sections governing their construction and use shall constitute approval.

3.16 Fall Distance - The actual distance between the location of an employee’s harness attachment point and the location of the attachment point when it comes to a full stop.

3.17 Hardware - Snap hooks, D-rings, buckles, carabineers, adjusters, and O-rings that are used to attach the components of a fall protection system together.

3.18 Hole - A gap or void 2 inches or more in its least dimension in a floor, roof, or other walking/working surface.

3.19 Horizontal Lifeline - A rail, wire rope, or synthetic rope that is installed in a horizontal plane between two anchorage points and used for attachment of a worker's lanyard or lifeline device while moving horizontally.

3.20 Lanyard - A flexible line of webbing, rope, or cable used to secure a harness to a lifeline or an anchorage point usually 2, 4, or 6 feet long.

3.21 Leading Edge - Means the advancing edge of a floor, roof, or formwork that changes location as additional floor, roof, or formwork sections are placed, formed, or constructed. Leading edges not actively under construction are considered to be "unprotected sides and edges," and positive methods of fall arrest or fall restraint shall be required to protect exposed workers.

3.22 Lifeline - A vertical line from a fixed anchorage or between two horizontal anchorage points, independent of walking or working surfaces, to which a lanyard or device is secured. Lifeline as referred to in this text is one that is part of a fall protection system used as back up for an elevated worker.

3.23 Locking Snap Hook - A connecting snap hook that requires two separate forces to open the gate, one to deactivate the gatekeeper and a second to depress and open the gate which automatically closes when released; used to minimize roll-out or accidental disengagement.

3.24 Low Pitched Roof - A roof having a slope equal to or less than 4 in 12.

3.25 Positioning Belt - Single or multiple strap that can be secured around the worker's body to hold the user in a work position, for example, a lineman's belt, a re-bar belt, or a saddle belt.

3.26 Restraint Line - A line from a fixed anchorage or between two anchorage points to which an employee is secured in such a way as to prevent the worker from falling.

3.27 Roll-Out - Unintentional disengagement of a snap hook caused by the gate being depressed under torque or contact while twisting or turn ing.

3.28 Rope Grab - A fall arresting device that is designed to move up or down a lifeline suspended from a fixed overhead or horizontal anchorage point, or lifeline, to which the harness is attached. In the event of a fall, the rope grab locks onto the lifeline rope


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through compression to arrest the fall. The use of a rope grab device is restricted for fall restraint applications.

3.29 Safety Line - see 3.019. - Horizontal lifeline, above.

3.30 Safety Monitor System - A system of fall restraint used in conjunction with a warning line system only. A Competent Person, as defined above under Competent Person, having no additional duties, monitors the proximity of workers to the fall hazard when working between the warning line and the unprotected sides and edges, including the leading edge of a low-pitched roof or walking/working surface.

3.31 Self-Retracting Lifeline - A deceleration device which, contains a drum-wound line that may be slowly extracted from, or retracted onto, the drum under slight tension during normal employee movement, and which after onset of a fall, automatically locks the drum and arrests the fall.

3.32 Shock-Absorbing Lanyard - A flexible line of webbing, cable, or rope used to secure a body belt or harness to a lifeline or anchorage point that has an integral shock absorber.

3.33 Single -Action Snap Hook - A connecting snap hook that requires a single force to open the gate, which automatically closes when released.

3.34 Snap Hook - A self-closing connecting device with a gatekeeper latch or similar arrangement that will remain closed until manually opened. This includes single-action snap hooks that open when the gatekeeper is depressed and double-action snap hooks that require a second action on a gatekeeper before the gate can be opened.

3.35 Static Line - see 3.019. - Horizontal Lifeline, above.

3.36 Strength Member - Any component of a fall protection system that could be subject to loading in the event of a fall.

3.37 Steep Roof - A roof having a slope greater than 4 in 12.

3.38 Unprotected Sides and Edges - Any side or edge (except at entrances to points of access) of a floor, roof, ramp, or runway where there is no wall or guardrail system as defined in this section.

3.39 Work Area - That portion of a walking/working surface where job duties are being performed.

4.0 Process

4.1 Requirements

4.1.1 It shall be the policy and intent of FLUOR ARABIA that employees shall be protected from fall hazards by using 100% fall protection as defined in 3.0 above.

4.1.2 Before starting a project, construction management shall make an initial survey of the types of fall hazards expected and develop a Plan for providing the kind and number of safeguards that shall protect employees from these fall hazards. A fall exposure occurs when an employee's feet are six (6) feet or more above a work area. The Plan shall meet the requirements of Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart M.

4.2 Fall Protection Plan

4.2.1 This written fall protection plan shall be updated quarterly.

4.2.2 The fall protection Plan covers:


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4.2.2.1 This procedure establishes minimum requirements for working at unguarded elevated work locations that are six (6) feet or more above floor or grade level.

4.2.2.2 Work sites adjacent to pits, trenches, docks and / or on platforms or catwalks where the fall potential is four (4) feet or greater.

4.2.2.3 Into openings of tanks, sewer openings, etc.

4.2.2.4 This procedure applies to all LGA employees and sub-contractors. It covers activities such as, but not limited to work in or on:

• Pipe racks

• Sloped roofs

• Unguarded scaffolding

• Suspended scaffolds

• Tank tops

• Process structures without guarded work platforms

• Ladders

4.2.3 Minimum Requirements

4.2.3.1 In order to protect against falls, the key factor is the recognition of hazards. Falls are generally a result of poor work practices, unsafe conditions or a combination of the same.

4.2.3.2 Fall prevention must be established by means of hazard analysis in the planning stage of a project and / or task. Examples of items to be analyzed are, but not limited to the following:

• Layout and arrangement of tools and / or equipment.

• Integrity of aisles, floors, entrances, exits and accessways

• Proper handrails, guardrails

• Exposure to weather conditions and illumination

• Methods of personnel / material hoisting equipment

• Utilization and effectiveness of fall protection systems or a combination of systems

4.2.3.3 Same Level Fall Protection

4.02.3.3.1. Good housekeeping is the key to the prevention of same level falls

4.02.3.3.2. Usable and waste material shall be stored out of pathways and shall not congest a work area

4.02.3.3.3. Surfaces shall be kept free of slipping hazards

4.02.3.3.4. Floor holes and openings shall be covered as not to create tripping hazards. Hole covers must be capable of supporting at least twice the maximum load that may be imposed on them. Covers must be secured and marked “HOLE” or “COVER”.

4.02.3.3.5. Materials shall not be allowed to collect around worktables, desks, threading machines, etc.


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4.02.3.3.6. Only lanyards which have both shock absorbing systems and double-locking snap hooks should be used

4.02.3.3.7. Personal fall protection must be used when an exposure to a free fall hazard cannot be prevented by the use of permanent or semi-permanent guarded platforms and the work location is at a height of six (6) feet or greater.

4.02.3.3.8. Personal fall protection must be used when erecting, moving or dismantling scaffolding at heights of six (6) feet or greater.

4.02.3.3.9. Personal fall protection must be worn at all times when utilizing any scaffold system, even if the scaffold is tagged as acceptable for use without fall protection (typically called a “Green Tag Scaffold”). Although the Green Tag scaffold indicates otherwise, FLUOR ARABIA requires that a user remains continually tied off while using any scaffold.

4.02.3.3.10. Personal fall protection must be used and anchored to a designated anchor point when using, traveling on or working from mobile work platforms such as:

• Manlifts

• Scissor-lifts and

• Crane baskets

4.02.3.3.11. Personal fall protection must be used as required by other policies such as Confined Space Entry.

4.02.3.3.12. All JHA’s should reference the information in this policy when elevated work at heights of six (6) feet or greater is required. The personal fall protection requirements for the work must be described in the JHA.

4.02.3.3.13. Personal fall arrest systems and their uses must comply with the provisions in 29 CFR 1926.502.The components of a personal fall arrest system include:

• Connectors (re: buckles, dee-rings, snaphooks). Non-locking snap hooks are not permitted.

• Lifelines (vertical, horizontal, self-retracting)

• Deceleration devices (rope grab, ripstitch lanyard, specially woven lanyard, tearing or deforming lanyard, automatic self-retracting lifeline / lanyard)

• Body harnesses (body belts are not permitted for fall arrest)

• Anchorages (secure point of attachment for lifeline, lanyards and deceleration devices)

• Lanyards (Double Lanyard Safety Harnesses are required for all personal fall arrest systems. Single Lanyard Harnesses are prohibited from use.)


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4.2.3.4 All personal fall protection equipment used by FLUOR ARABIA employees must meet OSHA and ANSI Standards.

4.02.3.4.1. In client facilities, warning signs should be permanently posted at work locations where the use of fall protection equipment / systems is required on a regular or routine basis and / or where the risk of falls is not obvious. Other work locations requiring temporary fall protection systems may, at the discretion of supervision, have portable signs posted.

4.02.3.4.2. Storage cabinets / boxes are to be provided for personal fall protection equipment and it is recommended that it is labeled “FOR FALL PROTECTION ONLY”. Personal fall protection equipment must be stored in designated cabinets.

4.2.3.5 Personal fall protection equipment must be stored as recommended by the manufacturer. Generally, the equipment should:

4.02.3.5.1. Be kept clean and dry

4.02.3.5.2. Be stored away from solvents, chemicals, oil, grease, etc.

4.02.3.5.3. Never be stored in tool bins

4.02.3.5.4. Never be stored where abrasion, fraying or other physical damage may occur

4.2.3.6 Personal fall protection equipment must be inspected monthly and records kept of the inspections. Any frayed or damaged equipment must be removed from service and replaced by the responsible supervisor (See Inspection Guidelines for Fall Protection Equipment).

4.2.3.7 Re-certification by the manufacturer is required for reel-type devices annually or after any fall arrest event. Records are to be made of re-certification.

4.2.3.8 Lanyards and harnesses that have been in-service loaded must be destroyed by the responsible supervisor.

4.3 Training

4.3.1 Employee Training as required by this section shall be documented and shall be available on the project site.

4.3.2 Employees shall be trained by a Competent person in the following areas:

4.3.2.1 The nature of the fall hazards.

4.3.2.2 The correct procedures for erecting, using, inspecting, and disassembling the fall protection systems.

4.3.2.3 The limitations of the fall protection systems.

4.3.2.4 Each employee’s role in the safety monitoring system (if used).

4.3.2.5 The correct procedure for handling, storing and inspecting fall protection equipment.


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4.3.2.6 The correct method of wearing and attaching safety harnesses and lanyards.

4.3.2.7 The requirements of the Company and OSHA.

4.3.3 Employees shall be retrained and appropriate documentation completed:

4.3.3.1 Annually.

4.3.3.2 When changes in the work place render previous training obsolete.

4.3.3.3 If the Plan proves to be inadequate in any way.

4.3.3.4 If a change in the types of fall protection systems or equipment to be used renders previous training obsolete.

4.4 Fall Restraint, Fall Arrest Systems

4.4.1 When employees are exposed to a hazard of falling from a location 6 feet or more in height, project management shall ensure that fall restraint or fall arrest systems are provided, installed, and imple mented according to the following requirements.

4.4.2 Fall restraint and fall arrest systems shall meet the minimum requirements of ANSI A10.14-1991—Requirements for Safety Belts, Harnesses, Lanyards, and Lifelines for Construction and Demolition Use.

4.4.3 Fall Restraint Systems (see definition 3.15.) shall:

4.4.3.1 Allow the movement of employees only as far as the sides and edges of the walking/working surface.

4.4.3.2 Include standard guardrails as described in applicable OSHA (1926.502) or state regulations.

4.4.3.3 Include a warning line system as prescribed in Title 29 CFR Part 1926 Subpart M and supple mented by the use of a safety monitor system as prescribed in 1926 Subpart M to pro tect workers engaged in duties between the forward edge of the warning line and the unprotected sides and edges, including the leading edge, of a low-pitched roof or wa lking/working surface.

4.4.3.4 Include safety harnesses attached to securely rigged restraint lines that keep employees constantly restrained from a fall hazard exposure.

• All safety harnesses and lanyard hardware assemblies shall be capable of withstanding a tensile loading of 5,000 pounds without cracking, breaking, or taking a permanent deformation.

• Project management shall ensure component compatibility.

• Components of fall restraint systems shall be inspected prior to each use for mildew, wear, damage, and other deterioration, and defective components shall be removed from service if their function or strength has been adversely affected.

• Anchorage points used for fall restraint shall be capable of supporting two times the intended load.

• Warning lines and safety monitor systems as described in 1926 Subpart M are prohibited on surfaces exceeding a 4-in-


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12 pitch, and on any surface whose dimensions are less than 45 inches in all directions.

4.4.4 Fall Arrest Systems shall consist of:

4.4.4.1 Full Body Harness

• An approved Class III full body harness shall be used.

• Body harness system or components subject to impact loading shall be immediately removed from service, tagged (with a “Do Not Use” tag) and shall not be used again for employee protection unless inspected and determined by a Competent Person (as defined by the manufacturer) to be undamaged and suitable for reuse.

• All safety lines and lanyards shall be protected against being cut or abraded.

• Body harness systems shall be rigged such that the fall distance is a maximum of 6 feet, and the employee will not contact any lower level.

• Hardware shall be drop forged, pressed or formed steel, or made of materials equivalent in strength.

• Hardware shall have a corrosion-resistant finish, and all surfaces and edges shall be smooth to prevent damage to the attached body harness or lanyard.

• When vertical lifelines (drop lines) are used, not more than one employee shall be attached to any one lifeline.

• Full body harness systems shall be secured to anchorage points capable of supporting 5,000 pounds per employee. When self-retracting lifelines or other deceleration devices that limit free fall to 2 feet are used, anchorage points shall be capable of withstanding 3,000 pounds.

• Independent lifelines (drop lines) shall have a minimum tensile strength of 5,000 pounds. Self-retracting lifelines and lanyards that automatically limit free fall dis tance to two feet or less shall have a minimum tensile strength of 3,000 pounds.

• Horizontal lifelines shall have a tensile strength capable of supporting a fall impact load of at least 5,000 pounds per employee using the lifeline, applied anywhere along the life-line. When more than one employee is using a horizontal life line, the life line shall be capable of supporting 5000 pounds per employee or an engineered safety factor of two (2) shall be maintained, based on a worst case scenario.

• Anchorage points shall be independent of any other system and shall be capable of supporting 5,000 pounds per employee using the anchorage.

• Employees shall not secure any part of their fall arrest system to a guardrail.

• Lanyards shall have a minimum tensile strength of 5,000 pounds.


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• All components of body harness systems whose strength is not otherwise specified above shall be capable of supporting a minimum fall impact load of 5,000 pounds applied at the lanyard point of connection.

• Snap hooks shall be locking type snap hooks.

• Snap hooks shall not be connected to each other.

• Full body harness systems shall be inspected prior to each use for mildew, wear, damage, and other deterioration, and effective components removed from service if their function or strength has been adversely affected.

• Full body harnesses and lanyards shall be inspected by a competent person on a monthly basis and documented.

• NOTE: Personnel will be required to wear full body harnesses when climbing onto scaffolds in excess of 6’, even if the scaffold has been approved with a green scaffold card.

4.4.4.2 Safety Nets

• Safety nets shall be installed as close as practicable under the walking/working surface on which employees are working, but in no case more than 10 feet below such level.

• Safety nets shall extend outward at least 8 feet from the outer most projection of the work surface.

• Safety nets shall be installed with sufficient clearance under them to prevent contact with the surface or structures below when subjected to an impact force equal to the drop test speci-fied below in this section.

• Safety nets and their in stallations shall be capable of absorbing an impact force equal to that produced by the drop test specified below in this section.

• Safety nets and safety net installations shall be drop-tested at the jobsite before use as a fall protection system. The drop-test shall consist of a 400-pound bag of sand 30 inches in diameter dropped into the net from the highest walking/working surface on which employees are to be protected.

• Exception: When Company management can demonstrate that a drop-test is not feasible or practicable, the net and net installa tion shall be certified by a qualified person to be in compliance with the provisions of this section.

• Safety nets shall be inspected weekly for mildew, wear, damage, and other deterioration, and defective components shall be removed from service.

• Materials, scrap pieces, and tools that have fallen into the safety net shall be removed as soon as possible and at least before the next work shift.

• The maximum size of each safety net mesh opening shall not exceed 36 square inches nor be longer than 6 inches on any side measured center-to-center of mesh ropes or webbing. All


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mesh crossings shall be secured to prevent enlargement of the mesh opening.

• Each safety net (or section of it) shall have a border rope for webbing with a minimum breaking strength of 5,000 pounds.

• Connections between safety net panels shall be as strong as integral net components and shall be spaced not more than 6 inches apart.

4.4.4.3 Catch Platforms

• A catch platform shall be installed within 6 vertical feet of the work area.

• The catch platform's width shall equal the distance of the fall but shall be a minimum of 45 inches wide and shall be equipped with standard guardrails on all open sides.

4.4.4.4 Independent lifelines used on rock-scaling operations, or in areas where the lifeline may be subjected to cutting or abrasion, shall be protected from such hazards and shall have a minimum breaking strength of 5,000 pounds.

4.4.4.5 Safety harnesses, lanyards, lifelines, independently attached shall be used while performing the following types of work when other equivalent protection is not provided:

• Work in hoppers, bins, silos, tanks, or other confined spaces.

• Work on hazardous slopes, or dismantling safety nets, working on poles or from boatswains chairs at elevations greater than 6 feet, swinging scaffolds, or other unguarded locations.

• Work on skips and platforms used in shafts by crews when the skip or cage does not include the opening to within 1 foot of the sides of the shaft, unless cages are provided.

4.5 Guarding of Low-Pitched Roof Perimeters

4.5.1 General

During the performance of work on low-pitched roofs with a ground-to-eaves height greater than 6 feet, project management shall ensure that employees engaged in such work are protected from falling from all unprotected sides and edges of the roof as follows:

4.5.1.1 By the use of a fall restraint or fall arrest system, as defined in applicable OSHA or state regulations

4.5.1.2 By the use of a warning line system, erected and maintained as described in this Practice, and supplemented for employees working between the warning line and the roof edge by the use of a safety monitor system as described in Title 29 Code of Federal Regulations Part 1926 Subpart M.

4.5.1.3 Mechanical equipment shall be used or stored only in areas where employees are protected by a warning line system, or fall restraint, or fall arrest systems as described in applicable federal or state regulations. Mechanical equipment may not be used or stored where the only protection provided is a safety monitor.


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Exceptions: The provisions above do not apply at points of access such as stairways, ladders and ramps, or when employees are on the roof only to inspect, investigate, or estimate roof level conditions. Roof edge materials handling areas and materials storage areas shall be guarded as provided in 4.06. below.

4.5.1.4 Employees engaged in built-up roofing on low-pitched roofs less than 50 feet wide may elect to use a safety system without warning lines where the use of hot tar poses an additional hazard to workers.

4.5.2 Warning Line Systems

4.5.2.1 Warning lines shall be erected around all sides of the work area:

• When mechanical equipment is not being used, the warning line shall be erected not less than 6 feet from the edge of the roof.

• When mechanical equipment is being used, the warning line shall be erected not less than six feet from the roof edge which is parallel to the direction of mechanical equipment operation, and not less than 10 feet from the roof edge which is perpendicular to the direction of me chanical equipment operation.

4.5.2.2 The warning line shall consist of a rope, wire, or chain and supporting stanchions erected as follows:

• The rope, wire, or chain shall be flagged at not more than 6 feet intervals with high-visibility material.

• The warning line shall be rigged and supported in such a way that its lowest point (including sag) is no less than 34 inches from the roof surface, and its highest point is no more than 39 inches from the roof surface.

• After the warning line is erected, the stanchions shall be capable of resisting, without tipping over, a force of at least 16 pounds applied horizontally against the stanchion, 30 inches above the roof surface, perpendicular to the warning line, and in the direction of the roof edge.

• The rope, wire, or chain shall have minimum tensile strength of 500 pounds, and after being attached to the stanchions, shall be capable of supporting, without breaking, the loads applied to the stanchions.

• The line shall be attached at each stanchion in such a way that pulling on one section of the line between stanchions will not result in slack being taken up in adjacent sections before the stanchion tips over.

4.5.2.3 Access paths shall be erected as follows:

• Points of access, material handling areas, and storage areas shall be connected to the work area by a clear access path formed by two warning lines.

• When the path to a point of access is not in use, a rope, wire, or chain, equal in strength and height to the warning line, shall


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be placed across the path at the point where the path intersects the warning line erected around the work area.

4.6 Roof Edge Material Handling Areas and Material Storage

4.6.1 Employees working in a roof edge material handling or storage area on a low-pitched roof with a ground-to-eave height greater than 6 feet shall be protected from falling along all unprotected roof sides and edges of the area.

4.6.1.1 When guardrails are used at hoisting areas, a minimum of 4 feet of guardrail shall be erected on each side of the access point through which materials are hoisted.

4.6.1.2 A chain or gate shall be placed across the opening between the guardrail sections when hoisting operations are not taking place.

4.6.1.3 When guardrails are used at bitumen pipe outlets, a minimum of 4 feet of guardrail shall be erected on each side of the pipe.

4.6.1.4 When safety harness systems are used, they shall not be attached to the hoist.

4.6.1.5 When fall restraint systems are used, they shall be rigged to allow the movement of employees only as far as the roof edge.

4.6.1.6 Materials shall not be stored within 6 feet of the roof edge unless guardrails are erected at the roof edge.

4.7 Leading Edge Control Zone

4.7.1 When performing leading edge work, project management shall ensure that a control zone is established according to the following require ments:

4.7.1.1 The control zone shall be a minimum of 6 feet and a maximum of 25 feet back from the leading edge to prevent exposure by employees who are not protected by fall restraint or fall arrest systems.

4.7.1.2 The control zone shall be separated from other areas of the low-pitched roof or walking/working surface by the erection of a warning line system.

4.7.1.3 The warning line system shall consist of wire, rope, or chain supported on stanchions, or a method that provides equivalent protection. Plastic ribbon shall not be used. Each line shall have a minimum breaking strength of 200 pounds.

4.7.1.4 Each line shall be flagged with a highly visible material at intervals not to exceed 6 feet.

4.7.1.5 The spacing and support of the line shall keep the line at least 39 inches (including sag) and not more than 45 inches above the working/walking surface.

4.7.1.6 The control line shall extend the entire length of the unprotected or leading edge and shall be roughly parallel to the leading edge.

4.7.2 When positive means of fall protection as described in this Practice are not used, a Safety Monitor System, as described in 4.8., shall be imple mented to protect employees working between the forward edge of the warning line and the leading edge.


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4.8 Safety Monitor System

4.8.1 A safety monitor system may be used in conjunction with a warning line system as a method of guarding against falls during work on low-pitched roofs and leading edge work only.

4.8.2 When selected, the employer shall ensure that the Safety Monitor System, shall be addressed in the Fall Protection Work Plan; shall include the name of the Safety Monitor(s) and the extent of their training in both the Safety Monitor and Warning Line Systems, and shall ensure that the following requirements are met.

4.8.3 The Safety Monitor System shall not be used when adverse weather conditions create additional hazards.

4.8.4 A person acting in the capacity of Safety Monitor(s) shall be trained in the function of both the Safety Monitor and Warning Lines Systems, and shall:

4.8.4.1 Be a Competent Person as defined in 3.9 and Title 29 CFR Part 1926,

4.8.4.2 Have control authority over the work as it relates to fall protec-tion,

4.8.4.3 Be instantly distinguishable from members of the work crew,

4.8.4.4 Engage in no other duties while acting as safety monitor,

4.8.4.5 Be positioned in relation to the workers under their protection, so as to have a clear, unobstructed view and be able to maintain normal voice communication, and

4.8.4.6 Not monitor more than eight exposed workers at one time.

4.8.5 Control zone workers shall be distinguished from other members of the crew by wearing a high-visibility vest only while in the control zone.

4.9 Hole Covers

4.9.1 All holes in floors, roofs, and walking/working surfaces shall be covered with approved covers.

4.9.2 Covers located in roadways and vehicular aisles shall be capable of supporting at least twice the maximum axle load of the largest vehicle expected to cross over the cover.

4.9.3 All other covers shall be capable of supporting at least twice the weight of employees.

4.9.4 All covers shall be secured to prevent accidental displacement.

4.9.5 All covers shall be colored coded or marked "Hole Cover, Do Not Remove".

4.10 Rescue of Suspended Employees

4.10.1 Rescue Plans shall be provided for suspended emp loyees. Employees shall be able to rescue themselves or prompt rescue shall be available.

4.10.2 Rescue equipment shall be inspected quarterly. The inspection shall be documented.

4.10.3 Rescue equipment shall be identified in the project Fall Protection Plan. All rescue equipment shall be immediately available.


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4.11 Guard Rail Systems

4.11.1 Temporary guardrail systems shall be capable of supporting 200 pounds of force directed either downward or toward the fall hazard.

4.11.2 Upright supports shall be no more than eight feet apart.

4.11.3 Guardrail systems shall consist of a hand rail about 42 inches above the floor (plus or minus 3 inches) and a mid-rail located midway between the floor and handrail. Toe boards shall be placed around the bottom of the guardrail system.

4.11.4 If wire rope is used for guardrail systems, the wire rope shall not have more than three inches of deflection. The openings between the wire ropes shall not exceed 19 inches.

4.11.5 Employees shall use a fall arrest system when placing or removing guard rail systems.

4.11.6 Employees shall not tie off to guard rail systems.

4.12 Additional Practices Requiring Fall Restraint/Arrest

4.12.1 Employees shall use Fall Restraint or Fall Arrest equipment when conducting the following activities or work on/from the following equipment:

4.12.1.1 Ladders

4.12.1.2 Suspended Scaffold

4.12.1.3 Two-Point Suspension Scaffold

4.12.1.4 Boatswain’s Chair Scaffold

4.12.1.5 Needle-Beam Scaffold

4.12.1.6 Ladder Jack Scaffold

4.12.1.7 Window Jack Scaffold

4.12.1.8 Float or Ship Scaffold

4.12.1.9 Pump Jack Scaffold

4.12.1.10 Boom-Supported Elevating Work Platforms

4.12.1.11 Vehicle-Mounted Elevated and Rotating Work Platform

4.12.1.12 Crane- and Derrick-Supported Work Platforms

4.12.1.13 Open-Sided Floors

4.12.1.14 Pile Driving

4.12.1.15 Vertical Slip Forms

4.12.1.16 Placing and Removal of Forms

4.12.1.17 Steel Erection Temporary Floors

4.12.1.18 Tunneling (Skips and Platforms)


5.1 The Fall Protection Plan shall be maintained in the project HSE office.

5.2 Documentation of training in the use of fall protection shall be kept on file in the project HSE office.

Inspection records of fall protection devices shall be kept on file in the project HSE office for the duration of the project.


HSE Practice 20 Steel Erection

® STEEL ERECTION PRACTICE 20 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This practice provides the minimum requirements to protect employees from the hazards associated with steel erection activities involved in the construction, alteration, and/or repair of single and multi-story buildings, bridges, and other structures where steel erection occurs. The requirements of this practice apply to employers, subcontractors, and vendors engaged in steel erection. This practice does not cover tanks.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart R (1926.750 - 1926.761)

2.2 SASO 337—Industrial Safety and Health Regulations: Parts 9, 10, 11, 12, 13, 14—Building and Construction

3.0 Definitions

3.1 Anchored Bridging—the steel joist bridging is connected to a bridging terminus point.

3.2 Bolted Diagonal Bridging—diagonal bridging that is bolted to a steel joist or joists.

3.3 Bridging Clip—a device that is attached to the steel joist to allow the bolting of the bridging to the steel joist.

3.4 Bridging Terminus Point—a wall, a beam, tandem joists (with all bridging installed and a horizontal truss in the plane of the top chord) or other element at an end or intermediate point(s) of a line of bridging that provides an anchor point for the steel joist bridging.

3.5 Choker—a wire rope or synthetic fiber rigging assembly that is used to attach a load to a hoisting device.

3.6 Cold Forming—means the process of using press brakes, rolls, or other methods to shape steel into desired cross sections at room temperature.

3.7 Column—a load-carrying vertical member that is part of the primary skeletal fra ming system. Columns do not include posts.

3.8 Competent Person—one who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

3.9 Connector—an employee who, working with hoisting equipment, is placing and connecting structural members and/or components.

3.10 Constructibility—the ability to erect structural steel members in accordance with subpart R without having to alter the over-all structural design.

3.11 Construction Load (for joist erection)—any load other than the weight of the employee(s), the joists and the bridging bundle.

3.12 Controlled Decking Zone (CDZ) —an area in which certain work (for example, initial installation and placement of metal decking) may take place without the use of guardrail systems, personal fall arrest systems, fall restraint systems, or safety net systems and where access to the zone is controlled.

3.13 Controlled Load Lowering—lowering a load by means of a mechanical hoist drum device that allows a hoisted load to be lowered with maximum control using the gear train or hydraulic components of the hoist mechanism. Controlled load lowering requires the use of the hoist drive motor, rather than the load hoist brake, to lower the load.

3.14 Critical Lift—a lift that (1) exceeds 75 percent of the rated capacity of the crane or derrick, or (2) requires the use of more than one crane or derrick.


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3.15 Decking Hole—a gap or void more than 2 inches (5.1 cm) in its least dimension and less than 12 inches (30.5 cm) in its greatest dimension in a floor, roof or other walking/working surface. Pre-engineered holes in cellular decking (for wires, cables, etc.) are not included in this definition.

3.16 Derrick Floor—an elevated floor of a building or structure that has been designated to receive hoisted pieces of steel before final placement.

3.17 Double Connection—an attachment method where the connection point is intended for two pieces of steel which share common bolts on either side of a central piece.

3.18 Double Connection Seat—a structural attachment that, during the installation of a double connection, supports the first member while the second member is connected.

3.19 Erection Bridging—the bolted diagonal bridging that is required to be installed before releasing the hoisting cables from the steel joists.

3.20 Fall Restraint System—a fall protection system that prevents the user from falling any distance. The system is comprised of either a body belt or body harness, along with an anchorage, connectors, and other necessary equipment. The other components typically include a lanyard, and may include a lifeline and other devices.

3.21 Final Interior Perimeter—the perimeter of a large permanent open space within a building such as an atrium or courtyard. This does not include openings for stairways, elevator shafts, etc.

3.22 Girt (in systems -engineered metal buildings)—a "Z" or "C" shaped member formed from sheet steel spanning between primary framing and supporting wall material.

3.23 Headache Ball—a weighted hook that is used to attach loads to the hoist load line of the crane.

3.24 Hoisting Equipment—commercially manufactured lifting equipment designed to lift and position a load of known weight to a location at some known elevation and horizontal distance from the equipment's center of rotation. "Hoisting equipment" includes but is not limited to cranes, derricks, tower cranes, barge-mounted derricks or cranes, gin poles and gantry hoist systems. A "come-a-long" (a mechanical device, usually consisting of a chain or cable attached at each end, that is used to facilitate movement of materials through leverage) is not considered "hoisting equipment."

3.25 Leading Edge—the unprotected side and edge of a floor, roof, or formwork for a floor or other walking/working surface (such as deck) which changes location as additional floor, roof, decking or formwork sections are placed, formed or constructed.

3.26 Metal Decking—a commercially manufactured, structural grade, cold rolled metal panel formed into a series of parallel ribs; for this subpart, this includes metal floor and roof decks, standing seam metal roofs, other metal roof systems and other products such as bar gratings, checker plate, expanded metal panels, and similar products. After installation and proper fastening, these decking materials serve a combination of functions including, but not limited to: a structural element designed in combination with the structure to resist, distribute and transfer loads, stiffen the structure and provide a diaphragm action; a walking/working surface; a form for concrete slabs; a support for roofing systems; and a finished floor or roof.

3.27 Multiple Lift Rigging—a rigging assembly manufactured by wire rope rigging suppliers that facilitates the attachment of up to five independent loads to the hoist rigging of a crane.

3.28 Opening—a gap or void 12 inches (30.5 cm) or more in its least dimension in a floor, roof, or other walking/working surface. For the purposes of this practice, skylights and


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smoke domes that do not meet the strength requirements of 29 CFR 1926.754(e)(3) shall be regarded as openings.

3.29 Permanent Floor—a structurally completed floor at any level or elevation (including slab on grade).

3.30 Personal Fall Arrest System—a system used to arrest an employee in a fall from a working level. A personal fall arrest system consists of an anchorage, connectors, a body harness and may include a lanyard, deceleration device, lifeline, or suitable combination of these. The use of a body belt for fall arrest is prohibited.

3.31 Positioning Device System—a body belt or body harness rigged to allow an employee to be supported on an elevated, vertical surface, such as a wall or column and work with both hands free while leaning.

3.32 Post—a structural member with a longitudinal axis that is essentially vertical, that: (1) weighs 300 pounds or less and is axially loaded (a load presses down on the top end), or (2) is not axially loaded, but is laterally restrained by the above member. Posts typically support stair landings, wall framing, mezzanines, and other substructures.

3.33 Project Structural Engineer of Record—the registered, licensed professional responsible for the design of structural steel framing and whose seal appears on the structural contract documents.

3.34 Purlin (in systems -engineered metal buildings)—a "Z" or "C" shaped member formed from sheet steel spanning between primary framing and supporting roof material.

3.35 Qualified Person—one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter, the work, or the project.

3.36 Safety Deck Attachment—an initial attachment that is used to secure an initially placed sheet of decking to keep proper alignment and bearing with structural support members.

3.37 Shear Connector—headed steel studs, steel bars, steel lugs, and similar devices which are attached to a structural member for the purpose of achieving composite action with concrete.

3.38 Steel Erection—the construction, alteration, or repair of steel buildings, bridges, and other structures, including the installation of metal decking and all planking used during the process of erection.

3.39 Steel Joist—an open web, secondary load-carrying member of 144 feet (43.9 m) or less, designed by the manufacturer, used for the support of floors and roofs. This does not include structural steel trusses or cold-formed joists.

3.40 Steel Joist Girder—an open web, primary load-carrying member, designed by the manufacturer, used for the support of floors and roofs. This does not include structural steel trusses.

3.41 Steel Truss—an open web member designed of structural steel components by the project structural engineer of record. For the purposes of this subpart, a steel truss is considered equivalent to a solid web structural member.

3.42 Structural Steel—a steel member, or a member made of a substitute material (such as, but not limited to, fiberglass, aluminum or composite members). These members include, but are not limited to, steel joists, joist girders, purlins, columns, beams, trusses, splices, seats, metal decking, girts, and all bridging, and cold formed metal framing which is integrated with the structural steel framing of a building.


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3.43 Systems -Engineered Metal Building—a metal, field-assembled building system consisting of framing, roof and wall coverings. Typically, many of these components are cold-formed shapes. These individual parts are fabricated in one or more manufacturing facilities and shipped to the job site for assembly into the final structure. The engineering design of the system is normally the responsibility of the systems -engineered metal building manufacturer.

3.44 Tank—a container for holding gases, liquids, or solids.

3.45 Unprotected Sides and Edges—any side or edge (except at entrances to points of access) of a walking/working surface, for example a, floor, roof, ramp or runway, where there is no wall or guardrail system at least 39 inches (1.0 m) high.

3.46 Anchorage—a tie -off point capable of supporting 5000 pounds per person.

3.47 Christmas Treeing—lifting more than one individual load with a crane's load hook.

4.0 Process

4.1 Approval to begin steel erection.

4.1.1 Before authorizing the commencement of steel erection, the Construction Manager shall ensure that the steel erector is provided with the following written notifications:

4.1.1.1 The concrete in the footings, piers and walls and the mortar in the masonry piers and walls has attained, on the basis of an appropriate ASTM standard test method of field-cured samples, either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection.

4.1.1.2 Any repairs, replacements, and modifications to the anchor bolts were conducted in accordance with the project specifications.

4.2 Commencement of steel erection.

4.2.1 A steel erection contractor shall not erect steel unless it has received written notification that the concrete in the footings, piers and walls or the mortar in the masonry piers and walls has attained, on the basis of an appropriate ASTM standard test method of field-cured samples, either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection.

4.3 Site layout.

4.4 The Construction Manager shall ensure that the following is provided and maintained:

4.5 Adequate access roads into and through the site for the safe delivery and movement of derricks, cranes, trucks, other necessary equipment, and the material to be erected and means and methods for pedestrian and vehicular control.1

4.6 A firm, properly graded, drained area, readily accessible to the work with adequate space for the safe storage of materials and the safe operation of the erector's equipment.

4.7 Pre-planning of overhead hoisting operations.

4.7.1 All hoisting operations in steel erection shall be pre-planned.

4.8 Site-specific erection plan.

4.8.1 Where employers elect, due to conditions specific to the site, to develop alternate means and methods that provide employee protection in accordance

1 Exception: this requirement does not apply to roads outside of the construction site.


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with 29 CFR 1926.753(c)(5), 29 CFR 1926.757(a)(4) or 29 CFR 1926.757(e)(4), a site-specific erection plan shall be developed by a qualified person and be available at the work site.

4.9 Hoisting and Rigging

4.9.1 Cranes being used in steel erection activities shall be visually inspected before each shift by a competent person; the inspection shall include observation for deficiencies during operation. At a minimum this inspection shall include the following:

4.9.1.1 All control mechanisms for maladjustments;

4.9.1.2 Control and drive mechanism for excessive wear of components and contamination by lubricants, water or other foreign matter;

4.9.1.3 Safety devices, including but not limited to boom angle indicators, boom stops, boom kick out devices, anti-two block devices, and load mo ment indicators where required;

4.9.1.4 Air, hydraulic, and other pressurized lines for deterioration or leakage, particularly those which flex in normal operation;

4.9.1.5 Hooks and latches for deformation, chemical damage, cracks, or wear;

4.9.1.6 Wire rope reeving for compliance with hoisting equipment manufacturer's specifications;

4.9.1.7 Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, or moisture accumulation;

4.9.1.8 Hydraulic system for proper fluid level;

4.9.1.9 Tires for proper inflation and condition;

4.9.1.10 Ground conditions around the hoisting equipment for proper support, including ground settling under and around outriggers, ground water accumulation, or similar conditions;

4.9.1.11 The hoisting equipment for level position; and

4.9.1.12 The hoisting equipment for level position after each move and setup.

4.9.2 If any deficiency is identified, an immediate determination shall be made by the competent person as to whether the deficiency constitutes a hazard.

4.9.3 If the deficiency is determined to constitute a hazard, the hoisting equipment shall be removed from service until the deficiency has been corrected.

4.9.4 The operator shall be responsible for those operations under the operator's direct control. Whenever there is any doubt as to safety, the operator shall have the authority to stop and refuse to handle loads until safety has been assured.

4.9.5 A qualified rigger (a rigger who is also a qualified person) shall inspect the rigging before each shift.

4.9.6 The headache ball, hook, or load shall not be used to transport personnel.

4.9.7 Safety latches on hooks shall not be deactivated or made inoperable.

4.9.8 Routes for suspended loads shall be pre-planned to ensure that no employee is required to work directly below a suspended load.

4.9.9 All loads shall be rigged by a qualified rigger


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4.9.10 A multiple lift shall only be performed if the following criteria are met:

4.9.10.1 A multiple lift rigging assembly is used;

4.9.10.2 A maximum of five members are hoisted per lift;

4.9.10.3 Only beams and similar structural members are lifted; and

4.9.10.4 All employees engaged in the multiple lift have been trained in thes e procedures.

4.9.11 No crane is permitted to be used for a multiple lift where such use is contrary to the manufacturer's specifications and limitations.

4.9.12 Components of the multiple lift rigging assembly shall be specifically designed and assembled with a maximum capacity for total assembly and for each individual attachment point. This capacity, certified by the manufacturer or a qualified rigger, shall be based on the manufacturer's specifications with a 5 to 1 safety factor for all components.

4.9.13 The total load shall not exceed:

4.9.13.1 The rated capacity of the hoisting equipment specified in the hoisting equipment load charts;

4.9.13.2 The rigging capacity specified in the rigging rating chart.

4.9.14 The multiple lift rigging assembly shall be rigged with members:

4.9.14.1 Attached at their center of gravity and maintained reasonably level;

4.9.14.2 Rigged from top down; and

4.9.14.3 Rigged at least 7 feet (2.1 m) apart.

4.9.15 The members on the multiple lift rigging assembly shall be set from the bottom up.

4.9.16 Controlled load lowering shall be used whenever the load is over the connectors

4.10 Structural Steel Assembly

4.10.1 Structural stability shall be maintained at all times during the erection process.

4.10.2 The following additional requirements shall apply for multi-story structures:

4.10.2.1 The permanent floors shall be installed as the erection of structural members progresses, and there shall be not more than eight stories between the erection floor and the upper-most permanent floor, except where the structural integrity is maintained because of the design.

4.10.2.2 At no time shall there be more than four floors or 48 feet (14.6 m), whichever is less, of unfinished bolting or welding above the foundation or uppermost permanently secured floor, except where the structural integrity is maintained as a result of the design.

4.10.2.3 A fully planked or decked floor or nets shall be maintained within two stories or 30 feet (9.1 m); whichever is less, directly under any erection work being performed.

4.11 Walking/working surfaces.

4.11.1 Shear connectors (such as headed steel studs, steel bars or steel lugs), reinforcing bars, deformed anchors or threaded studs shall not be attached to the top flanges of beams, joists or beam attachments so that they project vertically


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from or horizontally across the top flange of the member until after the metal decking, or other walking/working surface, has been installed.

4.11.2 Installation of shear connectors on composite floors, roofs and bridge decks. When shear connectors are used in construction of composite floors, roofs and bridge decks, employees shall lay out and install the shear connectors after the metal decking has been installed, using the metal decking as a working platform. Shear connectors shall not be installed from within a controlled decking zone (CDZ).

4.11.3 Workers shall not be permitted to walk the top surface of any structural steel member installed that has been coated with paint or similar material unless documentation or certification that the coating has achieved a minimum average slip resistance of .50 when measured with an English XL tribometer or equivalent tester on a wetted surface at a testing laboratory is provided. Such documentation or certification shall be based on the appropriate ASTM standard test method conducted by a laboratory capable of performing the test. The results shall be available at the site and to the steel erector.

4.11.4 When deemed necessary by a competent person, plumbing-up equipment shall be installed in conjunction with the steel erection process to ensure the stability of the structure.

4.11.5 When used, plumbing-up equipment shall be in place and properly installed before the structure is loaded with construction material such as loads of joists, bundles of decking or bundles of bridging.

4.11.6 Plumbing-up equipment shall be removed only with the approval of a competent person.

4.11.7 Hoisting, landing and placing of metal decking bundles.

4.11.7.1 Bundle packaging and strapping shall not be used for hoisting unless specifically designed for that purpose.

4.11.7.2 If loose items such as dunnage, flashing, or other materials are placed on the top of metal decking bundles to be hoisted, such items shall be secured to the bundles.

4.11.7.3 Metal decking bundles shall be landed on framing members so that enough support is provided to allow the bundles to be unbanded without dislodging the bundles from the supports.

4.11.7.4 At the end of the shift or when environmental or jobsite conditions require, metal decking shall be secured against displacement.

4.11.8 Metal decking at roof and floor holes and openings shall be installed as follows:

4.11.8.1 Framed metal deck openings shall have structural members turned down to allow continuous deck installation except where not allowed by structural design constraints or constructibility.

4.11.8.2 Roof and floor holes and openings shall be decked over. Where large size, configuration, or other structural design does not allow openings to be decked over (such as elevator shafts, stair wells, etc.) employees shall be protected in accordance with Practice 19 - Fall Protection.

4.11.8.3 Metal decking holes and openings shall not be cut until immediately prior to being permanently filled with the equipment or structure


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needed or intended to fulfill its specific use or shall be immediately covered.

4.11.8.4 Covering roof and floor openings.

4.11.8.4.1. Covers for roof and floor openings shall be capable of supporting, without failure, twice the weight of the employees, equipment, and materials that may be imposed on the cover at any one time.

4.11.8.4.2. All covers shall be secured when installed to prevent accidental displacement by the wind, equipment, or employees.

4.11.8.4.3. All covers shall be painted with high-visibility paint or shall be marked with the word "HOLE" or "COVER" to provide warning of the hazard.

4.11.8.4.4. Smoke dome or skylight fixtures that have been installed, are not considered covers for the purpose of this section unless they meet the strength requirements of section 4.8.8.4.1.

4.11.8.5 Decking gaps around columns. Wire mesh, exterior plywood, or equivalent, shall be installed around columns where planks or metal decking do not fit tightly. The materials used must be of sufficient strength to provide fall protection for personnel and prevent objects from falling through.

4.11.9 Installation of metal decking.

4.11.9.1 Metal decking shall be laid tightly and immediately secured upon placement to prevent accidental movement or displacement.

4.11.9.2 During initial placement, metal-decking panels shall be placed to ensure full support by structural members.

4.11.10Derrick floors.

4.11.10.1A derrick floor shall be fully decked and/or planked and the steel member connections completed to support the intended floor loading.

4.11.10.2Temporary loads placed on a derrick floor shall be distributed over the underlying support members to prevent local overloading of the deck material.

4.12 Column Anchorage

4.12.1 All columns shall be anchored by a minimum of 4 anchor rods (anchor bolts).

4.12.2 Columns shall be set on level finished floors, pre-grouted leveling plates, leveling nuts, or shim packs which are adequate to transfer the construction loads.

4.12.3 All columns shall be evaluated by a competent person to determine whether guying or bracing is needed; if guying or bracing is needed, it shall be installed.

4.12.4 Anchor rods (anchor bolts) shall not be repaired, replaced or field-modified without the approval of the project structural engineer of record.


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4.12.5 Prior to the erection of a column, the Construction Manager shall provide written notification to the steel erector if there has been any repair, replacement, or modification of the anchor rods (anchor bolts) of that column.

4.13 Beams and Columns

4.13.1 During the final placing of solid web structural members, the load shall not be released from the hoisting line until the members are secured with at least two bolts per connection, of the same size and strength as shown in the erection drawings, drawn up wrench-tight or the equivalent as specified by the project structural engineer of record.

4.13.2 A competent person shall determine if more than two bolts are necessary to ensure the stability of cantilevered members; if additional bolts are needed, they shall be installed.

4.13.3 Solid web structural members used as diagonal bracing shall be secured by at least one bolt per connection drawn up wrench-tight or the equivalent as specified by the project structural engineer of record.

4.13.4 When two structural members on opposite sides of a column web, or a beam web over a column, are connected sharing common connection holes, at least one bolt with its wrench-tight nut shall remain connected to the first member unless a shop-attached or field-attached seat or equivalent connection device is supplied with the member to secure the first member and prevent the column from being displaced.

4.13.5 If a seat or equivalent device is used, the seat (or device) shall be designed to support the load during the double connection process. It shall be adequately bolted or welded to both a supporting member and the first member before the nuts on the shared bolts are removed to make the double connection.

4.13.6 Each column splice shall be designed to resist a minimum eccentric gravity load of 300 pounds (136.2 kg) located 18 inches (.46 m) from the extreme outer face of the column in each direction at the top of the column shaft.

4.13.7 Perimeter columns shall not be erected unless:

4.13.7.1 The perimeter columns extend a minimum of 48 inches (1.2 m) above the finished floor to permit installation of perimeter safety cables prior to erection of the next tier, except where constructibility does not allow;

4.13.7.2 The perimeter columns have holes or other devices in or attached to perimeter columns at 42-45 inches (107-114 cm) above the finished floor and the midpoint between the finished floor and the top cable to permit installation of perimeter safety cables required by Practice LGH 6404-10—Fall Protection, except where constructibility does not allow.

4.14 Open Web Steel Joists

4.14.1 Where steel joists are used and columns are not framed in at least two directions with solid web structural steel members, a steel joist shall be field-bolted at the column to provide lateral stability to the column during erection. For the installation of this joist:

4.14.1.1 A vertical stabilizer plate shall be provided on each column for steel joists. The plate shall be a minimum of 6 inch by 6 inch (152 mm by 152 mm) and shall extend at least 3 inches (76 mm) below the


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bottom chord of the joist with a 13/16-inch (21 mm) hole to provide an attachment point for guying or plumbing cables.

4.14.1.2 The bottom chords of steel joists at columns shall be stabilized to prevent rotation during erection.

4.14.1.3 Hoisting cables shall not be released until the seat at each end of the steel joist is field-bolted, and each end of the bottom chord is restrained by the column stabilizer plate.

4.14.2 Where constructibility does not allow a steel joist to be installed at the column:

4.14.2.1 An alternate means of stabilizing joists shall be installed on both sides near the column and shall:

4.14.2.1.1. Be designed by a qualified person;

4.14.2.1.2. Be shop installed; and

4.14.2.1.3. Be included in the erection drawings.

4.14.2.2 Hoisting cables shall not be released until the seat at each end of the steel joist is field-bolted and the joist is stabilized.

4.14.3 Where steel joists at or near columns span 60 feet (18.3 m) or less, the joist shall be designed with sufficient strength to allow one employee to release the hoisting cable without the need for erection bridging.

4.14.4 Where steel joists at or near columns span more than 60 feet (18.3 m), the joists shall be set in tandem with all bridging installed unless an alternative method of erection, which provides equivalent stability to the steel joist, is designed by a qualified person and is included in the site-specific erection plan.

4.14.5 A steel joist or steel joist girder shall not be placed on any support structure unless such structure is stabilized.

4.14.6 When steel joist(s) are landed on a structure, they shall be secured to prevent unintentional displacement before installation.

4.14.7 No modification that affects the strength of a steel joist or steel joist girder shall be made without the approval of the project structural engineer of record.

4.14.8 Field-bolted joists.

4.14.8.1 Except for steel joists that have been pre-assembled into panels, connections of individual steel joists to steel structures in bays of 40 feet (12.2 m) or more shall be fabricated to allow for field bolting during erection.

4.14.8.2 These connections shall be field-bolted unless constructibility does not allow.

4.14.8.3 Containers shall be provided for storing or carrying rivets, bolts, and drift pins, and secured to prevent falling when aloft.

4.14.8.4 Pneumatic hand tools shall be disconnected from the power source, and pressure in hose lines shall be released, before any adjustments or repairs are made.

4.14.8.5 Air line hose sections shall be safely coupled together except when quick disconnect couplers are used to join sections.

4.14.8.6 When bolts or drift pins are being knocked out, means shall be provided to keep them from falling.


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4.14.8.7 Impact wrenches shall be provided with a locking device for retaining the socket.

4.14.9 Steel joists and steel joist girders shall not be used as anchorage points for a fall arrest system unless written approval to do so is obtained from a qualified person.

4.14.10A bridging terminus point shall be established before bridging is installed.

4.14.11Attachment of steel joists and steel joist girders.

4.14.11.1Each end of "K" series steel joists shall be attached to the support structure with a minimum of two 1/8-inch (3 mm) fillet welds 1 inch (25 mm) long or with two ½-inch (13 mm) bolts, or the equivalent.

4.14.11.2Each end of "LH" and "DLH" series steel joists and steel joist girders shall be attached to the support structure with a minimum of two ¼ -inch (6 mm) fillet welds 2 inches (51 mm) long, or with two ¾-inch (19 mm) bolts, or the equivalent.

4.14.11.3Each steel joist shall be attached to the support structure, at least at one end on both sides of the seat, immediately upon placement in the final erection position and before additional joists are placed.

4.14.11.4Panels that have been pre-assembled from steel joists with bridging shall be attached to the structure at each corner before the hoisting cables are released.

4.14.12Erection of steel joists.

4.14.12.1Both sides of the seat of one end of each steel joist that requires bridging under Tables A and B in 29 CFR 19.757(c)(3) shall be attached to the support structure before hoisting cables are released.

4.14.12.2For joists over 60 feet, both ends of the joist shall be attached as specified in this practice before the hoisting cables are released.

4.14.12.3On steel joists that do not require erection bridging under Tables A and B in 29 CFR 19.757(c)(3), only one employee shall be allowed on the joist until all bridging is installed and anchored.

4.14.13Employees shall not be allowed on steel joists where the span of the steel joist is equal to or greater than the span shown in Tables A and B in 29 CFR 19.757(c)(3).

4.14.14When permanent bridging terminus points cannot be used during erection, additional temporary bridging terminus points are required to provide stability.

4.14.15Erection bridging.

4.14.15.1Where the span of the steel joist is equal to or greater than the span shown in Tables A and B, in 29 CFR 19.757(c)(3) the following shall apply:

4.14.15.1.1. A row of bolted diagonal erection bridging shall be installed near the midspan of the steel joist;

4.14.15.1.2. Hoisting cables shall not be released until this bolted diagonal erection bridging is installed and anchored; and


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4.14.15.1.3. No more than one employee shall be allowed on these spans until all other bridging is installed and anchored.

4.14.15.2Where the span of the steel joist is over 60 feet (18.3 m) through 100 feet (30.5 m), the following shall apply:

4.14.15.2.1. All rows of bridging shall be bolted diagonal bridging;

4.14.15.2.2. Two rows of bolted diagonal erection bridging shall be installed near the third points of the steel joist;

4.14.15.2.3. Hoisting cables shall not be released until this bolted diagonal erection bridging is installed and anchored; and

4.14.15.2.4. No more than two employees shall be allowed on these spans until all other bridging is installed and anchored.

4.14.15.3Where the span of the steel joist is over 100 feet (30.5 m) through 144 feet (43.9 m), the following shall apply:

4.14.15.3.1. All rows of bridging shall be bolted diagonal bridging;

4.14.15.3.2. Hoisting cables shall not be released until all bridging is installed and anchored; and

4.14.15.3.3. No more than two employees shall be allowed on these spans until all bridging is installed and anchored.

4.14.15.4Where any steel joist is a bottom chord bearing joist, a row of bolted diagonal bridging shall be provided near the support(s). This bridging shall be installed and anchored before the hoisting cable(s) is released.

4.14.15.5When bolted diagonal erection bridging is required by this section, the following shall apply:

4.14.15.5.1. The bridging shall be indicated on the erection drawing;

4.14.15.5.2. The erection drawing shall be the exclusive indicator of the proper placement of this bridging;

4.14.15.5.3. Shop-installed bridging clips, or functional equivalents, shall be used where the bridging bolts to the steel joists;

4.14.15.5.4. When two pieces of bridging are attached to the steel joist by a common bolt, the nut that secures the first piece of bridging shall not be removed from the bolt for the attachment of the second; and

4.14.15.5.5. Bridging attachments shall not protrude above the top chord of the steel joist.


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4.14.16Landing and placing loads.

4.14.16.1During the construction period, a load placed on steel joists will be is distributed so as not to exceed the carrying capacity of any steel joist.

4.14.16.2No construction loads are allowed on the steel joists until all bridging is installed and anchored and all joist-bearing ends are attached.

4.14.16.3The weight of a bundle of joist bridging shall not exceed a total of 1,000 pounds (454 kg). A bundle of joist bridging shall be placed on a minimum of three steel joists that are secured at one end. The edge of the bridging bundle shall be positioned within 1 foot (.30 m) of the secured end.

4.14.16.4No bundle of decking may be placed on steel joists until all bridging has been installed and anchored and all joist bearing ends attached, unless all of the following conditions are met:

4.14.16.4.1. The employer has first determined from a qualified person and documented in a site-specific erection plan that the structure or portion of the structure is capable of supporting the load;

4.14.16.4.2. The bundle of decking is placed on a minimum of three steel joists;

4.14.16.4.3. The joists supporting the bundle of decking are attached at both ends;

4.14.16.4.4. At least one row of bridging is installed and anchored;

4.14.16.4.5. The total weight of the bundle of decking does not exceed 4,000 pounds (1816 kg); and

4.14.16.5The edge of the construction load shall be placed within 1 foot (.30 m) of the bearing surface of the joist end.

4.15 Systems Engineered Buildings

4.15.1 Each structural column shall be anchored by a minimum of four anchor rods (anchor bolts).

4.15.2 Rigid frames shall have 50 percent of their bolts or the number of bolts specified by the manufacturer (whichever is greater) installed and tightened on both sides of the web adjacent to each flange before the hoisting equipment is released.

4.15.3 Construction loads shall not be placed on any structural steel framework unless such framework is safely bolted, welded or otherwise adequately secured.

4.15.4 In girt and eave strut-to-frame connections, when girts or eave struts share common connection holes, at least one bolt with its wrench-tight nut shall remain connected to the first member unless a manufacturer-supplied, field-attached seat or similar connection device is present to secure the first member so that the girt or eave strut is always secured against displacement.

4.15.5 Both ends of all steel joists or cold-formed joists shall be fully bolted and/or welded to the support structure before:

4.15.5.1 Releasing the hoisting cables;

4.15.5.2 Allowing an employee on the joists; or

4.15.5.3 Allowing any construction loads on the joists.


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4.15.6 Purlins and girts shall not be used as an anchorage point for a fall arrest system unless written approval is obtained from a qualified person.

4.15.7 Purlins may only be used as a walking/working surface when installing safety systems, after all permanent bridging has been installed and fall protection is provided.

4.15.8 Construction loads may be placed only within a zone that is within 8 feet (2.5 m) of the centerline of the primary support member.

4.16 Falling Object Protection

4.16.1 Securing loose items aloft. All materials, equipment, and tools, which are not in use while aloft, shall be secured against accidental displacement.

4.16.2 Protection from falling objects other than materials being hoisted. The Construction Manager shall bar other construction processes below steel erection unless overhead protection for the employees below is provided.

4.17 Fall Protection

4.17.1 Each employee engaged in a steel erection activity who is on a walking/working surface with an unprotected side or edge more than 15 feet (4.6 m) above a lower level shall be protected from fall hazards by guardrail systems, safety net systems, personal fall arrest systems, positioning device systems or fall restraint systems.

4.17.2 On multi-story structures, perimeter safety cables shall be installed at the final interior and exterior perimeters of the floors as soon as the metal decking has been installed.

4.17.3 Connectors and employees working in controlled decking zones shall be protected from fall hazards.

4.17.4 Fall Protection will comply with Practice 19—Fall Protection.

4.17.5 Each connector shall:

4.17.5.1 Be protected in accordance with paragraph (a)(1) of this section from fall hazards of more than two stories or 30 feet (9.1 m) above a lower level, whichever is less;

4.17.5.2 Have completed connector training; and

4.17.5.3 Be provided, at heights over 15 and up to 30 feet above a lower level, with a personal fall arrest system, positioning device system or fall restraint system and wear the equipment necessary to be able to be tied off; or be provided with other means of protection from fall.

4.17.6 A controlled decking zone may be established in that area of the structure over 15 and up to 30 feet above a lower level where metal decking is initially being installed and forms the leading edge of a work area. In each CDZ, the following shall apply:

4.17.6.1 Each employee working at the leading edge in a CDZ shall be protected from fall hazards of more than two stories or 30 feet (9.1 m), whichever is less.

4.17.6.2 Access to a CDZ shall be limited to only those employees engaged in leading edge work.

4.17.6.3 The boundaries of a CDZ shall be designated and clearly marked. The CDZ shall not be more than 90 feet (27.4 m) wide and 90 (27.4


9905-02-000.doc 12/8/2004 15

m) feet deep from any leading edge. The CDZ shall be marked by the use of control lines or the equivalent. Examples of acceptable procedures for demarcating CDZ's can be found in Appendix D to this subpart.

4.17.6.4 Each employee working in a CDZ shall have completed CDZ training in accordance with § 1926.761.

4.17.6.5 Unsecured decking in a CDZ shall not exceed 3,000 square feet (914.4 m 2).

4.17.6.6 Safety deck attachments shall be performed in the CDZ from the leading edge back to the control line and shall have at least two attachments for each metal decking panel.

4.17.6.7 Final deck attachments and installation of shear connectors shall not be performed in the CDZ.

4.17.7 Criteria for fall protection equipment.

4.17.7.1 Guardrail systems, safety net systems, personal fall arrest systems, positioning device systems, and their components shall conform to the criteria in Practice 19—Fall Protection.

4.17.7.2 Fall arrest system components shall be used in fall restraint systems and shall conform to the criteria in Practice 19—Fall Protection. Either body belts or body harnesses shall be used in fall restraint systems.

4.17.7.3 Perimeter safety cables shall meet the criteria for guardrail systems in Practice 19—Fall Protection.

4.17.8 Fall protection provided by the steel erector shall remain in the area where steel erection activity has been completed, to be used by other trades, only if the Construction Manager or its authorized representative:

4.17.8.1 Has directed the steel erector to leave the fall protection in place; and

4.17.8.2 Has inspected and accepted control and responsibility of the fall protection prior to authorizing persons other than steel erectors to work in the area.

4.18 Training

4.18.1 Training required by this section shall be provided by a qualified person(s).

4.18.2 Training will be provided for all employees exposed to fall hazards and shall include training and instruction in the following areas:

4.18.2.1 The recognition and identification of fall hazards in the work area;

4.18.2.2 The use and operation of guardrail systems (including perimeter safety cable systems), personal fall arrest systems, positioning device systems, fall restraint systems, safety net systems, and other protection to be used;

4.18.2.3 The correct procedures for erecting, maintaining, disassembling, and inspecting the fall protection systems to be used;

4.18.2.4 The procedures to be followed to prevent falls to lower levels and through or into holes and openings in walking/working surfaces and walls; and

4.18.2.5 The fall protection requirements of this subpart.


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4.18.3 In addition to the training required in paragraph 4.15.3, the training shall be provided to employees engaged in the following activities.

4.18.4 Employees who performs multiple lift rigging will be provided training in the following areas:

4.18.4.1 The nature of the hazards associated with multiple lifts; and

4.18.4.2 The proper procedures and equipment to perform multiple.

4.18.5 Each connector will be provided training in the following areas:

4.18.5.1 The nature of the hazards associated with connecting; and

4.18.5.2 The establishment, access, proper connecting techniques and work practices.

4.18.6 Where CDZs are being used, the employer shall assure that each employee has been provided training in the following areas:

4.18.6.1 The nature of the hazards associated with work within a controlled decking zone; and

4.18.6.2 The establishment, access, proper installation techniques and work practices.

4.18.7 Structural steel erection crews shall work under the direction of experienced foremen.

4.18.8 Workers shall not ride on loads being hoisted, nor slide down ropes, columns, or ladders.

4.18.9 Wire rope chokers shall be used to lift loads of structural steel weighing over 500 pounds. Care shall be taken to avoid sharp bends in the rope by using softeners between the wire rope and the load. Bundle ties shall not lift reinforcing steel.

4.18.10If float scaffolds are used during steel erection, they shall be used in accordance with OSHA 1926 and Practice 16.

4.18.11The use of wire rope or similar material for temporary safety railing shall be discouraged. Planning and coordinating of timely steel shipments shall be arranged with vendors to maximize use of permanent perimeter protection (standard guardrail systems) as steel erection progresses.

4.18.12The fall protection plan (See Fall Protection Practice 19) shall be strictly enforced and adhered to by all personnel.

4.18.13Air hoses, extension cords, and welding leads shall not be laid, or run through, walkways, stairways. In the event that an air hose, extension cord or welding lead must be run across a walkway it shall be covered or otherwise protected to prevent a tripping hazard or damage and interference with the source.


5.1 None


HSE Practice 21 Hand Tools

® HAND TOOLS PRACTICE 21 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for the safe use of hand tools.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart I (1926.300 - 1926.307)

2.2 SASO 323—Industrial Safety and Health Regulations: Equipment—Portable Tools

3.0 Definitions

3.1 None

4.0 Procedures

4.1 General

4.1.1 Hand tools shall only be used for the purpose for which they were designed.

4.1.2 Employees shall only use tools that are in good condition. Worn or broken tools must be repaired or replaced immediately.

4.1.3 Employees shall use the appropriate safety equipment for each tool.

4.1.4 Employees shall properly store tools that are not in use. Proper storage includes toolboxes, tool racks, and cabinets.

4.1.5 Employees shall not leave tools in overhead work areas creating a hazard to personnel and equipment below.

4.1.6 Employees shall not carry a sharp or pointed tool in his/her pockets or belt.

4.1.7 The wooden handles of tools shall be kept free from splinters or cracks and shall be kept tightly fixed in the tool.

4.2 Hammers and Sledges

4.2.1 Employees shall wear appropriate eye protection.

4.2.2 Employees shall check behind themselves before swinging a hammer or sledge.

4.2.3 Employees shall be instructed to keep their eyes on the object to be hit.

4.2.4 Employees shall never use a damaged hammer or sledge.

4.3 Chisels and Punches

4.3.1 Employees are required to wear appropriate eye protection.

4.3.2 Employees shall keep chisels sharp and in good condition. Repair or replace dull or damaged tools.

4.3.3 Employees shall be instructed to strike blows squarely and aim a chisel or punch away from the body.

4.3.4 Mushroom heads of chisels and punches shall be ground down to prevent spalling.

4.4 Wrenches

4.4.1 Employees shall not use a "cheater" to increase leverage.

4.4.2 Whenever possible, employees shall pull on the wrench handle rather than push. They shall be instructed to adjust their stance to avoid a fall if the wrench slips.

4.4.3 Employees shall repair or discard any worn or damaged wrenches.

4.4.4 Employees shall never use hand sockets on power or impact tools.

® HAND TOOLS PRACTICE 21 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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4.4.5 Employees shall not use a hammer on a wrench unless it is the striking face type.

4.5 Pliers

4.5.1 Employees shall not use pliers for cutting hardened wire unless they are specifically made to do so.

4.5.2 Employees shall not use pliers as a striking tool.

4.5.3 Employees shall use dielectric pliers and shut off power when working with electricity.

4.6 Screwdrivers

4.6.1 Employees shall use a screwdriver with the right type of blade and one that properly fits the size screw.

4.6.2 Employees shall never use a bent or damaged screwdriver.

4.6.3 Employees shall not use a screwdriver as a prybar or a chisel.

4.6.4 Employees shall keep handles free of grease and oil.

4.7 Hand Saws


4.7.2 Employees shall keep saw blades sharp. Resharpen or replace blades that have lost cutting teeth.

4.7.3 Employees shall lubricate hacksaw blades with light machine oil to prevent heat build-up, which can cause the blade to break.

4.7.4 Employees shall store saws to prevent someone from falling onto or bumping into the blades.

5.0 Record Retention None


HSE Practice 22 Power Tools

® POWER TOOLS PRACTICE 22 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for the safe use of power tools.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart I (1926.300 - 1926.307)


3.0 Definitions

3.1 None

4.0 Process

4.1 General

4.1.1 Employees shall follow all Manufacturers’ instructions regarding the safe storage, operation, and maintenance of power tools.

4.1.2 Employees shall not use a power tool unless they have been trained to use it properly and safely.

4.1.3 All guards shall be in place before operating the tool.

4.1.4 Appropriate eye protection shall be worn when operating or working near power tools.

4.1.5 Employees shall not wear loose-fitting clothing or jewelry when using power tools.

4.1.6 Employees shall disconnect the tool before changing blades, bits, etc.

4.1.7 Employees shall remove chuck keys, etc., before using a power tool.

4.1.8 Employees shall disconnect power tools from the power source by pulling out on the plug; do not pull on the power cord.

4.1.9 Tools shall be either double insulated or have three-prong plugs with grounded extension cords and receptacles.

4.1.10 Tools that do not have the current assured grounding program color code tape shall not but used be will be immediately taken to the tool room for testing.

4.1.11 Employees shall be required to keep their finger off the trigger and make sure the switch is "off" before plugging in a tool.

4.1.12 Employees shall not use electric tools that have worn or damaged plugs or cords.

4.1.13 Employees shall secure small pieces of work with a clamp or in a vise.

4.1.14 When using power tools, the work area shall be kept free of any trip hazards or slippery conditions.

4.1.15 Employees shall never use compressed air to blow off equipment or clothing.

4.1.16 All power tools shall be used for their intended use only.

4.1.17 Cords of power tools shall not be used as handles for raising or lowering purposes.

4.1.18 All power tools and will be inspected prior to being allowed on-site to ensure the safety mechanisms and guards are worker properly.

4.1.19 Safety clips or retainers shall be securely installed and maintained on pneumatic impact (percussion tools to prevent attachments from being accidentally expelled.


9905-02-000.doc 12/8/2004 2

4.1.20 All pneumatically driven nailers, staplers, and other similar equipment provided with automatic fastener feed, which operate at more than 7kg/cm2 pressure, shall have a safety device on the muzzle to prevent the tool from ejecting fasteners, unless the muzzle is in contact with the work surface.

4.2 Saws

4.2.1 General

4.2.1.1 Employees shall not jam or force saws into the work.

4.2.1.2 Portable saws shall have a spring-loaded operating switch.

4.2.1.3 Employees shall be instructed to stay out of the saw's line of cutting.

4.2.1.4 Employees shall be instructed to start and stop the saw outside the work piece.

4.2.1.5 Employees shall not lock the trigger in case the saw needs to be stopped quickly.

4.2.1.6 Employees shall wear appropriate eye and hearing protection.

4.2.2 Circular Saws

4.2.2.1 Employees shall wear appropriate eye protection.

4.2.2.2 Employees shall not manually retract the lower guard while the blade is moving.

4.2.2.3 Employees shall use the retracting handle or safety lift lever to move the lower guard.

4.2.2.4 Employees shall not clamp or tie the guard open.

4.2.2.5 Employees shall not operate the saw if the guard is not working properly.

4.2.2.6 Employees shall keep their hand(s) away from the blade while using the saw.

4.2.2.7 Employees shall keep the power cord out of the line of the saw cut.

4.2.3 Reciprocating Saws

4.2.3.1 Employees shall wear appropriate eye protection.

4.2.3.2 Employees shall not use the saw unless the insulating boot is in place.

4.2.3.3 Employees shall be especially careful to keep their hands away from the blade when using this tool.

4.2.4 Portable Band Saws

4.2.4.1 Employees shall return dull or damaged blades to the Tool Room. Do not leave blades in the work area creating a trip hazards.

4.2.4.2 Employees shall not remove any Manufacturer’s guards or guides.

4.2.5 Radial Arm Saws

4.2.5.1 The radial arm shall be self-retracting.

4.2.5.2 Employees shall not remove any manufacturers' guards.

4.2.5.3 Only authorized employees shall use a radial arm saw.


9905-02-000.doc 12/8/2004 3

4.3 Drills


4.3.2 Employees shall not use dull or chipped bits .

4.3.3 Employees shall let the bit cool down before changing or adjusting it.

4.3.4 Employees shall not force the drill into the work.

4.3.5 Employees shall not lock the trigger in case the saw needs to be stopped quickly.

4.3.6 Employees shall use a light oil to keep the bit lubricated and cool during use.

4.4 Pneumatic Tools

4.4.1 Employees shall wear appropriate eye and hearing protection.

4.4.2 Pneumatic power tools shall be securely attached to the compressed air hose by the use of wire or a retaining pin.

4.4.3 Employees shall not make adjustments to pneumatic tools until air pressure is no longer being supplied to the hose or tool.

4.4.4 Employees shall not hoist, lower, or carry a tool by the hose.

4.4.5 Pneumatic impact tools shall have safety clips or retainers for tool bits.

4.4.6 Employees shall follow the manufacturers' guidelines for safe operating pressures.

4.4.7 Employees shall locate all air hoses so they do not present a tripping hazard.

4.4.8 A safety device shall be at the source of supply to reduce pressure in case of hose failure for all hoses exceeding ½ inch inside diameter.

4.4.9 Employees shall not lock the trigger in case the saw needs to be stopped quickly.

4.4.10 Airline hose section connections shall be secured against separation. "Chicago" couplings shall be pinned together.

4.5 Bench Grinders

4.5.1 Employees shall wear appropriate eye protection (goggles and a face shield).

4.5.2 Grinding wheels shall be covered with a safety guard.

4.5.3 Tool rests of bench grinders shall be well supported and be no more than 1/8 inch (3 mm) from the wheel. Employees shall not adjust a tool rest while the wheel is in motion.

4.5.4 Employees shall not grind on the side of the wheel unless it is designed to be used as a side grinder.

4.5.5 Employees shall never leave a running grinder unattended.

4.5.6 Employees shall make sure the work area around the grinder is clear before starting the grinder. Stand off to one side of the grinder when starting it.

4.5.7 Bench grinders shall be set up in a non-traffic area.

4.6 Portable Grinders

4.6.1 Employees shall wear full-face shield over safety goggles as a minimum.

4.6.2 Employees shall tuck shirt in when using grinders and long sleeves shall be buttoned.

4.6.3 Employees shall not operate grinders without proper guards.


9905-02-000.doc 12/8/2004 4

4.6.4 Employees shall not use a portable side grinder as a replacement for a bench grinder.

4.6.5 Employees shall never operate a portable grinder without the wheel guard installed.

4.7 Magnetic Base Drills

4.7.1 Employees shall use a safety chain to secure mag drills to the work.

4.7.2 Electrical cord connections shall be taped.


All applicable training records shall be maintained on file in the project HSE office for the duration of the project.


HSE Practice 23 Powdered Actuated Tools

® POWDERED ACTUATED TOOLS PRACTICE 23 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice establishes the minimum requirements for the safe use of powder-actuated tools.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart I (1926.302)


3.0 Definitions

3.1 Flammable Material - Liquids, solids, or gases that are capable of being easily ignited, burning intensely, or having a rapid rate of flame spread (usually dusts, fine powders, or substances that ignite spontaneously at low temperatures)

3.2 High Velocity Guns - Stud or fastener velocity exceeds 300 fps at 6.5 feet from muzzle.

3.3 Low Velocity, High Inertia Guns - Stud or fastener velocity does not exceed 300 FPS at 6.5 feet from muzzle.

4.0 Process

4.1 General

4.1.1. All manufacturer’s recommendations and local laws governing the proper use, inspection and maintenance of powder actuated tools shall be followed.

4.1.2. Only authorized, certified employees will be allowed to use powder-actuated tools.

4.1.3. The following general precautions are applicable to all types of powder-actuated stud guns:

4.1.3.1. Explosive powder-actuated tools and ammunition must be kept in a locked box at all times (other than when being used) to prevent unauthorized use.

4.1.3.2. Storage of tools, ammunition, and studs shall be controlled and only authorized, tra ined personnel can withdraw them for use.

4.1.3.3. Tool Manufacturer’s representatives shall train, qualify, and certify site employees in the use and maintenance of stud guns.

4.1.3.4. A current certification card (Tool Manufacturer’s specific card) for the powder-actuated tool being used must be in the operator's possession.

4.1.4. The powder-actuated tool shall not be used where the stud is to be driven into surface-hardened steel, cast iron, glazed brick or tile, marble, granite, live rock, the edge of concrete slabs or similar brittle materials.

4.1.5. Tools must not be used in any location where explosives, flammable gasses, vapors, or dusts are present.

4.1.6. The tool operator and any nearby workers must wear face shields and goggles when the tool is being used. Ear protection shall be used 100 percent of the time this tool is used. Other workers in the vicinity shall also wear ear protection.

4.1.7. The utmost care must be exercised to ensure that ammunition, studs, nails, etc., are of the proper specification.

4.1.8. At all times, the tool must be equipped with the proper ricochet or spall guard.

® POWDERED ACTUATED TOOLS PRACTICE 23 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 2

4.1.9. Barricades shall be erected and signs warning that powder-actuated tools are in use shall be posted.

4.1.10. Spent or misfired cartridges shall be disposed of and shall not be left in the work area.

4.1.11. The tools shall be so designed that all breeching parts will be reasonably visible to allow check of any foreign matter that may be present.

4.2 High Velocity Guns

4.2.1. Only the "captive stud" type of gun should be used. Guns capable of firing a stud into free flight at high velocity are prohibited.

4.2.2. No stud is to be driven closer than 3 inches to the edge of brick, concrete, or masonry surfaces because of their tendency to split or crack. Exceptions to this rule may be made where steel safety shields are placed on the sides of the surfaces, as in the case of concrete curbs to prevent flying spalls.

4.2.3. In case of misfire, the tool shall be kept in operating position for 1 full minute then placed in vertical position, muzzle down, while the charge is removed.

4.2.4. The tool shall never be pointed at anyone. The line of fire—whether up, down, or across—must be clear of personnel. Do not assume the stud will not shoot all the way through something.

4.2.5. Studs shall never be driven through predrilled or prepunched holes in fixtures or material without a special guard designed for this type of operation.

4.2.6. Barricades shall be erected and signs warning that powder-actuated tools are in use shall be posted.

4.2.7. The muzzle end of the tool shall have a protective shield or guard at least 9 cm in diameter, mounted perpendicular to and concentric with the barrel, and so designed as to confine any flying fragments or particles that might otherwise create a hazard at the time of firing.

4.2.8. Where a standard shield or guard cannot be sued, or where it does not cover all apparent avenues through which flying particles might escape, a special shield, guard, fixture, or jig designed and built by the manufacturer of the tool shall be used as a substitute, to provide this degree of protection.

4.3 Low Velocity, High Inertia Guns

4.3.1. This type of gun employs the principle of a powder-actuated captive piston (high mass) driving a free stud at low velocity. Stud-driving energy is derived from piston inertia. Once free of the piston, the stud alone has insufficient inertia to produce free flight, ricochets, penetration, etc. This type of gun is recommended from both safety and productivity standpoints.

4.3.2. The general precautions specified in 4.1 will be followed.

5.0 Record Retention A copy of the employee’s Powder Actuated Tool Certification Card (Tool Manufacturer’s card) shall be kept on file in the project HSE office for the duration of the project.


HSE Practice 24 Electrical Safety

® ELECTRICAL SAFETY PRACTICE 24 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice gives the requirements to minimize unsafe conditions involving electrical equipment and tools, including faulty insulation, improper grounding, loose electrical connections, defective parts, ground faults in equipment, and unguarded live electrical parts.

2.0 References

2.1 Title 29 Code of Federal Regulation (CFR) Part 1926 Subpart K (1926.400 - 1926.416)

2.2 UL Standard 943—Ground Fault Circuit Interrupter

2.3 National Electric Code (NEC)—1996

2.4 SASO 332 Industrial Safety and Health Regulations—Part 7 – Electrical—Section 7.1 General

2.5 SASO 333 Industrial Safety and Health Regulations—Part 7 – Electrical—Section 7.2 Low Voltage

2.6 SASO 334 Industrial Safety and Health Regulations—Part 7 – Electrical—Section 7.3 High Voltage

3.0 Definitions

3.1 Exposed (As applied to live parts)—Capable of being inadvertently touched or approached nearer than a safe distance by a person. It is applied to parts not suitably guarded, isolated, or insulated. (See Accessible. and Concealed.)

3.2 Ground—A conducting connection, whether intentional or accidental, between an electrical circuit or equipment and the earth, or to some conducting body that serves in place of the earth.

3.3 Ground-Fault Circuit-Interrupter—A device whose function is to interrupt the electric circuit to the load when a fault current to ground exceeds some predetermined value that is less than that required to operate the over current protective device of the supply circuit.

3.4 Guarded—Covered, shielded, fenced, enclosed, or otherwise protected by means of suitable covers, casings, barriers, rails, screens, mats, or platforms to remove the likelihood of approach to a point of danger or contact by persons or objects.

3.5 Isolated—Not readily accessible to persons unless special means for access are used.

3.6 Qualified Person1, 2—One familiar with the construction and operation of the equipment and the hazards involved.

4.0 Process

4.1 General

4.1.1 Only qualified persons may work on electric circuit parts or equipment that have not been deenergized. Such persons shall be capable of working safely on

1 Whether an employee is considered a "qualified person" will depend upon various circumstances in the

workplace. It is possible and, in fact, likely for an individual to be considered qualified" with regard to certain equipment in the workplace, but "unqualified" as to other equipment.

2 An employee, who is undergoing on-the-job training and who, in the course of such training, has demonstrated an ability to perform duties safely at his or her level of training and who is under the direct supervision of a qualified person is considered a qualified person for the performance of those duties.


9905-02-000.doc 12/8/2004 2

energized circuits and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools.

4.1.2 All employees shall be trained in and familiar with the safety-related work practices required by this practice that pertains to their respective job assignments.

4.1.3 Unqualified persons shall also be trained in and familiar with any electrically related safety practices not specifically addressed in this practice, but which are necessary for their safety.

4.1.4 Qualified persons (i.e. those permitted to work on or near exposed energized parts) shall, at a minimum, be trained in and familiar with the following:

4.1.4.1 The skills and techniques necessary to distinguish exposed live parts from other parts of electric equipment.

4.1.4.2 The skills and techniques necessary to determine the nominal voltage of exposed live parts, and

4.1.4.3 The clearance distances and the corresponding voltages to which the qualified person will be exposed.

4.1.5 If work is to be performed near overhead lines, the lines shall be deenergized and grounded, or other protective measures shall be provided before work is started. If the lines are to be deenergized, arrangements shall be made with the person or organization that operates or controls the electric circuits involved to deenergize and ground them. If protective measures, such as guarding, isolating, or insulating, are provided, these precautions shall prevent employees from contacting such lines directly with any part of their body or indirectly through conductive materials, tools, or equipment.

4.1.6 When an unqualified person is working in an elevated position near overhead lines, the location shall be such that the person and the longest conductive object he or she may contact cannot come closer to any unguarded, energized overhead line than the following distances:

4.1.6.1 For voltages to ground 50kV or below - 10 feet (305 cm);

4.1.6.2 For voltages to ground over 50kV - 10 feet (305 cm) plus 4 inches (10 cm) for every 10kV over 50kV.

4.1.7 When an unqualified person is working on the ground near overhead lines, the person may not bring any conductive object closer to unguarded, energized overhead lines than the distances given in 4.1.10.3.

4.1.8 For voltages normally encountered with overhead power line, objects that do not have an insulating rating for the voltage involved are considered conductive.

4.1.9 When a qualified person is working in the vicinity of overhead lines, whether in an elevated position or on the ground, the person may not approach or take any conductive object without an approved insulating handle closer to exposed energized parts than shown in 4.1.10.3 unless:

4.1.9.1 The person is insulated from the energized part (gloves, with sleeves if necessary, rated for the voltage involved are considered to be insulation of the person from the energized part on which work is performed), or


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4.1.9.2 The energized part is insulated both from all other conductive objects at a different potential and from the person, or

4.1.9.3 The person is insulated from all conductive objects at a potential different from that of the energized part.

Approach Distances for Qualified Employees—Alternating Current

Voltage Range (phase to phase) Minimum Approach Distance

300V and less Avoid Contact

Over 300V, not over 750V 1 ft. 0 in. (30.5 cm).

Over 750V, not over 2kV 1 ft. 6 in. (46 cm).

Over 2kV, not over 15kV 2 ft. 0 in. (61 cm).


Over 37kV, not over 87.5kV 3 ft. 6 in. (107 cm).

Over 87.5kV, not over 121kV 4 ft. 0 in. (122 cm).


4.1.10 Any vehicle or mechanical equipment capable of having parts of its structure elevated near energized overhead lines shall be operated so that a clearance of 10 ft. (305 cm) is maintained. If the voltage is higher than 50kV, the clearance shall be increased 4 in. (10 cm) for every 10kV over that voltage. However, under any of the following conditions, the clearance may be reduced:

4.1.10.1 If the vehicle is in transit with its structure lowered, the clearance may be reduced to 4 ft . (122 cm). If the voltage is higher than 50kV, the clearance shall be increased 4 in. (10 cm) for every 10 kV over that voltage.

4.1.10.2 If insulating barriers are installed to prevent contact with the lines, and if the barriers are rated for the voltage of the line being guarded and are not a part of or an attachment to the vehicle or its raised structure, the clearance may be reduced to a distance within the designed working dimensions of the insulating barrier.

4.1.11 If the equipment is an aerial lift insulated for the voltage involved, and if the work is performed by a qualified person, the clearance (between the uninsulated portion of the aerial lift and the power line) may be reduced to the distance given in 4.1.10.3.

4.1.12 Employees standing on the ground may not contact the vehicle or mechanical equipment or any of its attachments, unless:

4.1.12.1 The employee is using protective equipment rated for the voltage; or

4.1.12.2 The equipment is located so that no uninsulated part of its structure (that portion of the structure that provides a conductive path to employees on the ground) can come closer to the line than permitted in 4.1.10.3.

4.1.13 If any vehicle or mechanical equipment capable of having parts of its structure elevated near energized overhead lines is intentionally grounded, employees working on the ground near the point of grounding may not stand at the


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grounding location whenever there is a possibility of overhead line contact. Additional precautions, such as the use of barricades or insulation, shall be taken to protect employees from hazardous ground potentials, depending on earth resistivity and fault currents, which can develop within the first few feet or more outward from the grounding point.

4.1.14 Employees may not enter spaces containing exposed energized parts, unless illumination is provided that enables the employees to perform the work safely.

4.1.15 Where lack of illumination or an obstruction precludes observation of the work to be performed, employees may not perform tasks near exposed energized parts. Employees may not reach blindly into areas that may contain energized parts.

4.1.16 When an employee works in a confined or enclosed space (such as a manhole or vault) that contains exposed energized parts, the employee shall use protective shields, protective barriers, or insulating materials as necessary to avoid inadvertent contact with these parts. Doors, hinged panels, and the like shall be secured to prevent their swinging into an employee and causing the employee to contact exposed energized parts.

4.1.17 Conductive materials and equipment that are in contact with any part of an employee's body shall be handled in a manner that will prevent them from contacting exposed energized conductors or circuit parts. If an employee must handle long dimensional conductive objects (such as ducts and pipes) in areas with exposed live parts, the project shall institute work practices (such as the use of insulation, guarding, and material handling techniques) that will minimize the hazard.

4.1.18 Portable ladders shall have nonconductive side rails if they are used where the employee or the ladder could contact exposed energized parts.

4.1.19 Conductive articles of jewelry and clothing (such a watch bands, bracelets, rings, key chains, necklaces, metalized aprons, cloth with conductive thread, or metal headgear) may not be worn if they might contact exposed energized parts. However, such articles may be worn if they are rendered nonconductive by covering, wrapping, or other insulating means.

4.1.20 When an electrical ground fault occurs, the current flows through the path having minimum impedance to ground. It is imperative that an employee does not inadvertently become the conductor of the current.

4.1.21 Two approved methods of protecting the worker from a ground fault, in addition to other requirements for equipment-grounding conductors, are:

4.1.21.1 Use of ground fault circuit interrupters (GFCI)

4.1.21.2 An assured equipment grounding conductor program

4.1.22 Only one of the two methods specified in 4.1.3 can be used for personnel safety at a single location. A combination of both methods cannot be used within a single location.

4.2 Ground Fault Circuit Interrupter (GFCI)

4.2.1 Attention shall be given to proper installation and main tenance of GFCIs within the require ments of the National Electrical Code (NEC) current edition (1996). The system shall be tested before being put in service, and the test results shall be documented and kept on file.


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4.2.2 In purchasing GFCIs, the specifications shall state that GFCIs shall meet the Underwriters Laboratories Standard 943, Ground Fault Circuit Interrupters.

4.2.3 Each circuit protected by a circuit breaker GFCI requires its own neutral conductor.

4.2.4 Receptacle-type GFCIs may be used on common neutral systems and where receptacles are more than 250 feet from the breaker.

4.2.5 A GFCI polarity tester shall be used to ensure trip current values and to test the satellite receptacles downstream from the receptacle containing a GFCI.

4.2.6 GFCIs are to be installed on circuit breakers used for construction power.

4.3 Assured Equipment Grounding Program

Wherever possible, GFCIs are to be used instead of an Assured Grounding Program.

4.3.1 The goals of an effective program are:

4.3.1.1 To reduce the potential of injuries caused by electric shock from cord sets, receptacles, and equipment connected by cord and plug

4.3.1.2 To meet the requirements of local, state, and federal rules and regulations

4.3.2 The electrical supervisor shall ensure that an inspection and test be performed on each cord set, electric tool, piece of electrical equipment, and receptacle using the following schedule:

4.3.2.1 Before first use

4.3.2.2 Before equipment is returned to service following repairs

4.3.2.3 Before equipment is used following any incident that can be reasonably suspected to have caused damage to the cord set, electric tool, piece of electrical equipment, or receptacle.

4.3.2.4 Every month

4.3.3 The monthly inspections shall be the responsibility of the electrical supervisor. Each cord set, electric tool, receptacle, and piece of electrical equipment shall be tested to ensure a continuous ground circuit, and that the equipment grounding conductor is connected to its proper terminal. The testing equipment shall be capable of testing for ground conductor continuity and resistance line fault and proper connection of conductors to terminals. Testing equipment shall also be tested each month. These results shall be documented, and the documents shall be main tained by the electrical supervisor and a copy in the HSE files.

4.3.4 Receptacles that are a permanent part of the wiring of permanent buildings are excluded from the monthly testing and inspection requirements of this Practice. Also excluded are trailers, change shacks, butler-type buildings, and similar structures. However, after installa tion and before initial use and on a quarterly basis thereafter, each receptacle shall be tested.

Note: If permanent receptacle(s) of permanent buildings, trailers, change shacks, butler-type buildings, or similar structures are being used to support construction activities, a ground fault circuit interrupter device must be employed in conjunction with each cord set, electric tool, or piece of electrical equipment.

4.3.5 The user shall, visually inspect daily, each cord set, electric tool, or piece of electrical equipment, before it is used for signs of damage. These items shall be


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inspected for signs of frayed or damaged insulation, crushed cable, loose or missing covers or screws, missing ground prongs on plugs, and other similar substandard conditions. Equipment found to be damaged or defective shall not be used until repaired.

4.3.6 To verify inspection and testing, a piece of color-coded tape shall be affixed to each item inspected by the electrical inspector. Six colors of tape shall be used. The expiration date of each inspection period may be preprinted on the tape to avoid conflicts with other similar color-coded tapes on the project.

4.3.7 The inspection tape shall not be used for any other purpose. The Electrical Superintendent shall strictly control use of tape.

4.3.8 Any electric tool, cord set, or piece of electrical equipment bearing an expired inspection sticker or no inspection sticker shall be considered defective and is not to be used until it is inspected.

4.3.9 Only the electrical inspectors are authorized to remove inspection tape. Unauthorized removal or defacing of inspection tape shall be cause for disciplinary action.

4.3.10 A schedule shall be issued before each monthly inspection by the HSE Manager to coordinate the time and place for the inspection with each department or work area.

4.3.11 Each subcontractor's site manager shall implement the portions of this Practice that apply to its company.

4.3.12 The color-coding scheme shall be used by FLUOR ARABIA projects.

4.3.13 If an alternate color-coding scheme is required by client requirements, it shall be specified in the project’s written Assured Grounding Plan.

4.4 Temporary Construction Power

4.4.1 Construction distribution panels shall have no exposed openings into the energized buss bar. This includes exposed openings for breakers, conduit, or any other openings.

4.4.2 Only Qualified electricians shall install temporary construction power.

4.4.3 Breakers, control switches, knife switches, or pull boxes shall be labeled to indicate what they energize and their voltage rating.

4.4.4 Disconnects shall have a clear, unblocked path 3 feet wide or more in front of the disconnect to allow for ready access.

4.5 Use of Portable Electric Equipment—This applies to the use of cord- and plug-connected equipment, including flexible cord sets (extension cords).

4.5.1 Extension cords shall be marked as SJ, SJO, SJT, SJTO, S, SO, ST, or STO as required by OSHA 29 CFR 1926.

4.5.2 Splices shall retain the insulation, outer sheath properties, and usage characteristic of the cord being spliced.

4.5.3 Extension cords shall not be run through windows, doorways, walls, or similar openings unless they are protected from damage.

4.5.4 When cords are to be used in wet areas or exposed to the natural elements, they shall have connectors approved and designed for the location.

4.5.5 No receptacle or cord shall accept different voltage attachment plugs.


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4.5.6 Extension cords shall be protected from damage.

4.5.7 Extension cords shall be inspected before removal from a tool crib or before use (if not stored in the tool crib). Damaged cords shall not be used.

4.5.8 Extension cords used with portable electric tools and appliances shall be of a three-wire type.

4.5.9 Handling of portable electric equipment must be done in a manner that will not cause damage to the equipment.

4.5.10 Visual inspection of portable electric equipment must be made, before use, for external defects and for evidence of possible internal damage.

4.5.11 A flexible cord used with grounding type equipment must contain an equipment-grounding conductor.

4.5.12 A GFCI will be used on all outside work or in any area that has potential for shock (e.g., a wet area).

4.5.13 Portable electric equipment used in highly conductive work locations, or in job locations where employees are likely to contact water or conductive liquids, must be approved for those locations.

4.5.14 If energized equipment is involved, employees hands must not be wet when plugging or unplugging flexible cords.

4.6 Construction Offices

4.6.1 A qualified electrician shall wire construction offices.

4.6.2 Current OSHA and NEC codes for wiring temporary trailers/structures shall be followed.

4.6.3 Trailers shall have their frames grounded back through the service and locally grounded using ground rods and connections applicable to local conditions.

4.7 Guarding Live Parts

4.7.1 Live parts, 50 volts or more, shall be guarded against accidental contact except by qualified authorized persons.

4.8 Use of Electric Power and Lighting Circuits

4.8.1 Only approved equipment must be used for routine opening and closing of circuits.

4.8.2 After a circuit is deenergized by a circuit protective device, the circuit must not be manually reenergized until it has been determined that the equipment and circuit can be safety energized.

4.8.3 Overcurrent protection of circuits and conductors must not be modified, even on a temporary basis, beyond that allowed by Design Safety Procedure and the associated standards.

4.9 Use of Testing Instruments and Equipment.

4.9.1 Only qualified persons should perform testing work on electric circuits or equipment.

4.9.2 Test instruments and equipment must be visually inspected before the equipment is used.


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4.9.3 Test instruments and equipment must be rated for the circuits and equipment to which they will be connected and must be designed for the environment in which they will be used.

4.10 Occasional Use of Flammable or Ignitable Material

4.10.1 Electrical installation requirements for locations where flammable materials are present on a regular basis are covered by 29 CFR 1910.307.

4.10.2 Where flammable materials are present only occasionally, electric equipment capable of igniting them must not be used, unless measures are taken to prevent hazardous conditions from developing.

4.11 Use of Personal Protective Equipment

4.11.1 Employees working in areas where there are potential electrical hazards must use electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed.

4.11.2 Protective equipment must be maintained in a safe, reliable condition and must be periodically inspected or tested. Care must be taken to protect insulating material if subject to damage. Only non-conductive (type A or B) hard hats should be worn. Eye / face protection must be worn wherever there is a danger of injury from electric arcs or flashes or from flying objects resulting from an electrical explosion.

4.12 General Protective Equipment

4.12.1 When working near exposed energized conductors or circuit parts, each employee must use insulated tools or handling equipment if the tools or handling equipment might make contact with such conductors or parts.

4.12.2 Fuse handling equipment, insulated for the circuit voltage, must be used to remove or install fuses when the fuse terminals are energized. Ropes and handlines used near energized parts must be non-conductive.

4.12.3 Protective shields, protective barriers, or insulating materials must be used to protect each employee from shock, burns, or other electrically related injuries. When normally enclosed live parts are exposed for maintenance or repair, they must be guarded to protect unqualified persons from contact with the live parts.

4.13 Alerting Techniques

4.13.1 Safety signs, safety symbols, or accident prevention tags must be used where necessary to warn employees about electrical hazards which may endanger them.

4.13.2 Barricades must be used in conjunction with safety signs where it is necessary to prevent or limit employee access to work areas exposing employees to uninsulated energized conductors or circuit parts.

4.13.3 If signs and barricades do not provide sufficient warning and protection from electrical hazards, an attendant must be stationed to warn and protect employees.

4.14 Training

4.14.1 Training in electrical systems work safety procedures must include the following:

4.14.1.1 The hazards and safeguards associated with electrical systems.

4.14.1.2 New employee orientation level training should address inherent electrical hazards associated with the facility / site.


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4.14.1.3 Employees must be trained in and familiar with the safety-related work practices required by this procedure that pertain to their respective job assignments.

4.14.1.4 The training required by this procedure must be of the classroom or on the-job type. The degree of training provided must be determined by the risk to the employee. [OSHA 1910.332(c)]

4.14.1.5 Written training plans must be prepared and used for the training required by this procedure. Such training plans should be written to convey a record of training and:

4.014.1.5.1. Specific electrical hazards faced by the employee being trained must be addressed in the plan.

4.014.1.5.2. Provision for retraining and verification of retraining must be included in the training plan.

4.014.1.5.3. Verification of training must be accomplished by testing or practical demonstration. (See The Training Manual for test and training information)

4.014.1.5.4. All employees must have initial and periodic refresher training on the above. In addition, each supervisor must review any significant incidents involving electrical hazards or work practices in safety meetings.

4.14.2 Documentation of all electrical systems work safety procedures training is required. The following information should be included:

4.14.2.1 The date of the training.

4.14.2.2 Names of the participants and the instructor.

4.14.2.3 Summary of the subject matter presented.

4.14.2.4 Method of training and training aids used.

4.14.2.5 Method used to evaluate participant’s understanding.

SITE SUPERVISION SHOULD CONTINUE ON THE JOB INSTRUCTION TO EMPLOYEES AS NECESSARY TO ENSURE PROPER COMPLIANCE WITH THESE PROCEDURES.

5.0 Record Retention A record of each monthly equipment inspection shall be kept on file in the project HSE office for the duration of the project.


HSE Practice 25 Excavation & Trenching

® EXCAVATION & TRENCHING PRACTICE 25 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to provide the minimum requirements for work in and around excavations.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart P (1926.650 - 1926.652)

2.2 Yanpet H-P-0614—Excavations, Trenching & Shoring Procedure

2.3 SASO 337 Industrial Safety and Health Regulations—Parts 9, 10, 11, 12, 13, 14 Building Construction

3.0 Definitions

3.1 Accepted Engineering Practices—those requirements that are compatible with standards of practice required by a registered professional engineer.

3.2 Authorized Person for Underground Testing—the person(s) designated by the Construction Manager to identify underground utilities using a combination of blue prints and underground testing equipment. This individual shall coordinate excavation activities with the Client (as applicable) and outside utility companies. Several individuals (such as the Piping Superintendent, Electrical Superintendent, Equipment Superintendent, and Field Engineer) may serve as Authorized Persons as necessary.

3.3 Benching (Benching system)—a method of protecting employees from cave-ins by excavating the sides of an excavation to form one or a series of horizontal levels or steps, usually with vertical or near-vertical surfaces between levels.

3.4 Cave-In—the separation of a mass of soil or rock material from the side of an excavation, or the loss of soil from under a trench shield or support system, and its sudden movement into the excavation, either by falling or sliding, in sufficient quantity so that it could entrap, bury, or other wise injure and immobilize a person.

3.5 Competent Person—one who is capable of identifying existing and predictable hazards in the surroundings, or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

3.6 Excavation—any man-made cut, cavity, trench, or depression in an earth surface, formed by earth removal.

3.7 Excavation Competent Person—a person capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. The Construction Manager and Construction HSE Manager shall designate the Competent Person in writing and their qualifications shall be documented.

3.8 Hazardous Atmosphere—an atmosphere which by reason of being explosive, flammable, poisonous, corrosive, oxidizing, irritating, oxygen deficient, toxic, or otherwise harmful, may cause death, illness, or injury.

3.9 Protective System—a method of protecting employees from cave-ins, from material that could fall or roll from an excavation face, into an excavation, or from the collapse of adjacent structures. Protective systems include support systems, sloping and benching systems, shield systems, and other systems that provide the necessary protection.

3.10 Ramp—an inclined walking or working surface that is used to gain access to one point from another, and is constructed from earth or from structural materials such as steel or wood.


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3.11 Registered Professional Engineer—a person who is registered as a professional engineer in the state where the work is to be performed. However, a professional engineer, registered in any state is deemed to be a “registered professional engineer” within the meaning of this standard when approving designs for "manufactured protective systems" or “tabulated data” to be used in interstate commerce.

3.12 Shoring (Shoring System)—a structure such as a metal hydraulic, mechanical or timber shoring system that supports the sides of an excavation and which is designed to prevent cave-ins.

3.13 Sloping (Sloping System) —a method of protecting employees from cave-ins by excavating to form sides of an excavation that are inclined away from the excavation so as to prevent cave-ins. The angle of incline required to prevent a cave-in varies with differences in such factors as the soil type, environmental conditions of exposure, and application of surcharge loads.

3.14 Stable Rock—natural solid mineral material that can be excavated with vertical sides and will remain intact while exposed. Unstable rock is considered to be stable when the rock material on the side or sides of the excavation is secured against caving-in or movement by rock bolts or by another protective system that has been designed by a registered professional engineer.

3.15 Structural Ramp—a ramp built of steel or wood, usually used for vehicle access. Ramps made of soil or rock is not considered structural ramps.

3.16 Trench (Trench Excavation)—a narrow excavation (in relation to its length) made below the surface of the ground. In general, the depth is greater than the width, but the width of a trench (measured at the bottom) is not greater than 15 feet (4.6 m). If forms or other structures are installed or constructed in an excavation so as to reduce the dimension measured from the forms or structure to the side of the excavation to 15 feet (4.6 m) or less (measured at the bottom of the excavation), the excavation is also considered to be a trench.

4.0 Procedures

4.1 Requirements

4.1.1 This practice applies to any excavation or trench 300 mm or more in depth.

4.1.2 A designated Competent Person shall be onsite during which all excavation activities are conducted.

4.1.3 Before any excavation can be made, an Excavation Permit (DBN-F15) must be completed by the responsible Superintendent with input from the Authorized Person for underground testing (utility identification) and the Excavation Competent Person. DBN-F15—Excavation Permit will be completed and have proper project approval prior to obtaining a Yanpet Excavation Permit. Appropriate Client approval is also necessary where required by Client regulations. Client and/or utility company representatives shall be notified 24 hours prior to excavations begin. All utilities while exposed during an excavation will be protected from accidental damage.

4.1.4 Soil classification shall be made by the Competent Person or a registered Professional Engineer trained in soil classification. Unclassified soil shall be assumed to be Class “C” 1 and will be sloped 1½:1 or shored when the excavation exceeds 4 feet in depth. Additional guidance on soil classification will be made using the following table.

1 29 CFR 1926 Subpart P—Provides additional guidance on soil classification


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Soil Type1 Angle of Repose

Solid Rock, Shale, or Cemented Sand and Gravel2

90º

Compacted Angular Gravels 1 63º 26’ (½:1) Average Soils 1 45º (1:1) Compacted Sharp Sand1 33º 41’ (1-½:1) Well Rounded Loose Sand1 26º 34’ (2:1)

4.1.5 Excavations over 5 feet deep shall be shored, sloped, or benched as required. Excavations and the work scheduled to be performed in the excavation shall be evaluated by the Competent Person to determine if the shoring, sloping, or benching needs to begin at a depth less than 5 feet.

4.1.6 Shoring for excavations over 20 feet must be designed by a registered Profes-sional Engineer and shoring installed must be approved and signed off by a registered Professional Engineer.

4.1.7 Spoils must be placed a minimum of 3 feet from the edge of the excavation. Loose soil or rocks shall be removed from the sides of excavation walls.

4.1.8 Excavations 4 feet in depth or greater, must have a stairway, ladder, ramp, or other safe means of egress within 25 feet of any employee.

4.1.9 Excavations shall be inspected by a Competent Person before entry and the results recorded on DBN-F16.

4.1.9.1 At the start of each shift

4.1.9.2 After rain or snowfall

4.1.9.3 After freezing and/or thawing temperatures occur

4.1.9.4 After any condition that can change the integrity of the soil

4.1.10 During rainy weather, work in excavations shall cease until the Competent Person has evaluated the excavation and the effect of the rain on the excavation. The Competent Person will maintain a regular inspection schedule during rain events if employees continue to work in the excavation. Depending on the amount of rainfall, the duration of the rainfall and the soil type, the Competent Person may need to maintain continuous observation of the excavation conditions.

4.1.11 For excavations 4 feet in depth or greater, the potential for a hazardous atmosphere must be evaluated. If potential atmospheric hazards exist, then the atmosphere in the excavation must be tested. This test will be performed by the Construction HSE Manager or their designee. Indications of the potential for a hazardous atmosphere include, but are not limited to: gas lines, sewer lines, proximity to emissions sources for H2S, SO2, CO, CO2and other gases that are heavier than air.

4.1.12 Excavations shall be evaluated for hazards in addition to cave-in potential and atmospheric hazards. Electrical sources, energized (pressurized) pipes, underground tanks, etc. may also present a hazard to employees who are required to enter an excavation.

2 SASO 337/1982 Figure 9.4-1


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4.1.13 The Competent Person responsible for the crew working in the excavation must inspect the excavation throughout the work period, record the observations on LGH SFOR 6404-17.002, and stop operations when unsafe conditions exist.

4.1.14 The number of workers in the excavation shall be limited to the number needed to perform the work.

4.1.15 Water shall not be allowed to accumulate in excavations at any time. Pumps, drains, or other means shall be used to remove water constantly.

4.1.16 Stability of adjacent structures shall be evaluated before starting an excavation and monitored daily thereafter.

4.1.17 Emergency rescue equipment shall be readily available.

4.1.18 Each employee in an excavation shall be protected from cave-ins.

4.1.19 Employees will not be permitted to work under loads of digging equipment.

4.1.20 Employees exposed to falls by crossings and walkways will be provided with fall protection in accordance with Practice 19—Fall Protection.

4.1.21 Employees exposed to public traffic will be required to wear reflective vests.

4.1.22 If de-energization of underground utilities is NOT possible, or location is not definite, then the method of excavation shall be established to minimize hazards by such means as:

4.1.22.1 Use of hand tools in area of underground service.

4.1.22.2 Insulate men and equipment from possible electrical contact.

4.1.22.3 Use of tools or equipment that will reduce possibility of damage to underground service and hazard to workers (i.e. cable locator).

4.1.23 Unattended excavations must be barricaded to prevent inadvertent entry into the area. Adequate physical protection may be accomplished by placing “sawhorse” barricades at the avenues of approach and cordoning-off the area with barricade tape. During hours of darkness in high traffic areas, flashing yellow lights should be affixed to the sawhorse, or the area illuminated.

4.1.24 Personnel Entry Precautions—Personnel should not enter or perform work in an excavation which requires their head to be below the surface of the ground until:

4.1.24.1 Gas and oxygen tests have been secured.

4.1.24.2 A Confined Space Entry permit is obtained for entry into all excavations/trenches of more that 1.2 meters (4 feet) in depth and pits in which the lateral dimensions are less than the depth.

4.1.24.3 No person shall be permitted on or under load handling equipment such as power shovels, derricks, or hoist.

4.1.24.4 Daily inspection of excavations shall be made by a competent person. If evidence of possible cave-ins or slides is apparent, all work in the excavation shall cease until the necessary precautions have been taken to safeguard the employees.

4.1.24.5 Where employees or equipment are required or permitted to cross over excavations, walkways or bridges with standard guardrails shall be provided.


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4.2 Training

4.2.1 Employee training

4.2.1.1 Each employee who works in or around an excavation shall be trained to recognize potential hazards associated with excavations: cave-in potential, fall hazards, safe entry and exit, proximity to excavating equipment, air quality, back-filling and compacting activities, protective systems, etc. This training shall be documented and records maintained in the Project HSE files

4.2.2 Excavation Competent Person

4.2.2.1 Each individual assigned as an Excavation Competent Person shall have documented training or shall have documentation of experience and qualifications in excavation activities.


None


HSE Practice 26 Confined Space Entry

® CONFINED SPACE ENTRY PRACTICE 26 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to establish the minimum requirements for working in confined spaces.

2.0 References


2.2 Title 29 Code of Federal Regulations (CFR) Part 1910 Subpart J (1910.146)

2.3 Yanpet Confined Space Entry Procedure—H-P-0407

2.4 SASO 315 Industrial Safety and Health Regulations—Part 3 – Occupational Health and Environmental Controls

3.0 Definitions

3.1 Attendant—An individual stationed outside of a confined space assigned to monitor the confined space entry process and to perform the attendant's duties.

3.2 Acceptable Entry Conditions—the conditions that must exist in a permit space to allow entry and to ensure that employees involved with a permit-required confined space entry can safely enter into and work within the space.

3.3 Blanking or Blinding—the absolute closure of a pipe, line, or duct by the fastening of a solid plate (such as a spectacle blind or a skillet blind) that completely covers the bore and that is capable of withstanding the maximum pressure of the pipe, line, or duct with no leakage beyond the plate.

3.4 Calibration (for atmospheric monitoring equipment)— A process by which one documents that the atmospheric monitoring equipment is working properly and giving accurate readings. The process involves zeroing the instrument and a span check.

3.5 Combustible Material—Liquids, solids, or gases that are relatively difficult to ignite (140 degrees F. or more) and that burn relatively slowly (such as paper, wood, etc.)

3.6 Competent Person—One who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

3.7 Confined Space—a space that:

(1) Is large enough and so configured that an employee can bodily enter and perform assigned work; and (2) Has limited or restricted means for entry or exit (for example, tanks, vessels, silos, storage bins,

hoppers, vaults, and pits are spaces that may have limited means of entry.); and (3) Is not designed for continuous employee occupancy.

The space may also be subject to the accumulation of toxic or flammable contaminants or the development of an oxygen-deficient atmosphere, have the potential to engulf an entrant, have the potential to entrap an entrant, or have some electrical, mechanical or other physical hazard present. Confined spaces include, but are not limited to, storage tanks, bins, boilers, ventilation ducts, sewers, underground utility vaults, tunnels, pipelines, and open-top spaces more than four feet in depth, such as pits, vaults, trenches, excavations, sumps, vessels, drained swimming pools, etc.

3.8 Double Block and Bleed—the closure of a line, duct, or pipe by closing and locking or tagging two in-line valves and by opening and locking or tagging a drain or vent valve in the line between the two closed valves.


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3.9 Emergency—any occurrence (including any failure of hazard control or monitoring equipment) or event internal or external to the permit space that could endanger entrants.

3.10 Engulfment—the surrounding and effective capture of a person by a liquid or finely divided (flowable) solid substance that can be aspirated to cause death by filling or plugging the respiratory system or that can exert enough force on the body to cause death by strangulation, constriction, or crushing.

3.11 Entrapment—A person becoming trapped because of the configuration of the confined space, i.e., a hopper.

3.12 Entrant—The employees who have been trained and authorized to enter a particular confined space.

3.13 Entry—the action by which a person passes through an opening into a permit-required confined space. Entry includes ensuing work activities in that space and is considered to have occurred as soon as any part of the entrant's body breaks the plane of an opening into the space.

3.14 Entry Permit (permit)—the written or printed document to allow and control entry into a permit space and that contains the information specified in paragraph (f) of this section.

3.15 Entry Supervi sor 1—the person (such as the foreman, or crew chief) responsible for determining if acceptable entry conditions are present at a permit space where entry is planned, for authorizing entry and overseeing entry operations, ensuring that training requirements have been completed, and for terminating entry as required by this section.

3.16 Hazard Assessment—The process of evaluating a confined space to determine what safety precautions are required for safe entry. The hazard assessment is documented on the Safe Work Permit/Confined Space Entry Permit.

3.17 Hazardous Atmosphere—An atmosphere that exposes employees to a risk of death, incapacitation, injury, or acute illness. It may be caused by one or more of the following conditions:

3.17.1 An atmospheric oxygen concentration below 19.5 percent (an oxygen- deficient atmosphere) or above 23.5 percent (an oxygen-enriched atmo sphere) by volume

3.17.2 A flammable gas, vapor, or mist in excess of 10 percent of its Lower Explosive Limit (LEL)

3.17.3 A hydrogen sulfide gas concentration above 10 parts per million

3.17.4 A carbon monoxide gas concentration above 35 parts per million

3.17.5 An airborne combustible dust2 at a concentration that obscures vision at a distance of 5 feet or less

3.17.6 Presence of any acutely hazardous substance in an atmospheric concentration3 above the Permissible Exposure Limits (PEL) published in Subpart D of 29 CFR 1926.55. If a contaminant is not published in Subpart D, consult Material Safety Data Sheets, or other authoritative sources

1 An entry supervisor also may serve as an attendant or as an authorized entrant, as long as that person is

trained and equipped as required by this section for each role he or she fills. In addition, the duties of entry supervisor may be passed from one individual to another during the course of an entry operation.

2 This concentration may be approximated as a condition in which the dust obscures vision at a distance of 5 feet (1.52 m) or less.

3 An atmospheric concentration of any substance that is not capable of causing death, incapacitation, impairment of ability to self-rescue, injury, or acute illness due to its health effects is not covered by this provision.


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3.17.7 Any atmospheric condition4 recognized as Immediately Dangerous to Life or Health (IDLH) as specified by the National Institute of Occupational Safety and Health (NIOSH).

3.18 Hot Work Permit—the projects written authorization to perform operations (for example, riveting, welding, cutting, burning, and heating) capable of providing a source of ignition.

3.19 Immediately Dangerous to Life or Health (IDLH)5—any condition that poses an immediate or delayed threat to life or that would cause irreversible adverse health effects or that would interfere with an individual's ability to escape unaided from a permit space.

3.20 Inerting 6—the displacement of the atmosphere in a permit space by a noncombustible gas (such as nitrogen) to such an extent that the resulting atmosphere is noncombustible.

3.21 Isolation—the process by which a permit space is removed from service and completely protected against the release of energy and material into the space by such means as: blanking or blinding; misaligning or removing sections of lines, pipes, or ducts; a double block and bleed system; lockout or tagout of all sources of energy; or blocking or disconnecting all mechanical linkages.

3.22 Line Breaking—the intentional opening of a pipe, line, or duct that is or has been carrying flammable, corrosive, or toxic material, an inert gas, or any fluid at a volume, pressure, or temperature capable of causing injury.

3.23 Non-Permit Confined Space—a confined space that does not contain or, with respect to atmospheric hazards, have the potential to contain any hazard capable of causing death or serious physical harm.

3.24 Oxygen Deficient Atmosphere—an atmosphere containing less than 19.5 percent oxygen by volume.

3.25 Oxygen Enriched Atmosphere—an atmosphere containing more than 23.5 percent oxygen by volume.

3.26 Permit-Required Confined Space (permit space)—a confined space that has one or more of the following characteristics:

(1) Contains or has a potential to contain a hazardous atmosphere;

(2) Contains a material that has the potential for engulfing an entrant; (3) Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly

converging walls or by a floor which slopes downward and tapers to a smaller cross-section; or

(4) Contains any other recognized serious safety or health hazard.

3.27 Prohibited Condition—any condition in a permit space that is not allowed by the permit during the period when entry is authorized.

3.28 Rescue Service—the personnel designated to rescue employees from permit spaces.

4 For air contaminants for which OSHA has not determined a dose or permissible exposure limit, other

sources of information, such as Material Safety Data Sheets that comply with the Hazard Communication Standard, section 1910.1200 of this Part, published information, and internal documents can provide guidance in establishing acceptable atmospheric conditions.

5 Some materials -- hydrogen fluoride gas and cadmium vapor, for example -- may produce immediate transient effects that, even if severe, may pass without medical attention, but are followed by sudden, possibly fatal collapse 12-72 hours after exposure. The victim "feels normal" from recovery from transient effects until collapse. Such materials in hazardous quantities are considered to be "immediately" dangerous to life or health.

6 This procedure produces an IDLH oxygen-deficient atmosphere.


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3.29 Retrieval System—the equipment (including a retrieval line, chest or full-body harness, wristlets, if appropriate, and a lifting device or anchor) used for non-entry rescue of persons from permit spaces.

3.30 Span Check—A portion of the calibration procedure during which a gas mixture of known composition is passed over the sensors of the instrument and the instrument readings are verified. This is a distinct function within the calibration mode of most atmospheric monitoring instruments.

3.31 Testing7—the process by which the hazards that may confront entrants of a permit space are identified and evaluated. Testing includes specifying the tests that are to be performed in the permit space.

3.32 Zero Calibration—A portion of the calibration procedure during which the meter response is observed in clean room air or while administering bottled zero grade air.

4.0 Process

4.1 Written Plan

4.1.1 A site-specific, written Confined Space Plan shall be developed that: - Designates what types of training will be required

- Who will be trained - Rescue procedures - Personnel and training requirements

- Specific precautions for types of confined spaces, i.e., newly arrived/constructed confined spaces versus used contaminated confined spaces, and any other pertinent issues involving confined space entry.

4.2 Permit Required Confined Space Entry Program and Procedures

4.2.1 All permit required confined spaces will be identified by [supervisors, department heads, safety manager]. Exposed employees will be informed of such spaces through posting with warning signs or other equally effective means, such as facility maps or training [employer should specify which procedure is used in this program].

4.2.2 Only trained and qualified employees will be authorized as permit space entrants, attendant, or entry supervisor.

4.2.3 No employee shall enter a permit space without having a properly completed entry permit signed by an entry supervisor.

4.2.4 Entry permit procedures are as outlined below:

4.2.4.1 Entrants will obtain an entry permit from [location or person] prior to entry of the space.

7 Testing enables employers to both devise and implement adequate control measures for the protection of

authorized entrants and to determine if acceptable entry conditions are present immediately before, and during, entry.


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4.2.4.2 The entrant will accomplish all pre -permit actions required for entering the space, such as atmospheric testing, hazard control/elimination actions, have all required equipment on hand, provide for attendant and rescue services, etc.

4.2.4.3 Complete all items on the permit.

4.2.4.4 The entry will be authorized and the permit will be signed only by an authorized entry supervisor. If any item on the permit is checked as "NO" (meaning not yet completed or available), the permit will not be signed.

4.2.4.5 Entry may proceed. A copy of the entry permit will be placed outside the confined space until the permit has been cancelled by appropriate personnel.

4.3 Confined Space Identification

4.3.1 Confined spaces shall be identified as they develop or arrive on site. A survey of the project shall be on-going to identify the confined spaces and to determine the hazards associated with each confined space, i.e., past and present uses, access, mechanical energy sources, pipelines, etc.

4.3.2 A "Danger” - Confined Space sign shall be used to identify a confined space and is to remain at the entrance to the confined space.

4.4 Training

4.4.1 Employees shall receive awareness training regarding confined spaces.

4.4.2 Affected employees (entrants, attendant, rescuers, supervisors, monitoring/evaluating personnel, etc.) must be trained in aspects of the written plan that affect them. Training shall be documented. Entrants shall be trained in self-rescue.

4.4.3 Individuals entering Confined Spaces shall be provided with training. This training shall include a general confined space entry class and a specific pre -task review of any hazards identified for that space, a discussion of the work assignment and any control measures necessary for accomplishing the task in a safe manner.

4.4.4 Individuals entering confined spaces that have the potential for a hazardous atmosphere, materials that might engulf an entrant, a configuration that might trap an entrant or any other recognized hazard shall be provided with formal Confined Space Training. Training shall be developed for Authorized Entrants, Attendants, Entry Supervisors and Rescue/Emergency Service Personnel, and shall meet the requirements of 29 CFR Part 1910.146 (g)(1)-(4) and cover the duties outlined in 1910.146 (h)-(k).

4.4.5 Individuals conducting atmospheric monitoring shall be trained in the proper use and calibration of the monitoring equipment and documentation of the monitoring results.

4.4.6 Each employee will be trained before initial assignment, prior to a change in assigned duties, if a new hazard has been created, or special deviations have occurred.


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4.4.7 The training shall establish employee proficiency in the duties required by this section and shall introduce new or revised procedures, as necessary, for compliance with this practice.

4.5 Entry Practice

4.5.1 Safe Work Permit and Confined Space Entry Tag

4.5.1.1 A hazard assessment shall be performed and documented prior to entry. The supervisor in charge of the work must schedule this action.

4.5.1.2 Material Safety Data Sheets must be consulted for PPE requirements before entry into the space.

4.5.1.3 The supervisor will obtain a Yanpet Confined Space Entry Permit.

4.5.1.4 Permits will be cancelled by the entry supervisor upon completion of the work, or when any prohibited condition arises. Permits cannot just be let to expire. Cancelled permits must be kept for the annual review.

4.5.1.5 Program Review: Cancelled entry permits will be retained on file for at least one year. The Permit Space Program will be reviewed within one year of each entry using these cancelled permits to revise the program as necessary to ensure employees are protected from permit space hazards. A single review covering all entries in the preceding year may be conducted.

4.5.2 Atmospheric Monitoring

4.5.2.1 A Competent Person, prior to entering the Confined Space, shall test the internal atmosphere.

4.5.2.2 An attendant must be assigned to the confined space when the individual performing atmospheric monitoring is inside, in addition to other precautions necessary for the particular space.

4.5.2.3 The atmospheric testing shall be performed with a calibrated direct-reading instrument.

4.5.2.4 Instrument calibration (according to the manufacturer's instructions for zero calibration and span check) shall be conducted and documented each day the direct-reading instrument is used.

4.5.2.5 In order to account for the potential layering of contaminants in a confined space, the entire depth and width of the space shall be monitored.

4.5.2.6 The atmosphere shall be monitored for the following conditions in the order given:

• Oxygen content, (between 19.5 and 23.5 percent)

• Flammable gases and vapors, (less than 20% of the lower explosive limit (LEL)

• Potential toxic air contaminants below the permissible exposure limit (PEL).


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4.5.2.7 The monitoring results must be recorded on the Safe Work Permit and the Confined Space Entry Tag. (DBN-F36).

4.5.2.8 There may be no hazardous atmosphere within the space whenever any employee is inside. (Exception: in emergency maintenance/rescue situations, the atmosphere shall be considered IDLH and appropriate protective measures taken).

4.5.2.9 If tests indicate that the atmosphere is unsafe, the confined space shall be ventilated until the hazardous atmosphere is removed, before employee entry. The ventilation required shall be noted in the special “Precaution” section of the Safe Work Permit.

4.5.2.10 The atmosphere within the space shall be periodically tested as necessary to ensure that the continuous forced air ventilation is preventing the accumulation of a hazardous atmosphere.

4.5.2.11 If, after ventilating the space, tests indicate a hazardous atmosphere, no person will be allowed to enter unless equipped with an approved airline respirator equipped with an escape bottle or a self-contained breathing apparatus, safety harness, and lifeline. Such entries shall be made only during emergency situations and the number of workers participating shall be kept to a minimum.

4.5.3 Fire Prevention/Protection

4.5.3.1 Precautions shall be taken to prevent fires inside of confined spaces.

4.5.3.2 The need for a fire watch inside the confined space shall be evaluated and if needed one shall be assigned.

4.5.4 Piping/Vessel System Check

4.5.4.1 Energized piping systems shall be locked or blocked and tagged to isolate contaminants and energy.

4.5.5 Electrical Safety Check

4.5.5.1 Electrical energy sources shall be isolated.

4.5.6 Special Precautions

4.5.6.1 Communication requirements shall be evaluated during the hazard assessment. If an attendant is required, constant two-way communication shall be maintained between entrants and the attendant.

4.5.6.2 Low voltage, GFCI controlled or intrinsically safe lighting is required in metal tanks/vessels and in other confined spaces with flammable atmospheres. If GFCI’s are used on lights for confined space entry, backup lighting shall be immediately available in case the GFCI trips.

4.5.6.3 In potentially explosive or flammable atmospheres, non-sparking tools shall be used. Smoking, open flames, and cutting or welding is prohibited in these situations.

4.5.6.4 Continuous air monitoring, safety harnesses, and lifelines shall be required when the activities inside the confined space (such as cutting and welding, distributing accumulated sludge, or use of


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solvents) may produce a hazardous atmosphere; even if the initial atmospheric tests indicate a safe atmosphere.

4.5.6.5 As a minimum, an ATTENDANT is required for entries that involve any energy isolation, potential or actual hazardous atmosphere, engulfment, or entrapment.

4.5.6.6 Personal Protective Equipment such as coveralls, impervious gloves, boots, respirators, and face and eye protection shall be used as required by the nature of the operation to be performed.

4.5.6.7 Entrants shall wear a body harness with an attached lifeline secured to a fixed object outside the confined space unless there is written documentation on the safe work permit as to why it is more dangerous or impossible to do so.

4.5.6.8 In vertically accessed confined spaces, a mechanical hoisting device shall be immediately available for rescue.

4.5.7 Ventilation for Confined Space Entry

4.5.7.1 The forced air ventilation shall be so directed to ventilate the immediate areas where an employee is or will be present within the confined space and shall continue until employees have left the confined space;

4.5.7.2 The air supply of the forced air ventilation shall be from a clean source that does not increase the hazards in the space.

4.5.7.3 Ventilation smoke tubes shall be used to generate a visible smoke cloud in the confined space. This smoke shall be introduced into the space after the ventilation system has been set up so that the efficiency of the ventilation may be evaluated. If the "smoke test" indicates that the ventilation set up is not effective in carrying contaminants out of the confined space, the ventilation shall be rearranged and the smoke test repeated. This process shall be continued until the appropriate ventilation configuration has been established.

4.5.7.4 Exhaust fans should be used to provide local exhaust ventilation venting the fumes outside of the confined space during some tasks i.e., welding, and grinding. The hood/snorkel shall be located as close as possible to the point of generation of the fume or dust. As work progresses the hood/snorkel shall be moved in order to remain within inches of the work.

4.5.7.5 In some cases, it may be desirable to have exhaust fans located away from the work area. A supply of flexible hose may be attached to the suction end of the air mover and then be placed in the confined space to draw contaminants out of the space. Again, the efficiency of this set up shall be evaluated with a smoke test to ensure that contaminants are being pulled out of the space.

4.5.7.6 Ventilation shall consist of a pre-entry purge of several air changes, followed by additional air monitoring, and then continuous introduction of fresh air during occupancy.

4.5.7.7 Assuming the active generation of air borne contamination has been stopped, use the following equation to determine the


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minimum amount of time required to purge air contaminants to acceptable levels. This calculation must be performed for each air borne contaminant present and the longest purge time calculated will be used as the minimum purge time for the confined space.

ln-the natural logarithm

Q’—the effective flow rate of dilution air (cfm) V—the room volume (ft3) C1—initial concentration of air contaminants (ppm/106)

C2—final concentration ((exposure limit (ppm)/106)/2) SF—safety factor (minimum of 2)

4.5.8 Additional Training

4.5.8.1 A Competent Person shall review the additional training requirements. The training might include hazard communication; powder actuated tools, hearing conservation, respiratory protection, etc.

4.5.9 Hazards of near-by Areas

4.5.9.1 A Competent Person shall evaluate hazards of near-by areas. These hazards might include water run off, vehicle traffic, outside contaminants (exhaust emissions, pop-off valves, etc.), overhead work, etc.

4.5.10 Rescue Plan

4.5.10.1 The project will rely on Yanpet rescue team/services for any confined space rescues.

4.5.10.2 Non-entry rescue is the preferred method for rescue of personnel from a permit -required space. Employees will not enter a permit space for rescue unless they have been specifically trained and equipped for such rescue.

4.5.10.3 To facilitate non-entry rescue, retrieval systems or methods shall be used whenever an authorized entrant enter a permit space, unless the retrieval equipment would increase overall risk of entry or would not be of value to any rescue. Retrieval system requirements are:

4.05.10.3.1. Each entrant shall use a chest or full body harness, with a retrieval line attached at the center of the back near shoulder level, or other appropriate point.

∗

∗

−= SF

QV

CC

'lnTime Purge

1

2


9905-02-000.doc 12/8/2004 10

4.05.10.3.2. Other end of retrieval line shall be attached to a mechanical device or fixed point outside of permit space enabling immediate use. A mechanical device will be used to retrieve personnel from vertical type permit spaces more than five feet deep.

4.05.10.3.3. If injured entrant is exposed to any substance with a required MSDS or similar document, that MSDS or document will be made available to the medical facility treating the entrant.

4.5.10.4 If rescue should become necessary, the attendant will:

4.05.10.4.1. Notify and summon the Yanpet rescue team/service;

4.05.10.4.2. Monitor the situation and be ready to give rescuers information on how many victims and their status, what hazards, chemical types, concentrations, etc. are present.

4.5.10.5 Only designated Yanpet personnel will enter permit spaces for rescue purposes.

4.5.10.6 The Rescue Plan shall be developed by a Competent Person and shall include provisions for training, practice drills, body harnesses, life lines, hoisting equipment, communications, response ability, etc. as needed.

4.5.10.7 Self-rescue and non-entry rescue shall be the rescue method of choice when ever possible.

4.5.10.8 Only trained personnel shall attempt rescue. Training shall include

• Proper use of personal protective equipment

• Proper use of rescue equipment

• Current certification in first aid and CPR

• Blood-borne pathogens

• The same training as the authorized entrants

• Non-entry rescue techniques

• Rescue training on the types of rescues they will be expected to perform

• The rescue personnel shall be retrained in aspects of rescue at least annually.

4.5.11 The Safe Work Permit shall be posted at the confined space entrance while employees are working in the confined space.


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4.6 Equipment

4.6.1 A direct reading instrument that measures the percentage of the LEL and oxygen concentration simultaneously is recommended. Other atmo spheric monitoring equipment shall be used for monitoring other known gases such as hydrogen sulfide, sulfur dioxide, etc., which may be present in confined spaces (tanks, vessels, etc.) as needed.

4.6.2 A self-contained breathing apparatus (SCBA) or a TYPE-C supplied-air respirator with an escape bottle (10-minute) shall be used in atmospheres Immediately Dangerous to Life and Health (IDLH) and/or confined space rescues.

4.6.3 Harness and lifelines: A harness shall be capable of retrieving an inert body in an upright position. A parachute-type harness with a single lifting ring attached to the upper back, or with duel lifting rings attached to the shoulder straps, is required for confined space that have recognized hazards or a vertical entry of over five feet.

4.6.4 Ventilation: A portable blower shall be used to ventilate the space when atmospheric monitoring or the work to be done in the space indicates an actual or potential hazardous atmosphere.

4.7 Maintenance of Equipment

4.7.1 The Construction HSE Manager or designee shall main tain and ensure calibration of combustible gas/oxy gen meters, which must be readily available.

4.7.2 A Competent Person shall inspect rescue equipment each quarter. The inspection shall be documented by colored tape on the equipment (see color codes for assured grounding) or on logs.

4.8 Multiple Employer Entry

4.8.1 Procedures shall be developed to coordinate entry operations when employees of more than one employer, in addition to FLUOR ARABIA are working simultaneously as authorized entrants in a confined space, so that employees of one employer do not endanger the employees of any other employer.

4.8.2 At a minimum, in addition to complying with the confined space requirements of this procedure, each employer who is to perform confined space entry operations with FUOR ARABIA personnel shall:

4.8.2.1 Obtain any available information regarding confined space hazards and entry operations from FLUOR ARABIA.

4.8.2.2 Coordinate entry operations with FLUOR ARABIA, when both FLUOR ARABIA personnel and subcontractor personnel will be working in or near confined spaces as required.

4.8.2.3 Inform FLUOR ARABIA of the confined space program that the subcontractor will follow and of any hazards confronted or created in confined spaces, either through a debriefing or during the entry operation.

4.9 Entrants Shall:

4.9.1 Know the hazards that may be faced during entry, including information on the mode, signs or symptoms, and consequences of the exposure;

4.9.2 Properly use equipment as required by this practice;


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4.9.3 Communicate with the attendant as necessary to enable the attendant to monitor entrant status and to enable the attendant to alert entrants of the need to evacuate the space as required;

4.9.4 Alert the attendant whenever:

4.9.4.1 The entrant recognizes any warning sign or symptom of exposure to a dangerous situation, or

4.9.4.2 The entrant detects a prohibited condition; and

4.9.5 Exit from the permit space as quickly as possible whenever:

4.9.5.1 An order to evacuate is given by the attendant or the entry supervisor,

4.9.5.2 The entrant recognizes any warning sign or symptom of exposure to a dangerous situation,

4.9.5.3 The entrant detects a prohibited condition, or

4.9.5.4 An evacuation alarm is activated.

4.10 Attendants shall:

4.10.1 Know the hazards of the specific confined space,

4.10.2 Be aware of possible behavioral effects of exposure to the hazards by the entrants,

4.10.3 Maintain a constant, accurate count of authorized entrants in the confined space,

4.10.4 Remain outside the confined space as long as entrants are in the confined space,

4.10.5 Maintain communication with the entrants,

4.10.6 Monitor conditions inside and outside the confined space to insure it is safe for the entrants to remain in the confined space,

4.10.7 Require evacuation of the confined space when conditions warrant evacuation,

4.10.8 Summon rescue and emergency personnel when needed,

4.10.9 Never allow unauthorized personnel into a confined space.

4.10.10Attendants may be assigned to monitor more than one permit space provided the duties described in practice can be effectively performed for each permit space that is monitored. Likewise, attendants may be stationed at any location outside the permit space to be monitored as long as the duties described in this practice can be effectively performed for each permit space that is monitored.

4.10.11Assignment of attendants to monitor more than one permit space requires the written approval of the Construction HSE Manager.

4.11 Entry supervisor shall:

4.11.1 Knows the hazards that may be faced during entry, including information on the mode, signs or symptoms, and consequences of the exposure;

4.11.2 Verifies, by checking that the appropriate entries have been made on the permit, that all tests specified by the permit have been conducted and that all procedures and equipment specified by the permit are in place before endorsing the permit and allowing entry to begin;

4.11.3 Terminates the entry and cancels the permit as required by this practice;


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4.11.4 Verifies that rescue services are available and that the means for summoning them are operable;

4.11.5 Removes unauthorized individuals who enter or who attempt to enter the permit space during entry operations; and

4.11.6 Determines, whenever responsibility for a permit space entry operation is transferred and at intervals dictated by the hazards and operations performed within the space, that entry operations remain consistent with terms of the entry permit and that acceptable entry conditions are maintained.

4.12 Program Review

4.12.1 The project confined space entry program shall be re-evaluated by the Construction Manager, the Construction HSE Manager, and members of the safety committee after any failure of the process and at least annually. The review shall be documented.


5.1 A Yanpet Confined Space Entry Permit indicating its expiration time and date must remain posted at the entrance to the confined space during entry. The posted copy and results of the atmospheric testing for the confined space shall be filed in the safety office and retained for the duration of the project. These records shall be shipped to the EH&S Department in the home office for long-term storage (30 years).

5.2 The equipment inspection and calibration records shall be maintained for 30 years.

5.3 Training records shall be maintained for 30 years. Monitoring data shall be maintained for 30 years.


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safety committee after any failure of the process and at least annually. The review shall be documented.


5.1 A Yanpet Confined Space Entry Permit indicating its expiration time and date must remain posted at the entrance to the confined space during entry. The posted copy and results of the atmospheric testing for the confined space shall be filed in the safety office and retained for the duration of the project. These records shall be shipped to the EH&S Department in the home office for long-term storage (30 years).

5.2 The equipment inspection and calibration records shall be maintained for 30 years.

5.3 Training records shall be maintained for 30 years. Monitoring data shall be maintained for 30 years.


HSE Practice 27 Rope, Chain & Sling Inspection

® ROPE, CHAIN & SLING INSPECTION PRACTICE 27 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for the inspection of ropes, cables, and slings used for personnel and material handling.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart H (1926.251)

2.2 ANSI A10.5-1992—Safety Requirements for Material Hoists

2.3 ANSI A10.22-1990—Rope Guided and Non-guided Worker’s Hoists

2.4 ASME HST-1-1999—Performance Standard for Electric Chair Hosts

2.5 ASME HST-2-1999—Performance Standard for Hand Chain Hoists

2.6 ASME HST-4-1999—Performance Standard for Overhead Electric Rope Hoists

2.7 ASME HST-5-1999—Performance Standard for Air Chain Hoists

2.8 ASME HST-6-1999—Performance Standard for Air Wire Rope Hoists

2.9 SASO 325/1994 Industrial Safety and Health Regulations—Equipment – Materials Handling

3.0 Definitions

3.1 Competent Person - A person capable of identifying existing and potential hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. The Construction Manager and HSE Manager shall designate the Competent Person.

4.0 Process

The use of ropes, cables, and slings—whether they are made of natural or synthetic fibers, steel wire, or metal mesh—is subject to certain hazards that cannot be removed by mechanical means, but only by the exercise of intelligence, care, and common sense. It is therefore essential to involve personnel who are competent, careful, and well trained in the proper care, use, and inspec-tion of this equipment.

4.1 Documentation

4.1.1 Ropes, cables, and slings received on the project shall be logged by the manufacturers identification number or by an individually assigned number assigned at the project and affixed to the individual rope, cable, or sling.

4.1.2 Each rope, cable, and sling shall be listed on the Inspection Log (DBN-F17) by size, type of material and Manufacturer’s identification number or project assigned number.

4.1.3 Project assigned numbers shall be stamped on a metal tag and affixed to the rope, cable, or sling in such a manner that it is secure.

4.2 Visual Inspection

4.2.1 A trained, Competent Person must perform a visual inspection of ropes, cables, and slings daily. Items to look for while conducting the visual inspection should include the following:

4.2.1.1 Kinks or severe twists.

4.2.1.2 Nicks, breaks, and frayed or unraveled edges.

4.2.1.3 Deformed, worn, or flattened surfaces.


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4.2.1.4 Corroded or pitted surfaces.

4.2.1.5 Shortened or lengthened rope lays.

4.2.1.6 Weld spatter.

4.2.1.7 Indication of burning.

4.2.1.8 Missing or damaged labels (synthetic slings only).

4.3 Detailed Inspection

4.3.1 The following more detailed inspection must be performed and documented (DBN-F17) by a Competent Person at least monthly, or more frequently, depending on operating conditions and use:

4.3.1.1 Run out rope completely and note conditions, such as number of broken strands, broken wires in one lay, reduction in rope diame-ter, corrosion, shorting of the lay, or fraying.

4.3.1.2 Run a soft cloth, preferably cotton, over the entire length of wire rope and examine any rope lays that pick up threads of the cloth.

4.3.1.3 Ensure that wire rope is properly lubricated.

4.3.1.4 When any of the conditions above exist that show evidence of abnormal deterioration, the item must be monitored and re-inspect-ed daily. If the condition continues to worsen, the item must be discarded and replaced.

4.4 Disposition of Damaged Running Rope

4.4.1 The rope or cable must be discarded and the date that it was discarded must be entered on the Rope, Cable, Sling, and Shackle Inspection Log (DBN-F17) if any of the following conditions exist:

4.4.1.1 Broken wires - six or more wires damaged in any one wire lay; three or more wires damaged in any one strand of one rope lay.

4.4.1.2 Worn outside wires - wearing of 1/3 or more of the original diameter of any of the outside individual wires.

4.4.1.3 Broken strand -one or more broken strands.

4.4.1.4 Kinking, crushing, unstranding, or other damage - rope severely kinked, crushed, cut, frayed, birdcaged, unstranded, unraveled, or any other damage resulting in weakening of the wire rope structure.

4.4.1.5 Heat or weld damage - any evidence of heat damage or weld spatter.

4.4.1.6 Corrosion - severe corrosion in the valleys between strands or cor-roded or broken wires at end connections.

4.4.1.7 Reduction in diameter - noticeable reduction from normal rope diame ter.

4.5 Sling Inspection Practices

Slings are generally used with other material handling equipment for the movement of material by hoisting. Slings are made of alloy steel chain, wire rope, metal mesh, natural or synthetic fiber, or fibers woven into a web. The inspector must determine, using the guidelines below, when the sling shall be replaced.


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4.5.1 General

4.5.1.1 Each day before use, slings and fastenings and attachments must be inspected for damage or defects. Damaged slings shall be removed from service.

4.5.1.2 Additional monthly inspections shall be performed and documented on form DBN-F17 by a Competent Person as defined in 5.01.

4.5.1.3 Wire rope slings shall not be used if, in any length of 8 diameters, the total number of visible broken wires exceeds 10 percent of the total number of wires, or if the rope shows other signs of excessive wear, corrosion, or defect.

4.5.1.4 In the case of alloy steel chain slings, the inspection shall include a thorough check for wear, defective welds, deformation of the links, and increase in length. Where such defects or deterioration are present, the chain sling must be immediately removed from use.

4.5.1.5 Each sling and fastening and attachment will be inspected prior to being allowed on site to ensure they are in safe working condition.

4.5.1.6 Slings shall not be loaded in excess of their rated capacities which shall have a safety factor of 5.

4.5.2 Wire Rope

4.5.2.1 Wire Rope Slings shall be removed from service when the following conditions are present:

• For strand laid and single part slings, ten randomly distributed broken wires in one rope lay or five broken wires in one rope lay or five broken wires in one strand in one rope lay.

• Severe localized abrasions or scraping.

• Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure.

• Evidence of heat damage.

• End attachments that are cracked, deformed, or worn to the extent that the strength of the sling is substantially affected.

• Hooks that are cracked, spreading (more than 15 %), and/or missing throat-latches.

• Severe corrosion of the rope or end attachment.

4.5.3 Chain Slings

4.5.3.1 Conduct a visual inspection to check for stretched, bent, worn, or gouged links.

4.5.3.2 Multi-leg slings can be hung on a hook to check that legs are the same lengths.

4.5.3.3 Chain slings must have a tag with the grade, size, capacity, & manufacturer stamped on it.

4.5.4 Synthetic Web Slings

4.5.4.1 Inspect the label. The following information shall be legible on the label:


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• The manufacturer’s name or an identification trademark,

• The rated capacity for the type of hitch, and

• The type of synthetic material.

4.5.4.2 The sling must be removed from service when the following conditions exist:

• Acid or caustic marks are present.

• Melting or charring of any part of the sling.

• Holes, cuts, tears, or excessive fraying or snags.

• Broken or worn stitching in load bearing splices.

• Knots in any part of the sling.

• Excessive pitting or corrosion or cracked, distorted or broken fittings.

• Other visible damage that causes doubt as to the strength of the sling.

4.5.5 Metal Mesh Slings

4.5.5.1 Manufacturer’s tag with their trademark or name must be present.

4.5.5.2 The rated load in vertical basket and choker hitch configuration must be listed.

4.5.5.3 Metal mesh slings shall be removed from service when the following conditions exist:

• A broken weld or a broken brazed joint along the sling edge.

• A broken wire in any part of the mesh.

• Reduction in wire diameter of 25% due to abrasion or 15% due to corrosion.

• Lack of flexibility.

• Distortion of either end fitting such that the width of the eye opening is decreased by more than 10%.

• Distortion of the choker fittings so the depth of the slot is increased by more than 10%.

• A 15% reduction of the original cross-sectional area of metal around the hook opening or end fitting.

• Visible distortion or cracked fitting of either end.

4.6 Rope Clips

4.6.1 Wire rope clips are used to attach fixtures to wire rope and to make guy lines. To attach wire rope clips:

4.6.1.1 Turn back the required amount of wire rope from thimble or loop. Apply the first clip one base width from the dead end of the wire rope. Apply the U-bolt over the dead end of wire rope; the live end rests in the saddle. Tighten the nuts evenly, alternate from one nut to the other until reaching the recommended torque.

4.6.1.2 When two clips are required, apply the second clip as near the loop or thimble as possible. Tighten the nuts evenly, alternating until reaching the recommended torque. When more than two clips are


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required, apply the second clip as near the loop or thimble or loop as possible, turn the nuts on second clip firmly, but do not tighten. Proceed to step three.

4.6.1.3 When three or more clips are required, space the additional clips equally between the first two, take up the rope slack, tighten the nuts on each U-bolt evenly, alternating from one nut to the other until reaching the recommended torque.

4.6.1.4 IMPORTANT: Apply a load test to the assembly prior to use. This load shall be equal or greater than the intended load. Next check and retighten the nuts evenly to the recommended torque. Inspect the assembly periodically for wear, abuse, and general adequacy.

4.6.1.5 Never use wire rope clips to make slings/chokers.


Inspection Logs must be retained on the project site for the duration of the project.


HSE Practice 28 Mobile, Overhead & Gantry Cranes

® MOBILE, OVERHEAD AND GANTRY CRANES PRACTICE 28 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice provides the minimum requirements for operating mobile cranes or working in an area where mobile cranes are being operated.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart N (1926.550)

2.2 CSG 5603-00.000 - Preparing a Rigging Plan

2.3 ASME B30.5-2000-Mobile and Locomotive Cranes

2.4 ASME B30.22-2000—Articulating Boom Cranes

2.5 SAE J765—Crane Load Stability Test Code

2.6 ANSI B15.1-1958—Safety Code for Mechanical Power Transmission Apparatus

2.7 Power Crane and Shovel Association Mobile Hydraulic Crane Standard No. 2

2.8 ANSI B30.2.0-1967, Safety Code for Overhead and Gantry Cranes

2.9 49 CFR Parts 177 and 393

2.10 SASO 325 Industrial Safety and Health Regulations—Part 6 – Equipment, Section 6.3—Material Handling

3.0 Definitions

3.1 None

4.0 Process

4.1 Equipment Inspection and Testing

4.1.1 The Construction Manager and Construction HSE Manager shall designate a Competent Person(s) for mobile crane inspection. The designation shall be made in writing and documentation of the Competent Person(s)’ qualifications maintained on file.

4.1.2 A Competent Person shall inspect each mobile crane for defects upon its arrival and before its use on the project and at 30-day intervals thereafter on form DBN-F18. Maintenance records shall be completed and retained. An independent third-party inspector approved by the Department of Labor shall perform annual crane inspections. When a crane has been dismantled or has had major repairs, an independent third-party inspector approved by the Department of Labor shall inspect it.

4.1.3 The equipment shall be load-tested only in accordance with the manufacturer's specifications, limitations, and the American National Standard Institute.

4.1.4 All load tests will be documented and the documentation shall be maintained in the Project HSE files.

4.1.5 The project or any individual without the manufacturer’s written approval shall make no modifications or alterations to the equipment.

4.1.6 All mobile, overhead, and gantry cranes will be inspected prior to being allowed on-site.

4.1.7 Controls shall be tested each day prior to use to determine that such controls are in safe working condition.


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4.2 Operator Certification

4.2.1 Mobile crane operators must be instructed in, and given the opportunity to read and understand, the manufacturer's operators manual for each make and model of crane they will operate. The employee shall also be instructed in the applicable OSHA and ANSI standards.

4.2.2 The mobile crane operator must be licensed by the project Competent Person and Construction HSE Manager to operate the specific make and model as-signed. And documented on DBN-F24.

4.2.3 Operators shall pass a written examination that covers the following topics:

4.2.3.1 The ability to read and understand the crane's load chart.

4.2.3.2 An understanding of the ANSI crane hand signals.

4.2.3.3 How to determine the weight of a load.

4.2.3.4 Basic knowledge of safe crane operation.

4.2.4 The written/oral examination is a pre-hire qualification exam. Successful completion of the exam (85% correct) is a qualification for employment.

4.2.5 Operators shall meet the following physical qualifications:

4.2.5.1 Vision of at least 20/30 Snellen in one eye and 20/50 in the other eye, with or without corrective lenses;

4.2.5.2 Ability to distinguish colors, regardless of position, if color differentiation is required for operation;

4.2.5.3 Adequate hearing, with or without hearing aid, for the specific operation.

4.2.6 Evidence of physical defects or emotional instability which could render a hazard to the operator or others, or which in the opinion of the examiner could interfere with the operator's performance, shall be sufficient cause for disqualification. In such cases, specialized clinical or medical judgments and tests shall be required by a licensed examiner.

4.2.7 Evidence that an operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical evaluations shall be required to determine these conditions.

4.2.8 The physical examination is a post-hire, pre-assignment examination.

4.2.9 Operators shall be familiar with the operation and care of fire extinguishers.

4.3 Operations

4.3.1 Each day, the operator, before starting work, shall check all safety features of the crane and document the operable condition of the equipment using form DBN-F19 to include, but not limited to:

4.3.1.1 Fire extinguisher 5BC or better

4.3.1.2 Seat belts

4.3.1.3 Tire pressure

4.3.1.4 Window glass

4.3.1.5 Horn


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4.3.1.6 Back-up ala rm

4.3.1.7 Lights

4.3.1.8 Signs

4.3.2 Accessible areas within the swing radius of the rotating superstructure counterweight of a crane will be barricaded to prevent employees from being struck or crushed by the counterweight.

4.3.3 The ground shall be level to within 1 degree of the horizon.

4.3.4 All applicable danger signs shall be posted. These include, but are not limited to:

4.3.4.1 Danger Electrical Hazard

4.3.4.2 Swing Radius Warning

4.3.4.3 Step Warnings

4.3.5 The hand signals shall be those specified by the ANSI standard applicable to each crane. Only one individual will assume the flagging duties, and no other person shall flag during the lift, with the exception of a person giving an emergency stop signal. ANSI crane hand signals shall be posted at each project where a crane is in operation.

4.3.6 A copy of the manufacturer's operator's manual for each make and model must be on the equipment or project site, and the manufacturer's specifications and limitations noted in it will be observed.

4.3.7 When operating any hydraulic crane and/or when both auxilia ry and main hoist lines are reeved, an anti-two block warning system is required on both auxiliary and main hoist lines.

4.3.8 Attachments used with cranes shall not exceed the capacity rating or scope recommended by the crane's manufacturer.

4.3.9 No person shall ride the headache ball, the hook, or the load being handled by the crane. Operations involving the use of suspended personnel baskets or platforms shall comply with OSHA regulations, and the crane shall be equipped with a positive action anti-two blocking device (See Practice 30).

4.3.10 Equipment shall not be lubricated while in use unless it is designed for safe lubrication during use.

4.3.11 No person shall ride on a crane, and the crane should not be used to transport personnel or be equipped with a personnel carrier, without specific approval from the manufacturer and the Construction Manager after consultation with the Construction HSE Manager.

4.3.12 A boom angle indicator in good working order shall be provided and shall be visible to the operator on all cranes and boom trucks.

4.3.13 An accessible, approved fire extinguisher shall be available to all operating stations of cabs or equipment.

4.3.14 On lifts greater than 50 tons, or in excess of 80% of the cranes rated chart capacity, a Critical Lift Permit (DBN-F37) shall be completed and signed off by a Competent Supervisor and Competent Engineer.


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4.4 Electrical Hazards

4.4.1 A crane will not be operated, under any circumstances, when any part of the crane or load will come within 10 feet of energized electrical distribution lines rated 50 kV or below unless the following conditions are met:

4.4.1.1 The lines have been de-energized and are grounded at the point of work.

4.4.1.2 Insulating barriers that are not part of the hoisting equipment have been erected.

4.4.2 For lines rated over 50 kV, the minimum clearance between lines and any part of the crane or load will be 10 feet plus 0.4 inch for each kV over 50 kV or twice the length of the line insulator. The clearance will not be less than 10 feet.

4.4.3 Lines will be considered energized unless the person or utility owning the lines verifies that they are not energized and that the lines are grounded at the point of operation.

4.4.4 In transit with no load and the boom lowered, the equipment clearance shall be a minimum of 4 feet for voltages less than 50kV and 10 feet for voltages over 50 kV, up to and including 345 kV, and 16 feet for voltages up to and including 750 kV.

4.5 Traveling with a Load (Pick and Carry)

4.5.1 Traveling with a load (pick and carry) is not recommended as a means of transporting loads from one location to another on the project and should be used as a last resort. Farm wagons, forklifts, boom trucks, and flatbed trucks should be used to transport these loads rather than "pick and carry" operations.

4.5.2 Traveling with suspended loads entails many variables, i.e., the type of terrain, boom length, momentum in starting and stopping, etc. Therefore, it is impossible to formulate a single standard with any assurance of safety. Thus, when traveling with a load, the operator must evaluate the prevailing conditions and determine the applicable safety precautions. No matter what other precautions are taken, the manufacturers' guidelines shall not be exceed-ed.

4.5.3 Follow these general precautions for pick and carry:

4.5.3.1 Do not exceed rated "on rubber" capacity chart.

4.5.3.2 Position the boom parallel to the direction of travel.

4.5.3.3 Engage the swing (house) lock.

4.5.3.4 Maintain as short a boom length and as high a boom angle as possible.

4.5.3.5 Secure load to carrier.

4.5.3.6 Provide tag or restraint lines to snub load swing.

4.5.3.7 Carry the load close to the ground.

4.5.3.8 Do not start and travel until outriggers are fully stowed (re tracted).

4.5.3.9 Travel only on smooth, firm, and level terrain.

4.5.3.10 Maintain travel speed suitable to terrain.

4.5.3.11 Avoid sudden starting and stopping.


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4.5.3.12 Maintain correct tire pressure for type of tire used.

4.5.3.13 Always use flagmen, both front and rear, to give directions and watch for hazards.

4.5.3.14 Flagman should watch for power lines and other overhead obstruc-tions.

4.5.3.15 No person shall ride on the ma chine during "pick and carry" opera-tions.

4.5.3.16 Pick and carry operations shall not be conducted without specific approval from the manufacturer and the Construction Manager after consultation with the Construction HSE Manager.

4.6 Wire Rope

4.6.1 Wire rope with one or more of the following defects will be removed or replaced immediately. If one wire rope of a set (pendant lines, multi-leg slings, etc.) requires replacement, the entire set of ropes will be replaced:

4.6.1.1 In standing ropes, more than two broken wires in one lay in areas beyond end connections, or more than one broken wire at an end connection.

4.6.1.2 In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay.

4.6.1.3 Wear of one third of the original diameter of the outside individual wires caused by abrasion, scrubbing, flattening, or peening.

4.6.1.4 Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure.

4.6.1.5 Evidence of heat damage from any cause.

4.6.1.6 Reduction from nominal diameter of more than:

• 1/64 inch for diameters up to and including 5/16 inch;

• 1/32 inch for diameters from 3/8 inch up to and including 1/2 inch;

• 3/64 inch for diameters 9/16 inch to and including 3/4 inch;

• 1/16 inch for diame ters from 7/8 inch up to and including 1 inch;

• 3/32 inch for diameters from 1¼ inch up to and including 1½ inch.

4.6.1.7 Monthly wire rope inspections shall be documented using form DBN-F17.

4.6.2 All rope that has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed or authorized person whose approval shall be required for further use of the rope. A certification record that includes the date of inspection, the signature of the person who performed the inspection and an identifier for the rope that was inspected shall be prepared and kept readily available.


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4.7 Notices and Posting

4.7.1 Rated load capacities, recommended operating speeds, special hazard warn-ings, operating notes, and special instructions will be posted on equipment and will be visible to the operator while at the control station. Illustrations of hand signals used in operating equipment will be posted at the site.

4.8 Overhead and gantry cranes.

4.8.1 The rated load of the crane shall be plainly marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its load block, and this marking shall be clearly legible from the ground or floor.

4.8.2 Bridge trucks shall be equipped with sweeps which extend below the top of the rail and project in front of the truck wheels.

4.8.3 Except for floor-operated cranes, a gong or other effective audible warning signal shall be provided for each crane equipped with a power traveling mechanism.

4.8.4 Monthly visual inspections, with a certification record, that includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected shall be conducted.

4.8.5 For hooks with cracks or having more than 15 percent in excess of normal throat opening or more than 10< twist from the plane of the unbent hook shall be discarded. Repairs by welding or reshaping are not generally recommended. If such repairs are attempted, they shall only be done under competent supervision and the hook shall be tested to the load requirements specified in 4.8.6 before further use.

4.8.6 Test loads shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer. The test reports shall be placed on file where readily available to appointed personnel

4.8.7 All overhead and gantry cranes in use shall meet the applicable requirements for design, construction, installation, testing, maintenance, inspection, and operation as prescribed in the ANSI B30.2.0-1967, Safety Code for Overhead and Gantry Cranes.

4.8.8 Maintenance procedure.

4.8.8.1 Before adjustments and repairs are started on a crane the following precautions shall be taken:

4.8.8.2 The crane to be repaired shall be run to a location where it will cause the least interference with other cranes and operations in the area.

4.8.8.3 All controllers shall be at the off position.

4.8.8.4 The main or emergency switch shall be open and locked in the open position.

4.8.8.5 Warning or "out of order" signs shall be placed on the crane, also on the floor beneath or on the hook where visible from the floor.

4.8.8.6 Where other cranes are in operation on the same runway, rail stops or other suitable means shall be provided to prevent interference with the idle crane.


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4.8.8.7 After adjustments and repairs have been made the crane shall not be operated until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed.

4.8.9 Rope inspection.

4.8.9.1 A thorough inspection of all ropes shall be made at least once a month and a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:

4.8.9.1.1 Reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires.

4.8.9.1.2 A number of broken outside wires and the degree of distribution or concentration of such broken wires.

4.8.9.1.3 Worn outside wires.

4.8.9.1.4 Corroded or broken wires at end connections.

4.8.9.1.5 Corroded, cracked, bent, worn, or improperly applied end connections.

4.8.9.1.6 Severe kinking, crushing, cutting, or unstranding.

4.8.9.2 All rope that has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required for further use of the rope. A certification record shall be available for inspection that includes the date of inspection, the signature of the person who performed the inspection and an identifier for the rope that was inspected.


A copy of the inspections of cranes, including the annual inspection, shall be kept on file in the project HSE office for the duration of the project.


HSE Practice 29 Rigging / Lifting Plans

® RIGGING / LIFT PLANS PRACTICE 29 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 PURPOSE

The procedure provides guidelines for the requirements associated with lifting equipment such as pulley blocks, cranes, lifts for personnel, equipment or materials, and other similar equipment used for lifting.

2.0 SCOPE

This procedure addresses the purchasing, operation, inspection and testing, and maintenance of lifting equipment, and procedures for steel erections.

3.0 DEFINITIONS

Lifting Equipment

All forms of lifting appliance and lifting gear.

Lifting Appliance

A machine or component that can raise, lower or suspend a load or people. Lifting Appliances include cranes, elevators/lifts for personnel and materials, fork lift trucks, stacker trucks, mobile working platforms, pulley blocks, runway beams with trolleys, davits and conveyors.

Lifting Gear

Components such as shackles, slings, hooks, chains and spreader beams, lifting cradles for Oxy kits and oil drums, work boxes etc,

Lifting Point

Components or features of loads such as trunnions, lifting lugs, eyes and reinforcement pads designed for the attachment or bearing of Lifting Equipment.

Safe Working Load (SWL)

The maximum load, determined by a qualified engineer, that an item of Lifting Equipment may raise, lower or suspend under particular service conditions.

Proof Load

Test load applied to Lifting Equipment after manufacture, or following any repair, replacement or modification of any load bearing part. It is a specified load that must be withstood without the equipment showing permanent deformation beyond a specified amount or other defect.

Working Load Limit (WLL)

The maximum load that the Lifting Equipment is designed to raise, lower or suspend under ideal conditions (the Safe Working Load will usually be the same as the Working Load Limit but may be less).


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4.0 GENERAL

All cranes to have current inspection records that meet statutory requirements.

All lifting equipment / gear to meet statutory requirements.

All lifts will be assessed and where required a lift study (DBN-F21) completed.

Only competent persons will work with cranes and lifting equipment.

5.0 PURCHASING AND HIRE

Purchasing and hire specifications for lifting equipment shall include details such as type, load capacity, mode of operation and materials to be used.

A review shall be conducted prior to order to verify that equipment is suitable for the intended duty. The purchased equipment shall be inspected prior to acceptance.

6.0 INSPECTION AND MAINTENANCE

All lifting equipment shall be inspected every month in accordance with Practice 27. A register of all lifting equipment is to be maintained. All clamps and lifting beams will be clearly identified/labeled. Slings, chains, hooks and shackles will be stamped with the approved load limitation.

Lifting Equipment that is worn or damaged to such an extent that in the judgement of an approved person it cannot be repaired satisfactorily must be destroyed by cutting, and the Lifting Equipment register and record file amended accordingly.

Cranes are to be inspected on a DAILY basis (DBN-F19) and on an MONTHLY basis (DBN-F18).

7.0 TRAINING AND COMPETENCY

Crane Operator - All Crane Operators must meet the following requirements:

The operator must have a crane operator's license issued by an organization acceptable to the Project’s Fluor Crane and Rigging supervisor.

Crane operators must be licensed to operate the specific make and model of crane to which they are assigned.

Riggers shall be trained and assessed in the use of the rigging gear and equipment. Training shall place emphasis on the equipment capacity, type of loads to be carried and particularly the danger of overloading and Safe Work Practices.


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8.0 MODIFICATIONS

All modifications to lifting equipment shall be designed and fabricated in accordance with national standards and the modified design approved by the design authority. As a minimum the following must be complied with: After modification, Lifting Equipment must be tested by application of a Proof Load, specified by an approved person, and then thoroughly examined. A test certificate stating the Working Load Limit/Safe Working Load and the Proof Load must be obtained. Design and specifications for purpose made lifting equipment shall be approved by the ‘design authority’ and the responsible mechanical engineer. For Lifting Appliances the approved person is required to prepare a report of the examination and any necessary repairs. Modifications and repairs of lifting equipment shall be in accordance with regulatory standards.

9.0 REPAIRS

All repairs to Lifting Equipment must be carried out under the direction of a qualified person.

Repairs to lifting equipment, other than the replacement of parts, shall be carried out by the original manufacturer, the manufacturer's agent or a fabricator approved by the responsible mechanical engineer. Replacement parts shall be identical to the original. Appropriate certification shall be obtained.

Where load-bearing components are repaired or replaced, Lifting Equipment must be tested by application of a Proof Load, as specified by an approved person, and then thoroughly examined. A test certificate stating the W orking Load Limit/Safe Working Load and the Proof Load must be obtained. The test certificate and a record of the repair or modification should be placed in the registration file.

10.0 LIFTING APPLIANCE

10.1 General

All crane equipment shall be operated and utilized in accordance with the manufacturer’s specifications and guidelines. All assessments must be completed in accordance with the appropriate standards and documentation provided by the Contractor prior to mobilization to site. As a minimum the following should be adhered to: All crane operators shall hold the relevant certificate of competency for the size and type of crane to be used. Access to areas where lifting operations are carried out shall be restricted, protection provided or procedures put in place such that persons in the vicinity are not subject to danger. Areas where cranes and other lifting equipment, which may endanger other persons, operate, shall be clearly demarcated and sign-posted. Accessible areas within the swing radius of the rotating superstructure counterweight of a crane will be barricaded to prevent personnel being struck or crushed by the counterweight.


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In all lifting operations a single person shall have overall responsibility for the task. Where hand signals are used they shall be those as prescribed in the relevant standard. Similarly, where whistles are used for communication between a specified dogger and the crane operator they shall also be those as prescribed in the relevant standard. A copy of the manufacturer’s operators manual for each make and model machine, log book and load chart must be in the cabin of the crane and the manufacturer’s specifications and limitations noted in it will be observed. Loads shall not be lifted over persons. In the operation and use of any hydraulic crane when both an auxiliary and main hoist line are reeved, an anti two block warning system is recommended on both auxiliary and main hoist lines. However, any equipment installed or fitted to a crane must be functional and operable. Attachments used with cranes shall not exceed the capacity rating or scope recommended by the crane manufacturer. No person will ride the headache ball, the hook, or the load being handled by the crane. All operations involving the use of suspended personnel baskets or platforms shall comply with applicable regulatory agencies and the requirements noted in Section 8.8. Where lifting operations are not carried out in daylight, adequate illumination shall be provided. Where the operator of lifting equipment does not have a clear view of the load being lifted, a specially instructed rigger shall provide assistance. Electronic signaling and communications devices shall be protected from interference. In the event that malfunction of lifting equipment occurs, operations shall cease and the malfunction brought to the attention of an approved person and reports it to the Project HSE Manager. Lifting equipment shall not be used in circumstances where it’s stability is likely to be adversely affected, such as on soft or uneven ground or on slopes, unless adequate precautions are taken to provide for safe working. Any lifting equipment known, or suspected to have been overloaded shall be tagged “Out of Service”, and withdrawn from service. The equipment shall be re-tested under the supervision of an approved person and thoroughly examined by the approved person before being returned to use. Records of the incident, testing and examination should be entered in the registration file. All cases of failure shall be referred to the responsible mechanical engineer so the failure can be entered into the registration file. Under no circumstances are slewing cranes to be moved with the boom extended or with a load attached. Prior to movement the boom will be fully retracted. Once the boom has been fully retracted outriggers are to be lifted and withdrawn. Once this has been completed the crane is capable of being maneuvered or moved to another position.

The lifting of persons shall only be done in an approved designated workbox or basket, securely attached to the crane. The persons shall remain substantially within the confines of the box while being lifted. A safety harness shall be worn at all times in a work basket. See Section 8.8 for additional details.


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10.2 Mobile Crane Operation

Each mobile crane will be inspected by a competent person for mechanical defects upon its arrival, before its use on the Project/Site, and monthly thereafter. The operator shall perform documented daily inspections before use on each shift.

It is recommended that the equipment be load-tested only in accordance with the manufacturer's specifications and limitations and American National Standard Institute (ANSI) B30.5-1982, Mobile and Locomotive Cranes, 5-2.2.2.

The Project/Site or any individual may make no modifications or alterations that could affect the capacity or safe operation of the equipment without the manufacturer’s written approval

• Operator Training and Licensing

All mobile crane operators must review and understand the manufacturer's operations manual for the assigned make and model machine, and any additional applicable information concerning the operation of their assigned machine per

A mobile crane operator must be licensed to operate the specific make and model of crane to which they are assigned per Practice 34.

• Operation

Accessible areas within the swing radius of the rotating superstructure counterweight of a crane shall be barricaded to prevent employees from being struck or crushed by the counterweight.

The hand signals to be used are those prescribed by the ANSI standard applicable to each crane. One designated and properly trained flagger will assume flagger duties. No other person shall flag during the lift, with the exception of a person giving an emergency stop signal.

A copy of the manufacturer's operator's manual for each make and model of machine must be in the cab of the crane, and the manufacturer's specifications and limitations noted in it shall be observed.

In the operation and use of any hydraulic crane when both an auxiliary and main hoist line are reeved, an anti-two blocking warning system is recommended on both auxiliary and main hoist lines.

Attachments used with cranes shall not exceed the capacity rating or scope recommended by the crane’s manufacturer.

No person shall ride the headache ball, the hook, or the load being handled by the crane. All operations involving the use of suspended personnel baskets or platforms shall comply with applicable in-country regulatory agencies. The crane shall be equipped with an anti-two blocking device.


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Equipment shall not be lubricated while in use, unless it has been designed for safe lubrication application during use.

Only one (1) load will be hoisted at a time. Two (2) or more separately rigged loads (for example, skip pan and steel beam) must not be hoisted in one lift even if the combined loads are within the rated capacity.

Only qualified riggers shall rig loads.

No person(s) shall ride on the machine. The machine shall not be equipped with a personnel carrier.

• Electrical Hazards

A crane shall not be operated under any circumstances when any part of the crane or load will come within ten (10) feet (3.05 meters) of energized electrical distribution lines rated 50 kV or below, unless: the lines have been de-energized and are grounded at the point of work; and insulating barriers, that are not part of the equipment, have been erected.

For lines rated over 50 kV, the minimum clearance between lines and any part of the machine or load will be ten (10) feet (3.05 meters), plus 0.4 inches (1.02 centimeters) for each kilovolt over 50 kV or twice the length of the line insulator.

All lines shall be considered energized unless the authority or utility company owning the lines indicates in writing that they are not energized and that the lines are grounded at the point of operation.

• Traveling With A Load (Pick And Carry)

Traveling with a load (pick and carry) is not recommended as a means of transporting loads from one location to another on the Project/Site and should be used only as a last resort. The use of farm wagons, forklifts, boom trucks, and flatbed trucks should be used to transport loads.

Traveling with suspended loads entails many variables; which may include the type of terrain, boom length, or momentum in starting and stopping. Therefore, it is impossible to formulate a single standard procedure which would eliminate hazards under all variables. Thus, when traveling with a load, the operator must evaluate the prevailing conditions and determine the applicable safety precautions.

The following precautions would fall into a general category: Do not exceed rated "on rubber" capacity chart; Position the boom parallel to the direction of travel; Engage the swing (house) lock; Maintain as short a boom length and as low a boom angle as possible; Secure load off to carrier; Provide restraint lines;


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Load should be carried close to ground; Do not start and travel until outriggers are fully stowed (retracted); Terrain must be smooth, firm, and level; Maintain travel speed suitable to terrain; Avoid sudden starting and stopping; Maintain correct tire pressure for type of tire used; Always use flagmen, both front and rear, to give directions and watch for hazards; Flagman should watch for power lines and other overhead obstructions; and No person shall ride on the machine during "pick and carry" operations.

Note!!! A safety action plan must be developed when overhead hazards such as power lines, process lines, etc., have the potential to come into contact with the crane during operation.

• Wire Rope

Wire rope with one or more of the following defects will be removed or replaced immediately. If one wire rope of a set (pendent lines, multi-leg slings, and so forth) requires replacement, the entire set of ropes will be replaced.

Wire rope should be replaced in several circumstances, including, but not limited to: standing ropes have more than two (2) broken wires in one lay in areas beyond end connections or more than one (1) broken wire at an end connection; running ropes have six (6) randomly distributed broken wires in one lay or three (3) broken wires in one strand in one lay; wear of one-third (1/3) of the original diameter of the outside individual wires caused by abrasion, scrubbing, flattening, or peening; kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure; evidence of heat damage from any cause; or reduction from nominal diameter of: more than 1/64 inch for diameters up to and including 5/16 inch; 1/32 inch for diameters from 3/8 inch up to and including 1/2 inch; 3/64 inch for diameters 9/16 inch to and including 3/4 inch; 1/16 inch for diameters from 7/8 inch up to and including 1-1/8 inches; or 3/32 inch for diameters from 1-1/4 inches up to and including 1-1/2 inches.

• Notices And Posting

Rated load capacities, recommended operating speeds, special hazard warnings, operating notes, and special instructions will be posted on all equipment and will be visible to the operator while he/she is at the control station. Illustrations of the hand signals used in connection with the operation of equipment will be posted at the project /site.


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10.3 Aerial Lifts

• Inspection

Inspection of the lift or platform will be made in accordance with and at intervals specified in APS 8.3, Equipment Pre -operational and Periodical Inspections. This also includes documented inspections prior to starting the work shift.

• Operation

No employee will be permitted to use or operate lifts or platforms unless he/she has been instructed, trained, and licensed by a competent person in the use and operation of such equipment.

Manufacturer's specifications and limitations must be observed at all time while operating the lifts. Employees who tamper with controls and/or bypass safety devices, such as deadman switches, are subject to disciplinary action.

• Operator Licensing And Training

The operator's knowledge of the operating requirements and safety procedures of the assigned equipment shall be verified by written examination, by a hands-on test, and by observation of his/her performance during the first month of operation. A competent person designated by the Project/Site Manager, such as a Superintendent, will conduct the hands-on test to determine the applicant's operating ability.

Candidates for a motorized equipment permit must meet the following minimum requirements: be mentally alert and physically capable of driving motorized equipment safely; display a responsible attitude; and be familiar with the motorized equipment to be operated or be able to adapt quickly with proper training.References

10.4 Material and Personal Hoists

A. Inspection

Prior to use, a competent person must make a pre-operational inspection of all functions and safety devices on all hoists.

A competent person will make documented daily inspections. All reports will be kept readily available, and all unsatisfactory conditions will be reported to supervision and corrected before using material and personnel hoists.

All hoists will be formally inspected and tested by a qualified person at intervals not to exceed three (1) months. Records of such inspections and tests will be readily available at the Project/Site.


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• Operation

Rated load capacities, recommended operating speeds, special hazard warnings, operating rules, signal systems, and operating instructions will be conspicuously posted at the operator's station for the hoist or on the car frame or crosshead. Overhead protection of two (2)-inch (approximately 5 cm) planking, three-fourths (3/4)-inch (approximately 1.9 cm) plywood, or the equivalent will be provided on the top of every hoist.

No hoist will be placed in service until it has been inspected and tested by a competent person with a signed and dated written report of such inspection and test.

• Operator Licensing and Training

The operator's knowledge of the operating requirements and safety procedures of the assigned equipment shall be verified by written examination, by a hands-on test, and by observation of his/her performance during the first month of operation. A competent person designated by the Project/Site Manager, such as a Superintendent, will conduct the hands-on test to determine the applicant's operating ability. A hands-on test will be conducted on each equipment type and model to be operated.

Candidates for a motorized equipment permit must meet the following minimum requirements: Be mentally alert and physically capable of driving motorized equipment safely; Display a responsible attitude; and Be familiar with the motorized equipment to be operated or be able to adapt quickly with proper training.

• Wire Rope

Wire rope with defects will be removed or replaced immediately. If one wire rope of a set requires replacement, the entire set of ropes shall be replaced.

Any of the following defects render the wire unfit for use: Corrosion - Any development of slight corrosion should be noted and watched closely. Severe corrosion is cause for replacement. Broken Wires - One or more valley breaks, six randomly distributed broken wires in one rope lay, or three broken wires in one strand in one rope lay is cause for replacement. End Attachments - Development of broken wires in the vicinity of attachments is cause for replacement. If this condition is localized in an operating rope and the section in question can be eliminated by making a new attachment; this may be done rather than replacing the entire rope. Abrasion - Abrasion, scrubbing, flattening, or peening that causes loss of more than one-third of the original diameter of the outside wires is cause for replacement. Kinking - Severe kinking, crushing, birdcaging, or other damage resulting in the distortion of the rope structure is cause for replacement.


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Heat Damage - Evidence of heat damage resulting from contact with a torch or any damage caused by contact with electrical wires is cause for replacement. Reduction of Rope Diameter - Reduction from the normal rope diameter of more than 3/64 inch (0.12 cm) for diameters up to and including 3/4 inch (1.9 cm); 1/16 inch (0.16 cm) for diameters from 7/8 to 1-1/8 inches (approximately 2.2 to 2.8 cm); and 3/32 inch (0.24 cm) for diameters from 1-1/4 to 1-1/2 inches (approximately 3.2 to 3.8 cm) is cause for replacement.

• Material Hoists

No person shall ride on material hoists at any time except for the purpose of inspecting or maintaining the hoist. A sign stating "No Riders Allowed" will be posted on the car frames or crosshead.

All entrances to material hoistways will be protected by gates or bars that:

guard the full width of the landing entrance; are painted with diagonal contrasting colors; are equipped with a latching device; and in the case of bars, are no less than 2 x 4-inch (5 x 10 cm) lumber or an equivalent, 42 inches (approximately 1.07 meters) above the floor, and 2 feet (approximately 0.6 meters) from the hoistway line.

Inspection, testing, construction, operation, and maintenance of material hoists will be in accordance with the requirements of American National Standards Institute (ANSI) 10.5-1969, Occupational Safety and Health Administration (OSHA) 1926.552, or other applicable in-country regulatory compliance regulations.

• Personnel Hoists

Personnel hoistway doors shall be no less than six (6) feet six (6) inches (1.98 meters) high. Solid doors, where used, will be provided with a vision panel opening, having a width not exceeding six (6) inches (15.24 centimeters) and an area not exceeding eighty (80) square inches (2.03 square meters) that is covered with expanded metal. Landing doors will be provided that may be locked mechanically so that they cannot be opened from the landing side. These locks will be of a type that may be released only by a person in the car. For hoists located outside of structures, the enclosures on the building side of the hoistway will be full height or a minimum of ten (10) feet (3.05 meters) at each floor landing.

Inspection, testing, construction, operation, and maintenance of personnel hoists will meet the requirements of American National Standard Institute ANSI A10.4-1973 standards or applicable in -country standards, whichever is more strict.

10.5 Tower Cranes

Due to the high potential for personal injury, property damage, and the liability associated with the operation, erection, and disassembling of tower crane


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equipment, the basic precautions outlined in this procedure must be followed. However, this procedure is not to be considered all-inclusive, and additional sources should be consulted (See references).

B. OPERATIONS

A contractual hold-harmless agreement between Fluor and all other interested parties, such as the tower crane owner and/or vendor, the erecting/disassembling contractor, and all crane users should be evaluated. While there is a hold-harmless clause in the Fluor Safety Attachment portion of the Project/Site contract, some Projects/Sites use different client contracts and vendor contracts. Use of a separate agreement is recommended if the hold-harmless clause is not already in the contract.

Because of the nature of tower cranes, the stress placed on weld joints, the lack of a good visual inspection because of painting, and the causes of failure in past accidents, a complete and documented annual inspection prior to the machine arriving on Project/Site is required. An annual inspection thereafter is mandatory. The complete annual inspection of all structural crane parts, including non-destructive examination testing (NDE) of welded joints is to be carried out by a competent person. A copy of this inspection and NDE test results should be maintained on Project/Site. A registered engineer should also certify the inspection.

All tower, jib, and structural bolts and nuts should be new at erection time and meet the manufacturer specifications. The same conditions stated previously also affect the machine's other structural fasteners. The equipment and structural fasteners including all tower, jib, and slewing ringbolts and nuts should be closely inspected and replaced as required during erection. A qualified and competent person shall perform all inspections, NDE tests, preventive maintenance, and repairs of tower cranes.

Tower cranes shall have flags or other indicators on the jib that identifies the working load radius to the operator.

Tower cranes shall have limiting devices for: Trolley travel at both ends of the jib; Anti-two blocking device; Operating radius in accordance with load to be lifted; Pressures in hydraulic or pneumatic circuits; and Crane travel at both ends of the runway tracks.

Load-limiting devices and acceleration and deceleration limiters, when provided shall be installed in enclosures that can be locked or sealed to inhibit unauthorized tampering. Operational tests shall be conducted and a load-limit device setting shall be verified by applying test loads of one hundred (100) percent of the applicable ratings. These tests shall be performed before use of the newly erected and altered cranes, with documentation kept on Project/Site.

A wind velocity-indicating device shall be mounted at or near the top of the crane. A velocity readout shall be provided at the operator's station in the cab,


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and a visible or audible alarm shall be triggered in the cab and at remote control stations when a pre-determined wind velocity has been exceeded.

An operator’s manual, provided by the manufacturer, shall be kept in the cab of the crane while it is on Project/Site.

The operator must be trained, experienced, and licensed for the operation of that specific make and model of tower crane. Prior tower crane experience is mandatory because of the differences in tower cranes and other types of equipment operations. The utilizing contractor shall provide documentation of the operator’s experience, even if he/she is using a subcontractor on Project/Site.

Regular inspections and maintenance of the cranes shall be conducted and performed in accordance with the manufacturer's specifications and American National Standards Institute (ANSI) standards or other applicable in-country standards. Maintaining the tower crane in good working condition will eliminate unnecessary downtime and prevent possible accidents. Utilizing contractors must be able to provide documentation concerning crane condition, which should be monitored regularly.

11.0 LIFTING GEAR

11.1 Wire Rope

The following rules must be adhered to for ropes used on site: The minimum size wire rope for lifting purposes shall be 5 millimeters (approximately 0.2 inches) diameter. Store wire rope clear of the ground in a clean, dry place away from contact with corrosive substances when it is stored.

Wire rope with one or more of the following defects will be removed and tagged “Out of Service” and removed from service, destroyed or replaced immediately: A single broken wire below a metal socket, end fitting or machine splices. Abrasion and core collapse. Corrosion - Red oxide powder and loose and springy wires can indicate serious corrosion. Check the valleys between the wires for corrosion beneath the surface. Kinks, knots, or fractures from bending or reeving. Crushed or jammed strands. Birdcaging - Faulty whipping of bare ends allows the strands to loosen from their proper tight lay. It can be caused by rotation of the end of a rope or a sudden release from high loading. High stranding - Where a strand has slipped around the lay and projects above the surface due to faulty whipping and cutting of the rope ends. An excessive number of broken wires. Where broken wires are present count the number of broken wires in a length of rope eight times the rope diameter. The total number of broken wires must not exceed 10% of the total wires. In standing ropes, more than two (2) broken wires in one lay in areas beyond end connections or more than one (1) broken wire at an end connection.


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In running ropes, six (6) randomly distributed broken wires in one lay or three (3) broken wires in one strand in one lay. Wear of one-third of the original diameter of the outside individual wires caused by abrasion, scrubbing, flattening, or peeling. Evidence of heat damage from any cause. Where the rope diameter has reduced to 85% or less of the original diameter (even though there may be no broken wires). If one wire rope of a set (pendant lines, multi-leg slings, and so forth) requires replacement, the entire set of ropes shall be replaced.

11.2 Chain Slings

Chain slings used for lifting must be tagged. The tag must state the manufacturers’ name, grade of steel used for the chain, its WLL or SWL for different applications and conditions of use. Further requirements for chains include: Chain without a tag must not be used for lifting purposes. Chain used for lifting must be alloy steel chain Grade (T) or 80. No other chains are to be used. Wrought iron chain and proof coil are not graded and must not be used for lifting. Chain less than 5.5 millimeters (approximately 0.2 inches) diameter shall not be used for lifting. Prior to using a chain sling check to verify that the chain hooks, links and hammerlocks or couplers are all of the same grade and are in good repair. Do not lift a load greater than the WLL of the chain. Do not use a chain in which the links are stretched, frozen or do not move freely. Do not use chain that is gouged or worn more than 10% of the diameter. Do not twist, kink, or knot chain. Do not roll loads over chain. Do not use chain with a link that is cracked, or that has been spot welded other than by the manufacturer. Use protective padding when using chain around sharp corners. Do not use alloy steel chains when the temperature exceeds 260ºC. Chain slings must be inspected regularly. Discard chain that are: Cracked, worn, frozen together, stretched, nicked or gouged. Worn in excess of 10%. Elongated/stretched more than 10%.

Note!!! Chains are not to be used directly on steel unless a designated lifting point has been engineered and certified. Loads without designated lifting points must have the chain double wrapped at all times to prevent sliding and load instability.

11.3 Flat Slings or Webbing Slings

Flat or webbing slings are not to be used at any time and are not to be brought to site.


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11.4 Round Synthetic Slings

Round synthetic slings must comply with the following: Round synthetic slings may be made from nylon, polyester, polypropylene or aramid polyamide. Each sling must be labeled/tagged with the WLL/SWL. Slings should be sent for a proof load test every twelve months.

Discard slings if: It is considered that it has lost more than 10% of its original breaking strength. The label/tag has been removed or destroyed. There is any damage to the sleeve or protective coating. A nylon sling comes into contact with acid. A polyester sling comes into contact with alkaline substances. A polypropylene sling comes into contact with an organic solvent such as paint, coal tar or paint stripper. There are any visible cuts on the sling.

Note!!! A nylon sling could lose more than 10% of its strength when it is wet or after 6 months exposure to sunlight.

Synthetic slings must be stored: In a clean, well ventilated place Away from the ground or floor Away from direct sunlight, ultra -violet light and fluorescent lights. Away from extremes of heat Away from sources of ignition Away from atmospheric or liquid chemicals Away from the possibility of mechanical damage.

11.5 Shackles

All shackles used for lifting purposes shall be alloy steel shackles of Grade S or better and shall be obtained from a reputable manufacturer with a quantifiable history in the industry.

The usage of shackles shall be subject to the following:

At no time shall the shackle be subjected to a load greater than its WLL/SWL.

All shackles shall be visually inspected prior to and after each use. This inspection shall assess the condition of the shackle body and the pin, the presence of wear on either component or the compatibility of the body and the pin.

Shackles must not be used without the correct pin.

Shackles should never be installed such that bending moments are applied to the body of the shackle.

Nut and bolt type pins shall always be used with split pins.


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All shackles shall be subject to detailed and thorough inspection by a certified rigger every three months and color coded accordingly.

Chain Blocks/Lever Hoists/Come Alongs (Turfors)

Responsibilities of operators of Chain Blocks, Lever Hoists, or Come Alongs (turfors) shall include the following: Personnel competent to complete the required function and posses assessed certificates of competency shall only use these items. All these items shall be used in accordance with the manufacturer specifications and in the manner intended by the manufacturer. The operator of these items must visually inspect the condition of the item prior to and after each use. If there is any doubt of the integrity of the item then it must not be used. Each of the items noted above must be fully inspected prior to use and every month by a Certified Rigger and records kept in a register. A qualified person shall assess any attachment points for integrity as previously noted. Attachment fittings on all the above items shall be used only in the manner specified or intended by the manufacturer.

11.6 General Operating Procedure

Use slings or dedicated lifting points to attach lifting hooks to the load to be lifted. Reeving the load chain around the load to be lifted is not acceptable.

When used to balance a load in conjunction with fixed sling lengths in a crane lift, a chain block shall be loaded manually to balance the load such that its WLL/SWL is not exceeded. (i.e., The load should be taken on the fixed legs first then the load taken manually on the chain block.)

Lever hoists shall only be used for lifting if this practice is within the specifications and guidelines for the particular hoist. Backup chains or slings must always be used.

11.7 Suspended Workbaskets (Man-box)

Alternate methods shall be investigated before using the workbasket as a means of conducting work at height. A workbasket shall be used only when other means of access to the work are extremely hazardous or not possible because of structural design or work site conditions. In no case is a workbasket to be used as an elevator and SWL not to be exceeded.

Qualified engineers, competent in structural design shall design workbaskets. The workbasket will be constructed for the specific purpose of hoisting personnel by means of a crane. The use of the workbasket will require approval by the Project Manager. This responsibility may not be delegated to subordinates. A Suspended Personnel Workbasket Authorization (DBN-F22) is required. Registration certificates must be submitted and supporting shackles must be moused.


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Load and boom hoist drum brakes, swing brakes and locking devices such as dogs and pawls, as equipped, shall be engaged when the occupied workbox is in a stationary working position.

All crane work involving workbaskets must be positively isolated against Free Fall. If the workbasket is not landed, it shall be secured to the structure before employees exit or enter the basket using the double lanyard and tie off system. Prior to this a Safe Work Procedures, JHA and Permit must be develop by the Contractor and reviewed by the HSE department. A justification for Use of Suspended Personnel Hoist is presented in DBN-F23.

Generally, employees are not to exit or enter the basket while working at height. However, if this is impractical tasks which identify the requirement to enter and exit the workbasket while at height the following must be completed: A task specific work procedure; Risk assessment JRA signed by all personnel; and Hazardous Work and lift permit.

All documentation must be submitted to the Crane Supervisor and the Project Manager and/or HSE Manager for approval prior to work commencing.

Note!!! All attachments are to be moused prior to lift commencing. This activity should be included in the JRA.

Design Guidelines

Lifting bridles on the workbasket shall be designed as per engineering standards and inspected and registered.

If a gate is fitted it shall swing inward only and be equipped with a positive latch. The workbasket weight, maximum number of employees, and the load capacity of the workbasket mu st be posted permanently on the workbox.

The workbasket shall be easily identifiable by color or marking. Personnel workbaskets are not to be used to hoist materials or tools without employees.

A grab rail shall be provided inside the workbasket. Overhead protection shall also be provided when employees may be exposed to falling objects. A welder qualified for the weld grades, types and material specified in the design, shall perform all welding. All exposed rough edges shall be ground smooth.


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Rigging

All loads shall be rigged under the guidance or by a qualified, competent and assessed Rigger.

Load block or ball hooks shall be a type that can be closed and locked, thereby eliminating the throat opening. As an alternative, a shackle with a screw pin, nut and retaining pin may be used.

When a wire rope lifting bridle is used to connect the workbasket to the load line, the bridle legs shall be connected to a single ring or shackle which is moused. Lifting bridles and associated hardware used for attaching the workbasket to the hoist line shall not be used for any other service.

All eyes in wire rope slings shall be fabricated with thimbles. Wire rope, shackles, rings and other rigging hardware shall have a minimum safety factor of five.

A safety wire rope sling shall be affixed from the uppermost part of the lifting bridle to a point above the ball or the dead-end load line of the load block or to the load block.

Tag lines shall be used on all suspended loads. When operating a mobile crane all suspended loads shall be tied off to the crane.

Lifting Cradle

The following types of equipment will not be lifted under any circumstances unless contained in an engineered and certified lifting cradle: Drums; Tool boxes or tool kits; and Oxy Acetylene and other compressed gas cylinders.

All cradles must have a retention/restraint system.

Crane Set Up and Operation

The crane shall be uniformly level within one percent of level grade and located on firm footing. Crane outriggers, if provided, shall be used according to manufacturer’s specifications when hoisting employees. Crane travel is prohibited while the workbox is suspended. The crane operator shall remain at the controls at all times, with the engine running, when the workbasket is suspended. Outrigger pads shall be used when lifting a suspended workbasket.

The total weight of the loaded workbasket and related rigging shall not exceed 25 percent of the rated capacity for radius and configuration of the crane. The minimum load hoist wire rope safety factor shall be seven (7). Except where rotation resistance ropes are used, the line should be capable of supporting without failure at least ten times the maximum intended load. Lifting and lowering speeds shall not exceed 20m (67 feet) per minute.


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The load-line hoist drum shall have controlled (power) load lowering capability, free fall is prohibited and must be positively isolated.

Telescoping booms shall be marked or equipped with a device to clearly indicate to the operator, at all times, the boom’s extended length.

A positive acting device shall be used which prevents contact between the load block or overhaul ball and the boom tip (anti-two-blocking device), or a system shall be used which deactivates the hoisting action before damage occurs in the event of a two-blocking situation (two block damage prevention feature).

Inspection and Testing

The crane and the workbasket to be used shall be inspected by a competent person at the beginning of each shift and before hoisting employees in the workbasket. The crane and the workbasket to be used shall also be inspected before hoisting employees in the workbasket after the crane has been used for any material handling operation in which greater than 50 percent of the rated capacity was lifted.

A visual inspection of the crane, workbasket and base support shall be conducted immediately after the test lift to determine whether the testing had any adverse effect upon any component or structure. A trial lift with the unoccupied workbasket shall be made for each new work location and at the beginning of each shift to verify that all systems, controls, and safety devices are functioning properly. A full-cycle operational test lift at 200 percent of the intended load of the workbasket shall also be made at each new set up location before hoisting employees for the first time.

Any defects found during such inspections, which may create a safety hazard, shall be corrected before further use of the workbasket.

Workbasket and cranes must be approved/licensed for use. Documentation and certification for the workbasket must be stored and filed with the operator of the responsible crane at all times and copies provided to the Project HSE Department.

Safe Work Practices

Prior to any work commencing in a workbasket, a Safe Work Procedure, risk assessment and JHA must be provided and submitted during the application for a Permit. This documentation is to be developed by the Contractor/permit holder.

Employees shall keep all parts of their bodies inside the workbasket during raising, lowering and positioning.

Hoisting of employees shall be discontinued upon indication of any dangerous weather conditions or other impending danger.


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The workbasket shall be hoisted just above the ground and inspected to verify that it is secure and properly balanced before employees are allowed to occupy the workbasket.

Employees being hoisted shall be in continuous sight of and in communication with the crane operator or signal person. If at any time the operator cannot see hand signals or hear radio-relayed signals, he/she shall stop all operations until he/she can receive signals.

Employees occupying the workbasket shall wear a safety harness with a lanyard properly attached to a designated anchor point or suitable structural member within the workbasket.

A certified Rigger or Dogger shall be in the workbasket while it is hoisted aloft.

Pre-Lift Meeting

A meeting attended by the crane operator, signal person, person (s) to be lifted and the person responsible for the task to be performed shall be held to review this procedure and the work procedures to be followed.

This meeting shall be held before the beginning of personnel hoisting operations at each new work location and thereafter for any employees newly assigned to the operation.

12.0 ENGINEERED LIFT PROCEDURE

This section provides the following: Establishes the requirement for organizing a Fluor Crane and Rigging Group, lists personnel and defines their role in the successful execution of this practice and identifies the responsibilities of key personnel for this practice. Identifies the requirements for design and review of lifting lugs. Categorizes rigging lifts for Fluor projects and establishes responsibility for the design, engineering and approval of the transportation and rigging of all equipment and modules. This practice covers all crawler cranes, truck cranes, carry deck cranes, monorails, boom trucks, etc. Discusses the Special Circumstances and Legal and Contractual requirements pertaining to all lifts. Identifies the requirement of having a “Site-Specific Rigging Specification” for each project site. Establishes guidelines that must be adhered to when requiring a variance from this practice.

Note!!! All weights are in U.S. tons.

12.1 Application

Organization

A Fluor Crane and Rigging Group shall be formed on each project.


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The actual organization may vary, depending on the size of the project. Smaller projects with few crane and rigging activities shall be assigned at least one certified Rigging Supervisor. Larger projects shall have the following organization: Rigging Supervisor(s) Crane Inspector(s) Crane and Rigging Trainer(s)

Personnel

Rigging Supervisor - A certified Rigging Supervisor shall have completed the specified training requirements and demonstrate adequate experience and knowledge in rigging in order to be certified by Fluor’s Project Performance and Technology Rigging Group. This certification is required and shall be issued by a Rigging Engineer in a Fluor rigging office or on a field assignment.

Subcontractor Rigging Coordinator - Preferably an English-speaking graduate Engineer with rigging experience, approved by Fluor, who will work closely with the Fluor Crane and Rigging Group in designing and planning every lift. The Rigging Coordinator need not be solely dedicated to rigging.

Qualified Field Rigger – A qualified Field Rigger shall have training or experience equivalent to the NCCER (National Center for Construction Education and Research) rigging training for Ironworkers through Ironworker Level II.

Rigging Engineer - A Fluor Rigging Engineer is a graduate engineer who has been trained in a Fluor rigging office and is competent in the methods and means to design, evaluate, plan, oversee, and estimate transportation and lifting activities during any phase of a project.

Crane Operator - All Crane Operators must meet the following requirements: An up-to-date resume shall be on file with Fluor, detailing specific experience in crane operation. The operator must have a Fluor crane operator's license, or in the case of a Subcontractor, a crane operator's license issued by an organization acceptable to the Project’s Fluor Crane and Rigging Group. The operator must pass a theoretical test and/or assessment that incorporates Fluor site specific “Safety Rules and Regulations” and “Rigging Specifications” and a crane operating proficiency test. This theoretical test and/or assessment and crane operating proficiency test shall be administered either by the Rigging Supervisor or a Fluor approved agency. The operator must have documentation whenever operating a crane that shows that the operator has passed all the requirements to operate cranes on the site. The documentation could be an operator’s badge, a special notation on their site badge and/or a decal on their hard hat, etc.

Responsibilities

Contractors/Subcontractors Nominate a Rigging Coordinator. Develop a lifting schedule for all engineered lifts.


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Execute all lifts in accordance with this practice and the “Site-Specific Rigging Specifications”.

Field Rigging Supervisor Fully responsible for the site preparation and safe execution of all rigging operations. Responsible to see that all lifts are executed in accordance with this practice and the “Site-Specific Rigging Specifications”. Responsible for evaluating the qualifications of Field Riggers and Operators and certifying them as “Qualified Riggers or Operators”.

Field Rigger – (All lifts require one “Qualified Field Rigger”.) Assist the Operator in moving and setting up the crane. Verify with the Operator that the crane is set up correctly and is at the correct operating radius. Verify that the crane is not working at a capacity greater than 50 percent of the load/capacity chart without a GREEN LIFT CHECKLIST (DBN-F41) (See Categories of Lifts section). Prepare GREEN LIFT CHECKLISTS (DBN-F41) and any required rigging designs.

12.2 Lifting Lugs

The Rigging Department shall design or review the lifting lugs for all equipment over 10 tons, or any equipment that must be upended during erection causing the load to the lug(s) to be applied in more than one direction.

Review of the lifting lugs for equipment below 10 tons shall be the responsibility of the Home Office Discipline Engineer.

The Rigging Supervisor shall be responsible for requesting that a Fluor Rigging Engineer review any questionable lifting lugs encountered in the field.

12.3 Categories of Lifts

Note!!! The use of the word "lifts" in the heading of the following categories denotes both transportation and lifting.

Note!!! The designer and checker cannot be the same person. The lead engineer can function in a dual role as designer/approver or checker/approver.

Non-Engineered Lifts

Vessels* Vertical Under 30 tons

Vertical Under 8 feet diameter (approximately 2.4 meters)

Horizontal Under 60 tons


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* A vertical vessel greater than 8 feet (2.5 meters) in diameter and weighing up to 60 tons may be loaded, transported and off loaded at the site as a non-engineered lift; this would be considered a horizontal lift.

All other equipment and structures under 60 tons.

All lifts under eighty (80) percent of the capacity chart of the crane for the boom length and radius being used or under ninety (90) percent if the crane has an operational load indication device with an overload cut-off.

Transportation - All plant equipment under 60 tons.

Non-Engineered lifts shall be further divided into two categories: those requiring a GREEN LIFT CHECKLIST and those that do not.

Lifts that do not require a GREEN LIFT CHECKLIST are those that, including the weight of the load block and rigging, are either: Less than five (5) tons in weight; or Below fifty (50) percent of the gross capacity of the crane at the operating radius being used.

Responsible Personnel - The crane operator and the qualified Field Rigger are jointly responsible for determination of the load weight and placement of the crane so that it is set up within the operating radius selected. The Rigging Supervisor has final responsibility for all operations.

Loads that require a GREEN LIFT CHECKLIST are those with: loads that are over fifty (50) percent and under eighty (80) percent of the load/capacity of the crane at the operating radius being used or under ninety (90) percent if the crane has an operational load indication device with an overload cut-off; loads that are greater than five (5) tons in weight; loads that are being lifted over energized electrical lines and/or live process/plant equipment; loads that are being lifted by two or more cranes. (Excluding tailing cranes).

Responsible personnel for a non-engineered lift requiring a GREEN LIFT CHECKLIST - The crane operator and the qualified Field Rigger are jointly responsible for determination of the load weight and placement of the crane so that it is set up within the operating radius selected. The Field Rigger is responsible for filling out and signing the GREEN LIFT CHECKLIST. The Rigging Supervisor has final responsibility for all operations.

Engineered Lifts

“A” Lifts

Lifts up to one hundred (100) tons per the following requirements: Vessels Vertical 30 tons and over Vertical 8 feet (approximately 2.4 meters)

diameter and over


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Horizontal 60 tons and over All other equipment and structures sixty (60) tons and over. Equipment or vessels over twenty (20) tons that are inside structures, in inaccessible locations, over operating processes or in hazardous areas as determined by the Project/Site Manager or Rigging Engineer. Also included are equipment and vessels constructed of nonferrous materials or are otherwise prone to damage during handling. All multiple crane lifts (exclusive of a tailing crane) in which the load could be transferred from one crane to another during the lift. All lifts over eighty (80) percent of the capacity chart of the crane for the boom length and operating radius being used, or over ninety (90) percent if the crane has an operational load indication device with an overload cut-off. Transportation - All plant equipment over sixty (60) tons.

Responsible personnel for a Type “A” engineered lift must be: Designer: Responsible Site Rigging Supervisor, Fluor Rigging Engineer

or Subcontractor Checker: Fluor Rigging Engineer Reviewer: Rigging Supervisor

“B” Lifts

Lifts 100 to 600 tons.

Responsible personnel for a Type “B” engineered lift must be: Designer: Fluor Rigging Engineer or Contractor/Subcontractor Checker: Fluor Rigging Engineer Reviewer: Fluor Rigging Engineer Reviewer: Fluor Lead Rigging Engineer and Project/Site Manager

“C” Lifts

Lifts six hundred (600) tons and above.

Prior to awarding a rigging contract and approving a rigging plan, the Project Manager along with the Site Manager and Rigging Manager shall review the rigging plan, risk analysis, and/or Contractor bid evaluation to ensure that risk/liabilities are understood and mitigated to the maximum extent possible.

Responsible personnel for a Type “C” engineered lift must be: Designer: Fluor Rigging Engineer or Subcontractor Checker: Fluor Rigging Engineer Reviewer: Fluor Lead Rigging Engineer Reviewer: Fluor Lead Rigging Engineer from another rigging office Reviewer: Optional third-party rigging consultant. The Site Manager, the Rigging Manager, and the Project Manager will determine if the lift requires an independent review by a third-party rigging consultant. Reviewer: Rigging Manager, Site Manager and Project Manager

Note!!! REVIEW BY THE ABOVE MANAGERS IS ABSOLUTELY MANDATORY!


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Note!!! See Lift Classifications (DBN-F42) for quick references to lift classifications.

Special Circumstances with Lifts

All lifts that are greater than ninety-five (95) percent of the crane load/capacity chart require a Fluor Rigging Engineer to be present at the site to review and witness the lift.

Also, special circumstances shall be considered by the Rigging Engineer and the Site Manager on a case by case basis to determine if a lift needs to be elevated to a higher level or design and/or approval.


HSE Practice 30 Personnel Hoisting

® PERSONNEL HOISTING PRACTICE 30 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to establish the minimum requirements for the use of personnel hoisting platforms.

2.0 References

2.1 Title 29 Code of Federal Regulations Part 1926 Subpart N (1910.550)

2.2 Title 29 Code of Federal Regulations Part 1926 Subpart N (1910.550)

2.3 ANSI A10.4—Personnel Hoists and Employee Elevators

2.4 ANSI A10.28—Safety Requirements for Work Platforms Suspended from Cranes and Derricks for Construction and Demolition Operations

2.5 ASME B30.23—Personnel Lifting Systems

3.0 Definitions

3.1 Failure—load refusal, breakage, or separation of components.

3.2 Hoist (or hoisting)— all crane or derrick functions such as lowering, lifting, swinging, booming in and out or up and down, or suspending a personnel platform.

3.3 Load Refusal—the point where the ultimate strength is exceeded.

3.4 Maximum Intended Load—the total load of all employees, tools, materials, and other loads reasonably anticipated to be applies to a personnel platform or personnel platform component at any one time.

3.5 Mousing—using wire to close the crane hook opening.

3.6 Runway—a firm, level surface designed, prepared and designated as a path of travel for the weight and configuration of the crane being used to lift and travel with the crane suspended platform. An existing surface may be used as long as it meets these criteria.

4.0 Process

4.1 Approvals

4.1.1 The use of a crane or other similar hoisting equipment to hoist personnel is strictly forbidden unless the use of conventional means would be more hazardous, without regard to the time or expense involved.

4.1.2 It is Management's (Construction Manager or Superintendent) responsibility to determine that no other method can accomplish the task in a safer manner. This determination shall be documented. It is also management's responsibility to ensure that these Practices are strictly adhered to when using personnel hoisting platforms.

4.1.3 Once it has been determined that personnel hoisting is the only safe method of accomplishing the job, a formal, written Rigging and Lift Plan shall be completed

4.1.4 A copy of the Rigging and Lift plan (DBN-F21) and the evaluation of alternate methods (DBN-F38) shall be approved by the Construction Manager and Construction HSE Manager. This authorization is required prior to conducting any personnel hoisting.


4.2.1 No lifting, lowering, holding, swing, or travel shall be done while anyone is in the hoisting platform, until all of the following conditions have been complied with:


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4.2.1.1 There must be documented reasons why other alternative means of access, egress, and work activity were eliminated.

4.2.1.2 Ladders, scaffolding, aerial lifts, etc. must be used wherever possible for access, egress, and work activity.

4.2.1.3 Cranes will not be used to hoist or suspend personnel on a hoisting platform in situations where other equipment designed for the purpose is feasible.

4.2.1.4 Time and cost factors should not be applied to alternative methods of access and egress that are considered.

4.2.2 Prior to lifting any personnel, the hoisting device shall be inspected, and documentation shall be made and maintained in accordance with the requirements for that particular piece of equipment.

4.2.3 The hoisting machine must be equipped with a positive shut off anti-two block devices.

4.2.4 A Rigging and Lift Plan shall be developed and documented for each lift or group of lifts. The Rigging and Lift Plan shall be used as documentation of lift planning for personnel hoisting.

4.2.5 A firm footing, uniformly level within one- percent (1 foot in 100 feet), shall be provided for all boom-type cranes. Cranes equipped with outriggers shall have them all fully deployed following manufacturer's specifications, insofar as applicable, when hoisting employees.

4.2.6 A meeting for planning the lift and work activities shall be attended by the operator of the hoisting equipment; signal person(s); person(s) to be lifted; the Site HSE Manager; the superintendent of the work activity; and the Construction Manager. The work procedure shall be discussed step-by-step from start through comple tion. Notes shall be made of the entire meeting and shall be main tained in the project HSE files.

4.2.7 Voice communication between the operator and the person(s) being lifted shall be maintained whenever voice communication is available. If two-way radios are used, an isolated frequency for the personnel lifting operation will be used.

4.2.8 If hand signals are used, the operator shall only follow signals of a designated, competent signal person on the lifting platform. Multiple person signaling is not permitted.

4.2.9 Hoisting equipment in no instance shall exceed a speed of 100 feet per minute.

4.2.10 When welding is being performed from a suspended personnel hoisting platform, welding leads shall be protected from contact with any surface of the platform. Ground fault circuit interrupters shall protect all 110-volt service used in the platform.

4.2.11 Employees on the platform shall wear safety harnesses and lanyards attached to an independent line, which shall be attached above the headache or load block.

4.2.12 The operator of the lifting equipment shall remain at the controls and maintain visual/voice contact with the signal person(s) the entire time the personnel hoisting platform is elevated.

4.2.13 The number of employees to be hoisted shall be kept to a minimum, and in no situation shall the number exceed four. Employees using the hoisting platform shall be considered to weigh a minimum of 300 pounds each.


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4.2.14 The hoisting platform shall not be used during high winds (winds exceeding 25 MPH), electrical storms, snow, or other adverse weather conditions that could endanger personnel on the hoisting platform.

4.2.15 All lifts shall be made in accordance with the hoisting equipment manufacturer's lifting recommendations.

4.2.16 Load lines shall be capable of supporting, without failure, at least seven times the maximum intended load, except that where rotation resistant rope is used, the lines shall be capable of supporting without failure, at least ten times the maximum intended load. The required design factor is achieved by taking the current safety factor of 3.5 and applying the 50 per cent derating of the crane capacity.

4.2.17 Load and boom hoist drum brakes, swing brakes, and locking devices such as pawls or dogs shall be engaged when the occupied personnel platform is in a stationary position.

4.2.18 The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the rated capacity for the radius and configuration of the crane or derrick.

4.2.19 The use of machines having live booms (booms in which lowering is controlled by a brake without aid from other devices which slow the lowering speeds) is prohibited.

4.2.20 Cranes and derricks with variable angle booms shall be equipped with a boom angle indicator, readily visible to the operator.

4.2.21 Cranes with telescoping booms shall be equipped with a device to indicate clearly to the operator, at all times, the boom's ext ended length or an accurate determination of the load radius to be used during the lift shall be made prior to hoisting personnel.

4.2.22 A positive acting device shall be used which prevents contact between the load block or overhaul ball and the boom tip (anti-two-blocking device), or a system shall be used which deactivates the hoisting action before damage occurs in the event of a two-blocking situation (two-block damage prevention feature).

4.3 Personnel Platforms

4.3.1 The platforms used for lifting personnel must be designed with a minimum safety factor of 5, and must be designed by a qualified engineer who is competent in structural design. The suspension system must be designed to minimize tipping when personnel move on the platform.

4.3.2 Each personnel platform must be provided with a standard guardrail system that is enclosed from the toe board to the mid-rail to keep tools, materials, and equipment from falling out of the basket. The platform also must have a grab rail on the inside of the guardrail, overhead protection, adequate headroom for employees, and a plate or other perma nent marking that clearly indicates the platform's weight and rated load capacity or maximum intended load.

4.3.3 The access gate must not swing outward and must have a restraining device to prevent accidental opening.

4.3.4 Employees must not be exposed to any rough edges on the platform.

4.3.5 A qualified welder who is knowledgeable of weld grades must perform all welding of the platform and types as well as the materials specified in the platform design.


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4.3.6 Headroom shall be provided which allows employees to stand upright in the platform.

4.3.7 In addition to the use of hard hats, employees shall be protected by overhead protection on the personnel platform when employees are exposed to falling objects.

4.3.8 All rough edges exposed to contact by employees shall be surfaced or smoothed in order to prevent injury to employees from punctures or lacerations.

4.3.9 All welding of the personnel platform and its components shall be performed by a qualified welder familiar with the weld grades, types, and material specified in the platform design.

4.3.10 The personnel platform shall be conspicuously posted with a plate or other permanent marking which indicates the weight of the platform, and it’s rated load capacity or maximum intended load.

4.4 Loading

4.4.1 The rated load capacity of the platform must not be exceeded.

4.4.2 Only authorized personnel, their tools, equipment, and materials needed for the job is allowed on the platform.

4.4.3 Materials and tools must be secured and evenly distributed to balance the load while the platform is in motion.

4.5 Rigging

4.5.1 When a wire rope bridle is used to connect the platform to the load line, the bridle legs must be connected to a master link or shackle so that the load is evenly positioned between the legs. Bridles used as a connection for the personnel platform must not be used for any other purpose.

4.5.2 Attachment assemblies such as hooks must close and lock to keep the hook throat from opening; an alloy anchor-type shackle with a bolt, nut, and retaining pin may be used as an alternative.

4.5.3 A separate wire rope choker will be used as a "safety" and will be connected to a shackle on the load line directly above the headache ball to the padeye or shackled to the hoisting platform.

4.6 Inspection and Testing

4.6.1 A trial lift must be made before employees are allowed to be hoisted. During the trial lift, the personnel platform must be loaded to twice its anticipated lift weight. The lift must start at ground level or at the location where employees will enter the platform and proceed to each location where the personnel platform is to be hoisted and positioned.

4.6.2 The crane or derrick operator must check all systems, controls, and safety devices to ensure that:

§ They are functioning properly.

§ There is no interference § All configurations necessary to reach work locations will allow the operator to

remain within the 50-percent load limit of the hoist's rated capacity.

4.6.3 If a crane or derrick is moved to a new location or returned to a previously used one, the trial lift must be repeated before hoisting personnel.


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4.6.4 After the trial lift, the personnel platform must be hoisted a few inches and inspected to ensure that it remains secured and is properly balanced.

4.6.5 Before employees are hoisted, a designated person must check to ensure the following:

§ Hoist ropes are free of kinks.

§ Multiple-part lines are not twisted. § The primary attachment is centered over the platform. § There is no slack in the wire rope. If the rope is slack, the hoisting system must

be inspected.

4.7 Movement of Cranes

4.7.1 Personnel hoisting is prohibited while the crane is traveling except when the employer demonstrates that this is the least hazardous way to accomplish the task or when portal, tower, or locomotive crane are used.

4.7.2 When cranes are moving while hoisting personnel, the following rules apply:

§ Travel must be restricted to a fixed track or runway. § Travel must be limited to the radius of the boom.

§ The boom must be parallel to the direction of travel. § There must be a complete trial run before employees occupy the platform. § If the crane has rubber tires, the condition and air pressure of the tires must be

checked, and the chart capacity for lifts must be applied to remain under the 50-percent limit of the hoist's rated capacity.

4.8 Authorization for the use of a Suspended Personnel Hoisting Platform

4.8.1 After all requirements have been properly complied with, and prior to the use of the personnel hoisting platform, the Authorization for the use of a Suspended Personnel Hoisting Platform (DBN-F22) shall be completed by the Construction Manager.

4.8.2 In each instance where a personnel hoisting platform is required for elevated work, the Rigging and Lift Plan (DBN-F21) shall be completed and signed by the project's rigging superintendent or designee (appointed by the Construction Manager). The plan shall then be reviewed and approved by the site HSE Manager and the Construction Manager.

4.8.3 Upon approval of personnel hoisting, a copy of the Rigging and Lift Plan, Evaluation of Alternate Methods and the Authorization for the use of a Suspended Personnel Hoisting Platform shall be maintained at the operator’s station for the duration of the lift.

4.9 Work practices.

4.9.1 Employees shall keep all parts of the body inside the platform during raising lowering, and positioning. This provision does not apply to an occupant of the platform performing the duties of a signal person.

4.9.2 Before employees exit or enter a hoisted personnel platform that is not landed, the platform shall be secured to the structure where the work is to be performed, unless securing to the structure creates an unsafe situation.

4.9.3 Tag lines shall be used unless their use creates an unsafe condition.

4.9.4 The crane or derrick operator shall remain at the controls at all times when the crane engine is running and the platform is occupied.


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4.9.5 Hoisting of employees shall be promptly discontinued upon indication of any dangerous weather conditions or other impending danger.

4.9.6 Employees being hoisted shall remain in continuous sight of and in direct communication with the operator or signal person. In those situations where direct visual contact with the operator is not possible, and the use of a signal person would create a greater hazard for the person, direct communication alone such as by radio may be used.

4.9.7 Except over water, employees occupying the personnel platform shall use a body belt/harness system with lanyard appropriately attached to the lower load block or overhaul ball, or to a structural member within the personnel platform capable of supporting a fall impact for employees using the anchorage. When working over water the requirements of 1926.106 shall apply.

4.9.8 No lifts shall be made on another of the crane's or derrick's load lines while personnel are suspended on a platform.

5.0 Record Retention The Project shall retain in the HSE files, and produce when requested, documentation of all meeting notes pertaining to each lift, construction and testing of the hoisting platform (Hoisting Platform Certification), all lifting plans including the full-cycle operational test (Rigging and Lift Plan,, the Alternative Method Evaluation and Authorization for the use of a Suspended Personnel Hoisting Platform)


HSE Practice 31 Welding, Cutting & Heating

® WELDING, CUTTING AND HEATING PRACTICE 31 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for employees to perform safe welding, cutting, and heating.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart J (1926.350 - 1926.354)

2.2 NFPA 51B—Standard for Fire Prevention During Welding, Cutting, and Other Hot Work (National Fire Codes, Vol. 2)

2.3 NFPA 55—Standards fro the Storage, Use, and Handling of Compressed and Liquefied Gases in Portable Containers

2.4 NFPA FPH, Section 3-14—Welding and Cutting

2.5 Yanpet Safe Work Authorization Procedure H-P-0406

2.6 SASO 336/1994 Industrial Safety and Health Regulations—Welding, Cutting, and Brazing

3.0 Definitions

3.1 Acetylene - Acetylene is an unstable gas when compressed above 15 psig. Acetylene cylinders are filled with a porous material and saturated with liquid acetone. Acetylene, when pumped into the cylinder, dissolves in the acetone and is held in a stable condition. If the acetylene cylinder is stored or used in the horizontal position, the acetone may leak out, leaving an explosive mixture of acetylene. For this reason, all acetylene cylinders must be stored and used in the vertical position.

3.2 Adequate Ventilation - Ventilation (natural or mechanical) that maintains contaminant levels below OSHA action levels (if such levels exist). If action levels do not exist a value of one-half the TLV or PEL (see 5.013. and 5.014.), whichever is lower, will be substituted.

3.3 Combustible Material - liquids, solids, or gases that are relatively difficult to ignite (at 140° F or higher) and that burn relatively slowly (such as paper, wood, etc.).

3.4 Enclosed space(s) - A space of less than 10,000 cubic feet per welder with a ceiling height of less than 16 feet.

3.5 Exposure assessment - Air sampling performed in the breathing zone of the affected employee, utilizing a properly calibrated air sampling pump connected via flexible tubing to the proper sampling media.

3.6 Flammable Material - Liquids, solids, or gases that are capable of being easily ignited, (at less than 140° F) burning intensely, or having a rapid rate of flame spread (usually dusts, fine powders, or substances that ignite spontaneously at low tempera tures).

3.7 General ventilation - A ventilation system that adds or removes air in an attempt to dilute the concentration of a contaminant.

3.8 High Efficiency Particulate Air (HEPA) filter - A filter capable of trapping and retaining at least 99.97 percent of mono-dispersed particles of 0.3 microns in diameter.

3.9 Local Exhaust ventilation - A ventilation system that captures or contains contaminants at their source before they escape into the work area then exhausts them away from the work area. A typical system for welding operations consists of freely movable hoods placed as close to the welder or burner as practical to remove fumes and smoke at the source without having them pass through the worker’s breathing zone.


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3.10 MAPP Gas - MAPP is a stabilized mixture of methyl acetylene and has considerably less tendency to backfire than acetylene. Maximum allowable use pressure is 94 psig versus 15 psig for acetylene.

3.11 Mechanical ventilation - Ventilation that consists of either general mechanical ventilation systems or local exhaust systems.

3.12 Oxygen - Oxygen itself is not flammable, but the presence of pure oxygen accelerates the combustion reaction. Oil and grease, in the presence of oxygen, become highly explosive. Oxygen must not be allowed to contact petroleum- based substances.

3.13 Permissible Exposure Limit (PEL) - The limit set by OSHA that triggers certain requirements in addition to those required by exceeding the action level.

3.14 Threshold Limit Value (TLV) - A value designated by the American Conference of Governmental Industrial Hygienists to serve as a guideline to assist in the control of health hazards.

4.0 Process


4.1.1 Fire fighting equipment shall be within 25 feet of all welding and burning activities.

4.1.2 All flammable and combustible materials shall be removed or covered by fire resistant material before starting to weld or burn.

4.1.3 Proper personal protective equipment shall be worn, i.e.,

• Long sleeve shirts

• Cutting goggles/welding hood

• Gloves/aprons/capes

• Clothing without frays or rips

• Hard hats

• Respirators

4.1.4 A “Hot Work” permit will be obtained in accordance with Yanpet Safe Work Authorization Procedure H-P-0406 prior to start of work.

4.1.5 Any receivers of Hot Work Permits must have successfully attended Safe Work Authorization training.

4.1.6 Fire watchers shall be required whenever welding or cutting is performed in locations where other than a minor fire might develop, or any of the following conditions exist:

4.1.6.1 Appreciable combustible material, in building construction or contents, closer than 35 feet (10.7 m) to the point of operation.

4.1.6.2 Appreciable combustibles are more than 35 feet (10.7 m) away but are easily ignited by sparks.

4.1.6.3 Wall or floor openings within a 35-foot (10.7 m) radius expose combustible material in adjacent areas including concealed spaces in walls or floors.

4.1.6.4 Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or roofs and are likely to be ignited by conduction or radiation.


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4.1.7 Fire watchers shall have fire extinguishing equipment readily available and be trained in its use. They shall be familiar with facilities for sounding an alarm in the event of a fire. They shall watch for fires in all exposed areas, try to extinguish them only when obviously within the capacity of the equipment available, or otherwise sound the alarm. A fire watch shall be maintained for at least a half hour after completion of welding or cutting operations to detect and extinguish possible smoldering fires .

4.2 Setting Up Equipment

4.2.1 All operators of welding and/or cutting equipment must be trained to operate the equipment they will use. Appropriate HSE Practices must be reviewed and understood prior to use of this equipment.

4.2.2 Clean all threaded connections. Carefully open the cylinder valve slightly to blow out any foreign particles. After the regulator is connected, stand to one side of the gauge while opening the cylinder valve slowly.

4.2.3 The second stage of the regulator must be closed before opening the cylinder valve.

4.2.4 Open valves one full turn only on fuel gas cylinders (propane, acetylene, natural gas). Open oxygen cylinder valves wide open. Keep the valve wrench in place during use.

4.2.5 When using acetylene, do not exceed 15 psig on the torch side of the gauge.

4.2.6 Reverse-flow check valves shall be used at the regulator end and are recommended on the torch end for both fuel and oxygen hoses.

4.3 Repair and Testing of Gas Hoses

4.3.1 Hose(s) which has been subject to flashback or which shows evidence of wear or damage, shall be tested to twice the normal pressure to which it is subject, but in no case less than 300psi. Defective hose, or hose in doubtful condition, shall not be used. This requirement shall also apply following the repair of damaged hose.

4.4 Lighting the Torch

4.4.1 Open the oxygen valve on the torch handle and adjust the oxygen regulator to the desired pressure (usually 45 p.s.i.g.). Allow the gas to flow a minimum of 10 seconds for every 50 feet of hose. Close the oxygen valve on the torch.

4.4.2 With the regulator valve backed out, open the fuel valve on the cylinder. Remember, for acetylene the valve is only opened a maximum of one full turn. Open the fuel gas valve on the torch and adjust the fuel gas regulator to the desired setting. Purge the lines the same way as described above for oxygen. Close the fuel valve on the torch.

4.4.3 Hold the torch in one hand and the spark lighter in the other. Open the torch fuel valve approximately one-half turn and ignite the gas. Keep opening the fuel valve until the flame stops smoking and is about 1/8 inch from the tip. Then slightly reduce the fuel supply to bring the flame back to the tip.

4.4.4 Open the oxygen fuel valve on the torch until a bright neutral flame appears. If a backfire or flashback occurs, immediately turn off the fuel valve and then the oxygen valve. Begin again by holding the torch in one hand and the spark lighter in the other, and proceed from there.


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4.5 Shutting Off the Torch

4.5.1 First shut off the torch fuel valve, and then shut off the torch oxygen valve. If this method is reversed, a "pop" may occur which will cause carbon to form in the torch. Now close both cylinder valves. Open the torch oxygen valve to release the pressure in the system. Now close the torch oxy gen valve, and release

4.6 Safety Considerations

4.6.1 Never use oil or grease on any fittings or apparatus in contact with oxygen.

4.6.2 Blow out cylinder valves before attaching regulators to cylinders.

4.6.3 Back off the pressure adjusting screw prior to opening cylinder valves.

4.6.4 Never stand directly in front or in back of a regulator when opening the cylinder valve. Stand so that the cylinder valve is between you and the regulator.

4.6.5 Always open the cylinder valves slowly. If a wrench is used, keep it on the valve.

4.6.6 An acetylene cylinder should never be opened more than one full turn.

4.6.7 Always purge the oxygen and fuel passages individually before lighting the torch.

4.6.8 First-aid equipment shall be available at all times. All injuries shall be reported as soon as possible for medical attention. First aid shall be rendered until medical attention can be provided.

4.7 Arc Welding and Cutting

4.7.1 Welders must wear the head and eye protection required in their work area. They must wear appropriate welding helmets, long-sleeve shirts, leathers, and welders gloves. If grinding, chipping, or buffing is done, a face shield over monogoggles must be worn. If respirators are required, these also must be used.

4.7.2 Heli-arc and MIG welding operations emit intense ultraviolet radia tion that can result in third-degree burns to exposed skin as well as painful flash burns to the eyes. Welding helmets must be checked periodically to insure they are light tight. Arc gouging generally produces a great deal of slag and hot metal sparks. Additional personal protective equipment such as boots, Nomex suits, hearing protection and mono-goggles may be appropriate.

4.7.3 Welding screens shall be utilized in congested work areas or when welding, cutting or grinding operations are being performed in fabrication shop areas or in areas where there is an exposure hazard from flying particles to other employees.

4.8 Equipment and Inspection

4.8.1 Equipment must be industrial rated, in good condition, and meet OSHA requirements governing application, installation, and operation of arc-welding and cutting equipment.

4.8.2 Before each use, the following items shall be inspected:

4.8.2.1 All leads for broken or cut insulation

4.8.2.2 Electrode holders for broken insulators or worn holders


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4.8.2.3 Oil and fuels on gas- or diesel-powered units

4.8.3 All welding equipment will be inspected prior to being allowed on-site to ensure it is in safe working condition.

4.9 Electric Shock Hazard

4.9.1 Almost any electric currents present some degree of potential shock hazard. Under optimum conditions, even welding voltages as low as 30 volts can be hazardous. Operating voltages listed on nameplates are usually much lower than open-circuit voltages, which should not exceed 100 volts D.C. or 80 volts AC

4.9.2 Either AC or DC current can be used for welding, and, although both present serious shock hazard, AC is potentially more hazardous. Be certain not to use any equipment that is either wet or has been drenched recently. Welding units that are powered by AC, including portable welding machines, must be adequately grounded. To change polarity, the unit must be shut down.

4.9.3 Electrodes shall never be changed with bare hands or wet gloves or when standing on a wet floor or grounded surface. Whenever possible, welding receptacles should be interlocked so that the power must be shut off before the plug can be withdrawn. Cables that become worn enough to present a hazard must be replaced immediately. Keep welding cables away from power supply cables and high voltage wires, and do not dip hot electrode holders in water to quick cool them.

4.9.4 GFCI’s SHALL NOT be used on welding machines with D.C. current.

4.10 Inert and Toxic Gas Exposure

4.10.1 Many welding Practices require an inert gas, such as argon and/or helium. These gases present an asphyxiation hazard, and welders and fitters need to keep these points in mind:

4.10.1.1 Large-diameter pipe will contain larger volumes of inert gas and greater potential problems

4.10.1.2 Temporary enclosures over field installations should be checked for oxygen level before use and monitored continuously when in use

4.10.1.3 Where argon (or any other inert gas) is used, the area shall be monitored for oxygen concentration and Lower Explosive Level (LEL). Note: LEL readings will be inaccurate in an oxygen deficient atmosphere, so measure oxygen concentration first.

4.11 Ventilation Requirement

4.11.1 General requirements

4.11.1.1 Oxygen and fuel gas bottles shall not be taken into a confined space. The torch and hose assembly shall only be taken into a confined space long enough to perform the actual work and shall then be stored on the outside of the confined space.

4.11.1.2 Mechanical ventilation shall be provided during all welding operations when natural ventilation is not sufficient to lower concentrations to levels below OSHA action levels and/or the ACGIH TLV’s. Mechanical ventilation is required in all enclosed


9905-02-000.doc 12/8/2004 6

spaces. The following requirements apply to mechanical ventilation:

• General mechanical ventilation shall be of sufficient capacity and so arranged as to produce the number of air changes per hour necessary to maintain welding fumes and smoke within safe limits.

• Contaminated air exhausted from a working space shall be discharged into the open air or otherwise clear of the source of intake air.

• Oxygen shall not be used for ventilating purposes.

4.11.2 Welding, Cutting and Heating in Enclosed Spaces

4.11.2.1 General mechanical or local exhaust ventilation shall be provided whenever welding, cutting, or heating is performed in areas with inadequate ventilation and in enclosed spaces. The ventilation shall be of sufficient capacity and so arranged as to produce the number of air changes necessary to maintain welding fumes and smoke within safe limits. (Levels below OSHA PEL’s and/or ACGIH TLV’s will be considered to be “safe limits” as described above. In some cases OSHA Action Levels, excursion limits and STEL’s may be substituted as “safe limits”). The adequacy of the ventilation shall be determined by air monitoring.

• When sufficient ventilation, as described above, cannot be obtained, the employees shall be protected by appropriate respiratory protection.

• Employees performing welding and/or cutting operations on the materials listed below in enclosed spaces shall use local exhaust ventilation or the employees will be protected with airline respirators. Airline respirators shall also protect other employees working in the immediate area (i.e. helpers and fitters).

⇒ Lead base metals or materials coated with lead-bearing materials (must also comply with the lead standard 1926.62)

⇒ Cadmium bearing or cadmium coated materials (must also comply with the cadmium standard 1926.1127)

⇒ Metals coated with mercury-bearing materials

⇒ Beryllium-containing base or filler metals (Note: because of its high toxicity, work involving beryllium shall be done with both local exhaust ventilation and air-supplied respirators).

4.11.3 Welding, Cutting, and Heating in Open Air (areas with adequate ventilation)

4.11.3.1 Employees performing welding and/or cutting operations on the materials listed below in the open air shall be protected by air-purifying respirators (filter type).

• Lead base metals or materials coated with lead-bearing materials (must also comply with the lead standard Title 29 CFR Part 1926.62).


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• Cadmium bearing filler materials (must also comply with the cadmium standard Title 29 CFR Part 1926.1127).

• Chromium-bearing metals or metals coated with chromium-bearing materials (i.e. stainless steel).

• Metals coated with mercury-bearing materials

• Beryllium-containing base or filler metals. (Note: Because of its high toxicity, work involving beryllium shall be done with both local exhaust ventilation and air-supplied respirators).

4.11.4 Inert-Gas Metal Arc Welding

4.11.4.1 The use of chlorinated solvents (exa mple: Tap-free) shall be kept at least 200 feet away from any inert-gas metal arc welding unless shielded from the exposed arc.

4.11.4.2 Surfaces prepared with chlorinated solvents shall be thoroughly dry before welding is permitted on such surfaces.

4.11.4.3 Welders and other employees who are exposed to welding flash shall be protected so that skin is covered completely to prevent burns and other exposure to ultraviolet radiation.

4.11.4.4 When inert gas metal-arc welding is performed on stainless steel, either local ventilation or air-supplied respirators must be utilized. The local ventilation shall be of sufficient capacity and so arranged as to maintain nitrogen dioxide levels at or below the current ACGIH TLV for nitrogen dioxide (3ppm).

4.12 Welding, Cutting and Heating - Paints and Coatings

4.12.1 Before welding, cutting or heating any surface covered by a coating whose flammability is not known, a test shall be made by a competent person to determine its flammability.

4.12.2 When coatings are determined to be flammable, they shall be stripped from the area to be heated/burned/welded to prevent ignition (a minimum of 4 inches to each side of the location heated).

4.12.3 When coatings are determined to be toxic, the coating shall be stripped at least 4 inches from the area of heat application, or the employees must be protected with appropriate respiratory protection. Half-mask cartridge respirators equipped with HEPA filters are the minimum acceptable respiratory protection that can be used when welding on surfaces with toxic coatings.

4.12.4 When working in enclosed spaces on surfaces covered with toxic preservatives (i.e. lead, cadmium or zinc chromate paints, etc.), the coating shall be stripped at least 4 inches from the area of heat application. If this is not possible, air-supplied respirators shall protect the employees in the enclosed space.

4.12.5 When working in enclosed spaces on surfaces covered with coatings that have been determined to be other than toxic, the coatings shall be removed a sufficient distance from the area that is to be heated to ensure that the temperature of the un-stripped metal will not be appreciably raised. Artificial cooling of the metal surrounding the heated area may be used to limit the size of the area required to be stripped.


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4.13 Storage of Compressed Gas Cylinders

4.13.1 Cylinders shall be kept away from radiators and other sources of heat.

4.13.2 Inside buildings, cylinders shall be stored in a dry, well-ventilated, well-protected location. Assigned storage spaces shall be located where cylinders will not be knocked over or damaged by passing or falling objects or be subject to tampering by unauthorized persons. Cylin ders shall not be kept in unventilated enclosures such as lockers and cupboards.

4.13.3 Empty cylinders shall have their valves closed.

4.13.4 Empty cylinders shall be separated from charged cylinders. Storage racks shall be identified by compressed-gas -cylinder content and condition ("Full" or "Empty").

4.13.5 Valve protection caps, where the cylinder is designed to accept a cap, shall always be in place and hand tight (except when cylinders are in use or connected for use).

4.13.6 Protection from solar radiant heat shall be provided where cylinders are directly exposed to sunlight.

4.13.7 Compressed gas cylinders shall be secured in a vertical position at all times, including when being hoisted or transported.

4.13.8 Retention chains or straps will be provid ed on storage racks and carts so that compressed gas cylinders will be secured against falling.

4.13.9 Small, handheld compressed gas cylinders used for propane torches, gas detector test cylinders, etc., may be stored without retention chains or straps. However, these cylinders should be stored away from open flames or sources of heat and in a manner that will protect them from being damaged by work activities.

4.14 Compressed Gas Cylinder Storage Area

4.14.1 A 20-pound ABC-rated fire extinguisher (minimum) shall be placed no closer than 25 feet but no further than 75 feet from fuel-gas storage areas.

4.14.2 Warning signs shall be conspicuously placed and shall read, "Danger - No Smoking, Matches, Open Lights, or Flames," or other equivalent wording.

4.14.3 Inside buildings, cylinders (except those in actual use or attached for use) shall be limited to a total gas capacity of 2,000 cubic feet or 300 pounds of liquefied petroleum gas.

4.14.4 Oxygen cylinders in storage shall be separated from fuel-gas cylin ders or combustible materials (especially oil or grease) a minimum of 20 feet or by a noncombustible barrier at least 5 feet high having a fire -resistant rating of at least ½ hour.

5.0 Record Retention A copy of each Safe Work (Hot Work) permit is to be kept on file in the safety office.


HSE Practice 32 Fire Protection & Prevention

® FIRE PROTECTION & PREVENTION PRACTICE 32 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 This Practice provides the minimum requirements for preventing and controlling fires.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart F (1926.150 - 1926.159)

2.2 NFPA 1H, Part 1, Chapter 7—Fire Protection Systems

2.3 NFPA 1H, Part 1, Chapter 18—Flammable and Combustible Liquids

2.4 NFPA 10, 2002-07-19—Standard for Portable Fire Extinguishers

2.5 SASO 314/1982 Industrial Safety and Health Regulations—Part 2 - Buildings

2.6 Yanpet Safety Regulations for Contractors Procedure H-P-0301

3.0 Definitions

3.1 Combustible Liquid - liquid having a flash point at or above 140 °F (60 °C).

3.2 Combustible Material - liquids, solids, or gases that are relatively difficult to ignite and that burn relatively slowly (such as paper, wood, etc.).

3.3 Flammable Liquid - liquid having a flash point below 140 °F and a vapor pressure not exceeding 40 pounds per square inch (absolute) at 100 °F.

3.4 Flammable Material - liquids, solids, or gases that are capable of being easily ignited, burning intensely, or having a rapid rate of flame spread (usually dusts, fine powders, or substances that ignite spontaneously at low temperatures).

3.5 Type B Fire Extinguisher - used for flammable and combustible liquids.

3.6 Type C Fire Extinguisher - used for extinguishing electrical fires.

4.0 Practices

4.1 General

4.1.1 An alarm system shall be established as part of the Emergency Preparedness and Contingency Plan (Practice 6) to alert all employees at the site in the event of an emergency. The alarm system should include lights, horns, sirens, or other appropriate devices to ensure that every employee is aware of project emergencies.

4.1.2 To prevent ignition hazards, electrical wiring and equipment shall be installed in accordance with the National Electrical Code and National Fire Protection Association (NFPA) standards. Smoking shall be prohibited in areas where fire hazards may exist, and "No Smoking" signs shall be posted.

4.1.3 Fire extinguisher, fire hoses, and nozzles are not to be removed from their containers except to fight fires.

4.1.4 Fire fighting equipment is not to be blocked. This equipment includes fire apparatus, extinguisher, hydrants, and monitors.

4.1.5 Project personnel are authorized to use hand held fire extinguishers only. Yanpet personnel will operate any fixed fire protection equipment if necessary.

4.2 Fire Extinguishers

4.2.1 A fire extinguisher rated not less than 2A shall be provided for each 3,000 square feet of building area and in each yard storage area. Travel distance to any fire extinguisher shall not exceed 100 feet from any protected area.


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4.2.2 One or more extinguishers rated not less than 2A shall be located on each floor of a multi-storied building. At least one 2A-rated extinguisher shall be located adjacent to each stairway in a multi-storied building. Extinguishers rated not less than 10B will be provided between 25 feet and 75 feet of any area in which more than 5 gallons of flammable or combustible liquids or 5 pounds of flammable gas are used or stored.

4.2.3 Extinguishers shall be conspicuously located where they will be readily accessible and immediately available in case of a fire. Their locations shall be conspicuously marked. Extinguishers shall be installed on hangers or in the brackets provided and shall not be more than 5 feet from the floor. Extinguishers weighing more than 40 pounds shall be installed so that the top is not more than 3½ feet from the floor.

4.2.4 Training and Education.

4.2.4.1 Where the employer has provided portable fire extinguishers for employee use in the workplace, the employer shall also provide an educational program to familiarize employees with the general principles of fire extinguisher use and the hazards involved with incipient stage fire fighting.

4.2.4.2 The employer shall provide the education required upon initial employment and at least annually thereafter.

4.2.4.3 The employer shall provide employees who have been designated to use fire fighting equipment as part of an emergency action plan with training in the use of the appropriate equipment.

4.2.4.4 The employer shall provide the training required upon initial assignment to the designated group of employees and at least annually thereafter.

4.3 Storage of Flammable and Combustible Liquids - (See Practice 13)

4.3.1 Bulk storage of fuels shall be discouraged at all projects. Off site fuel trucks shall be used whenever possible. If off site fuel trucks are not possible, fuel storage containers shall be restricted in size to 660 gallons capacity per container and/or 1120 gallons capacity total. If these limits have to be exceeded, government agencies will be notified, and SPCC plans developed.

4.3.2 Aboveground storage tanks shall have spill containment capable of controlling 110 percent of the capacity of the tanks. Spills in the diked area shall be cleaned up. (Earthen dikes shall be sealed/lined for leach control.)

4.3.3 A 20-pound BC fire extinguisher shall be posted between 25 feet and 75 feet from the bulk storage area.

4.3.4 Storage tanks shall be grounded.

4.3.5 Storage tanks and the container to be filled shall be bonded.

4.3.6 Storage tanks shall be vented.

4.3.7 Storage tanks shall have an automatic shut off on dispensing hoses.

4.3.8 Storage tanks shall have some form of impact protection from vehicle traffic.

4.3.9 Storage areas shall be at least 25 feet from buildings.


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4.4 Inspections

4.4.1 Extinguishers shall be inspected monthly - or more often when circumstances warrant - to ensure that they have not been actuated or tampered with and to detect any damage. Inspection tags shall be attached to extinguishers, and the date of the inspection will be indicated after each inspection.

4.4.2 Hydro testing or weighing in accordance with NFPA requirements should include the following:

TYPE FREQUENCY

Water Pump No test required

Cartridge 5 years

Soda Acid 5 years

Pressure 5 years

Foam 5 years

Carbon Dioxide (CO2) 5 years

Dry Chemical 12 years

4.4.3 Each extinguisher shall have a durable tag securely attached to show the maintenance test and recharge date and the initials or signature of the person who performed the services. A discharged fire extinguisher shall be removed from service immediately and replaced with another extinguisher.

4.5 Recharging

4.5.1 A plan shall be established for the prompt recharging and testing of fire extinguishers in accordance with NFPA standards.

4.6 Substitutions

4.6.1 In areas where 2A extinguishers are required, the following may be substituted for each extinguisher:

4.6.1.1 One 55-gallon drum of water with three pails.

4.6.1.2 One water hose of not less than ½-inch diameter, not more than 100 feet in length, and with a discharge capacity of 5 gallons per minute.

4.6.1.3 One fire hose of not less than 1½-inch diameter, not more than 100 feet in length, and with a discharge capacity of 25 gallons per minute. Note: The hoses referred to above must be of sufficient length and have a stream range so as to reach all points in the protected area. These substitutions will not apply where the possibility of freezing exits.


A copy of all inspection records and certifications shall be kept on file in the project HSE safety office.


HSE Practice 33 Heat Stress Prevention

® HEAT STRESS PREVENTION PRACTICE 33 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to provide an effective Heat Stress Prevention Program to reduce and control the hazards of heat stress in the workplace.

2.0 References

2.1 Title 29 Code of Federal Regulations Part 1926

3.0 Definitions

3.1 Heat Rash - Heat rash, also known as prickly heat, may occur in hot, humid environments where sweat is not easily removed from the surface of the skin by evaporation. This is common when using protective equipment especially impermeable clothing. Heat rash can become uncomfortable when extensive or complicated by infection.

3.2 Heat Cramps - Heat cramps, which are painful muscle spasms, are caused when workers fail to replace the body's salt loss that occurs during excessive perspiration (especially with non-acclimatized workers).

3.3 Heat Exhaustion - Heat exhaustion results from excessive loss of salt and/or water through sweating. The worker with heat exhaustion still sweats, but experiences extreme fatigue, weakness, giddiness, nausea or headache. The skin is clammy and moist, the complexion pale or flushed and the body temperature normal or slightly higher.

3.4 Heat Stroke - Heat stroke, the most serious health problem for workers in hot environments, is caused by the failure of the body's internal mechanism to regulate its core temperature. Sweating stops and the body can no longer rid itself of excess heat. Signs include: mental confusion, delirium, loss of consciousness, convulsions or coma, a body temperature of 105 degrees or higher, and hot dry skin which may be red and flushed. Victims of heat stroke may die unless treated promptly and correctly.

4.0 Process

4.1 Heat Stress

4.1.1 Heat stress is the result of the combination of several factors; the following factors should be evaluated to determine the potential for heat stress.

4.1.1.1 Ambient temperature

4.1.1.2 Humidity

4.1.1.3 Type of work required - heavy, moderate or light work

4.1.1.4 Required work clothing - the potential for heat stress increases as the impermeability of the work clothing increases

4.1.1.5 Employee conditioning and/or acclimatization

4.1.1.6 Previous project experience or history

4.1.2 Whenever it is determined that a heat stress environment exists heat stress preventive measures shall be implemented.


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4.2 Preventive Measures

4.2.1 Heat stress is the combination of environmental and physical work factors that constitute the total heat load imposed on the body. One of the best ways to reduce heat stress on workers is to minimize the amount of heat in the workplace. However, there are some work environments where heat production is difficult to control, such as active steam lines, high ambient temperature processes, humid work areas, or radiant heat from the sun or a furnace. However, most heat related health problems can be prevented or the risk of developing them reduced. When unacceptable levels of heat stress can potentially occur, there are generally five approaches to a solution:

4.2.1.1 Modify the environment;

4.2.1.2 Modify the clothing or equipment;

4.2.1.3 Modify the work practices;

4.2.1.4 Modify the worker by heat acclimatization;

4.2.1.5 Modify production with a work/rest regiment.

4.3 Engineering Controls

4.3.1 A variety of engineering controls, including ventilation and spot cooling at points of high heat production, may be helpful. Shielding may be required as protection from radiant heat sources. Evaporative cooling and mechanical refrigeration are other ways to reduce heat by engineering controls. The use of extra air moving can be added to increase the turn over rate of interior air and remove heat inside enclosures. Cooling fans can increase air velocity and promote evaporation in hot conditions. Shutting down hot process or feed lines is most effective, but equipment modifications, such as using mechanical equipment over manual labor also reduce the exposure.

4.3.2 Auxiliary cooling systems can range from simple ice vests, pre-frozen and worn under the clothing, to more complex systems; however, cost of operation and maintenance vary considerably in all of these systems. Four auxiliary cooling systems presently available are:

4.3.2.1 Water-cooled garments, such as water-cooled vest, undergarments, hoods, etc., which require a circulating pump, liquid container, and battery;

4.3.2.2 Air-cooled garments, such as suits and hoods, that require a vortex tube, connecting hose and a constant source of compressed air;

4.3.2.3 Ice pack vest, which although frozen before worn, do not provide continuous regulated cooling and require the use of backup frozen units every 2 to 3 hours; and

4.3.2.4 Wetted over-garments, which can be as simple as wet cotton terry cloth coveralls worn over protective clothing; the wetted overgarment works best when there is air blowing across the wet garment to increase evaporation.


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4.4 Work Practices

4.4.1 Work practices can help reduce the risk of heat disorders. Making plenty of drinking water available at the workplace and urging workers to drink often shall be standard practice in all situations of potential heat stress. In high heat stress environments, an employee can lose as much as one quart of liquid per hour. When possible and especially during acclimatization, products that have been formulated to replace electrolytes and match the weight of the body fluids lost by the sweating process should be used. This is necessary to enable the body to quickly absorb replacement minerals. Do not use salt tablets.

4.4.2 Training supervisors to recognize and be able to correctly treat heat stress disorders is absolutely essential. Prospective workers physical conditions should also be considered when determining their fitness for working in a hot environment. Older workers, obese workers, and those workers taking some type of medication are usually at a greater risk.

4.5 Acclimatization

4.5.1 Acclimatization to heat through short exposures followed by longer periods of work in the hot environment can reduce heat stress. New employees and workers returning from an absence of two weeks or more should have a five-day period of acclimatization. This period should begin with a less than normal workload and time exposure on the first day and gradually build up to normal workload and exposure on the fifth day.

4.6 Work/Rest Regimen

4.6.1 There are many times when engineering and other controls are not sufficient, and administrative controls must be instituted for worker protection. One effective administrative control is the work/rest regimen that limits the time worked in the hot environment according to the type of work, environmental conditions, and clothing requirements. Work/rest periods are generally conservative because they are:

§ Based on calculated approximations of heat stress and § Designed to protect most workers. As a result, many acclimatized workers can

work longer than the allotted time period.

4.6.2 Alternating work and rest periods with longer rest periods in a cool area (77°F. or less) can help workers avoid heat strain. Keep in mind that poor physical condition will also impair the ability to work in a hot environment. Older, over-weight individuals or those in poor health may not be able to follow average work/rest regimens. Supervisors shall permit employees to take additional rest breaks as needed in potential heat stress conditions.

4.6.3 The work/rest regimen for acclimatized workers will follow the table below. Yanpet Safety Department conducts periodic monitoring and the work rest regimens identified below may be modified to be more stringent based on their input. Supervisors, may at their discretion, institute a more stringent work/rest regimen based on their specific Job Planning and Safety Analysis.


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WORK /REST REGIMEN GUIDELINES 1 Light Work Moderate Work Heavy Work Heat

Index2 ºC (ºF)

Full Sun

Partly Cloudy

Shade or No

Shadow

Full Sun

Partly Cloudy

Shade or No

Shadow

Full Sun

Partly Cloudy

Shade or No

Shadow

Water

28 (82) C C C C C C 15 C C 30 (86) C C C C C C 25 C C 32 (90) C C C 15 C C 35 C C

16 oz. water/30 minutes

34 (93) C C C 25 C C 45 C C 36 (97) 15 C C 35 C C A 15 C 38 (100)

25 C C 45 15 C A 25 C

40 (104)

35 C C A 25 C A 35 C


42 (108)

45 15 C A 35 C A 45 15

44 (111)

A 25 C A 45 15 A A 25

46 (115)

A 35 C A A 25 A A 35

48 (118)

A 45 15 A A 35 A A 45

>50 (122)

NO WORK ACTIVITIES TO BE PERFORMED OUTDOORS


C = continuous work permitted 15 or 25 = minutes of rest per hour (including rests, pauses, and operational waiting periods during work, or equivalent slowing of pace) A = adjust the work (e.g. delay work until cooler or implement other controls)

1 Work Rest Regimen Guidelines obtained using the Construction Safety Association of Ontario—Heat

Stress Guidelines for Recognition, Assessment, and Control in Construction 2

Examples of Work Light Work Flat welding instrument fitting, pipe fitting, bench grinding, bench fabrication,

drilling at grade, light rigging, etc. Moderate Work Position welding, position grinding with large grinder, impact guns on small

bolts, heavy rigging, etc. Heavy Work Lifting, pulling, pushing heavy material without mechanical equipment, using

large hand equipment such as large impact guns or sledgehammers, prolonged overhead grinding, etc.


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4.7 Employee Training

4.7.1 For both employees and supervisory personnel, heat stress training is the key to avoiding problems. Employees must understand the reasons for using appropriate work practices in order for the program to succeed. A heat stress training program for employees shall cover the following:

4.7.1.1 Heat stress, its components and effects,

4.7.1.2 Signs and symptoms of heat disorders,

4.7.1.3 First-aid Practices for and potential health effects of heat stress,

4.7.1.4 Pre-disposing factors to heat stress; drug use, (including therapeutic) and alcohol in a hot work environment,

4.7.1.5 Protective clothing, equipment and its impact in hot environments,

4.7.1.6 Environmental and medical surveillance programs,

4.7.1.7 Importance of maintaining body fluids at normal levels,

4.7.1.8 Various engineering controls to reduce the impact of hot environments,

4.7.1.9 Administrative measures such as work/rest regimens in use to prevent heat stress,

4.7.1.10 Acclimatization; how it is achieved and its limitations, and

4.7.1.11 The components of the heat stress prevention program.

4.8 Technical Assistance

4.8.1 In some situations, we will accept work in extremely hot environments that cannot be controlled or mitigated. When faced with this type of situation, the FLUOR ARABIA Safety Department shall be notified for assistance.


None


HSE Practice 34 Operator Licensing

® OPERATOR LICENSING PRACTICE 34 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to specify the minimum requirements for licensing employees to operate equipment.

2.0 References

2.1 Title 29 Code of Federal Regulations Part 1926

3.0 Definitions

3.1 Equipment - For the purposes of this Practice, equipment shall mean all construction related off-road equipment, including but not limited to, backhoes, “Bob Cats”, cranes, boom lifts, fork lifts, scissor lifts, loaders, etc.

4.0 Practices

4.1 Requirements

4.1.1 Employees who are assigned work involving the operation of construction equipment shall be trained to use that equipment.

4.1.2 Employee training shall include a practical examination including a demonstration of ability to operate the equipment.

4.1.3 The training and practical examination shall be conducted by a supervisor designated as an equipment competent person by the Construction Manager and Construction HSE Manager or by a manufacturer’s representative.

4.1.4 Upon completion of the training and successfully demonstrating competence in the operation of the equipment, the employee shall be issued a license to operate the equipment.

4.1.5 The employee shall maintain possession of the license on his/her person at all times when operating the equipment.

4.1.6 Equipment operators who are licensed in accordance with Saudi Arabian requirements will be required to provide a copy of the licensing and complete DBN-F24.


A record of each licensed operator on the project shall be maintained in the project HSE files for the duration of the project.


HSE Practice 35 Abrasive Blasting

® ABRASIVE BLASTING PRACTICE 35 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This practice applies to all operations where an abrasive is forcibly applied to a surface by pneumatic or hydraulic pressure, or by centrifugal force. It does not apply to steam blasting, steam cleaning, or hydraulic cleaning methods where work is done without the aid of abrasives.

2.0 References

2.1 Title 29 Code of Federal Regulations Part 1926.21

2.2 American National Standard Installation of Blower and Exhaust Systems for Dust, Stock, and Vapor Removal or Conveying, Z33.1-1961 (NFPA 91-1961)

2.3 Preventing Silicosis and Deaths from Sandblasting, NIOSH ALERT: August 1992 DHHS (NIOSH) Publication No. 92-102

2.4 National Fire Protection Association Explosion venting Guide. NFPA 68-1954

2.5 American National Standard Installation of Blower and Exhaust Systems for Dust, Stock, and Vapor Removal or Conveying, Z33.1-1961 (NFPA 91-1961)

2.6 SASO 315/1982 Industrial Safety and Health Regulations—Part 3 – Occupational Health and Environmental Control

3.0 Definitions

3.1 Abrasive —A solid substance used in an abrasive blasting operation.

3.2 Abrasive Blasting—The forcible application of an abrasive to a surface by pneumatic pressure, hydraulic pressure, or centrifugal force.

3.3 Abrasive -Blasting Respirator—A respirator constructed so that it covers the wearer's head, neck, and shoulders to protect the wearer from rebounding abrasive.

3.4 Blast Cleaning Barrel—A complete enclosure which rotates on an axis, or which has an internal moving tread to tumble the parts, in order to expose various surfaces of the parts to the action of an automatic blast spray.

3.5 Blast Cleaning Room—A complete enclosure in which blasting operations are performed and where the operator works inside of the room to operate the blasting nozzle and direct the flow of the abrasive material.

3.6 Blasting Cabinet—An enclosure where the operator stands outside and operates the blasting nozzle through an opening or openings in the enclosure.

3.7 Clean Air—Air of such purity that it will not cause harm or discomfort to an individual if it is inhaled for extended periods of time.

3.8 Dust Collector—A device or combination of devices for separating dust from the air handled by an exhaust ventilation system.

3.9 Exhaust Ventilation System—A system for removing contaminated air from a space, comprising two or more of the following elements (A) enclosure or hood, (B) duct work, (C) dust collecting equipment, (D) exhauster, and (E) discharge stack.

3.10 Particulate-Filter Respirator—An air-purifying respirator, commonly referred to as a dust or a fume respirator, which removes most of the dust or fume from the air passing through the device.

3.11 Respirable Dust—Airborne dust in sizes capable of passing through the upper respiratory system to reach the lower lung passages.


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3.12 Rotary Blast Cleaning Table—An enclosure where the pieces to be cleaned are positioned on a rotating table and are passed automatically through a series of blast sprays.

4.0 Process

4.1 Description of Silicosis

4.1.1 When workers inhale the crystalline silica used in abrasive blasting, the lung tissue reacts by developing fibrotic nodules and scarring around the trapped silica particles. This fibrotic condition of the lung is called silicosis. If the nodules grow too large, breathing becomes difficult and death may result. Silicosis victims are also at high risk of developing active tuberculosis.

4.1.2 A worker may develop any of three types of silicosis, depending on the airborne concentration of crystalline silica:

4.1.2.1 Chronic silicosis, which usually occurs after 10 or more years of exposure to crystalline silica at relatively low concentrations

4.1.2.2 Accelerated silicosis, which results from exposure to high concentrations of crystalline silica and develops 5 to 10 years after the initial exposure

4.1.2.3 Acute silicosis, which occurs where exposure concentrations are the highest and can cause symptoms to develop within a few weeks to 4 or 5 years after the initial exposure.

4.2 General Safe Work Practices

4.2.1 Use of Alternative Abrasives

4.2.1.1 A variety of materials (corundum, glass beads, pumice, sawdust, slags, steel grit and shot, and walnut shells) is available as alternative blasting media. However, no comprehensive studies have been conducted to evaluate the health effects of these substitute materials. Until comprehensive data are available, engineering controls and personal protective equipment should be used with any of the alternative abrasives.

4.2.1.2 In addition to the health hazards of abrasive blasting materials, the finely fractured particles of material being removed (lead paint, for example) may also create health risks for workers.

4.2.1.3 Use of crystalline silica containing materials requires prior approval from the Construction HSES Manager and justification for its use.

4.2.2 Provide engineering or administrative controls, where feasible, such as local exhaust ventilation, and blasting cabinets.

4.2.3 Where necessary to reduce exposures below the PEL, use protective equipment or other protective measures.

4.2.4 Conduct air monitoring to measure worker exposures.

4.2.5 Use all available work practices to control dust exposures (i.e., such as water sprays).

4.2.6 If respiratory protection is required, use only a N95 NIOSH certified respirator.

4.2.7 Wear only a Type CE abrasive-blast supplied-air respirator for abrasive blasting.


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4.2.8 Wear disposable or washable work clothes and shower if facilities are available. Vacuum the dust from clothing or change into clean clothing before leaving the work site.

4.2.9 Implement in training, exposure monitoring, and health screening and surveillance programs to monitor any adverse health effects caused by crystalline silica exposures.

4.2.10 Implement a medical surveillance program for all workers who may be exposed to crystalline silica.

4.2.11 Post signs to warn workers about the hazard and to inform them about required protective equipment.

4.2.12 Provide workers with training that includes information about health effects, work practices, and protective equipment for crystalline silica.

4.2.13 Do not eat, drink, smoke, or apply cosmetics in areas where crystalline silica dust is present. Wash your hands and face outside of dusty areas before performing any of these activities.

4.3 Dust hazards from abrasive blasting

4.3.1 Abrasives and the surface coatings on the materials blasted are shattered and pulverized during blasting operations and the dust formed will contain particles of respirable size. The composition and toxicity of the dust from these sources shall be considered in making an evaluation of the potential health hazards.

4.3.2 The concentration of respirable dust or fume in the breathing zone of the abrasive-blasting operator or any other worker shall be kept below the levels specified in 29 CFR 1926.55.

4.3.3 Organic abrasives that are combustible shall be used only in automatic systems. Where flammable or explosive dust mixtures may be present, the construction of the equipment, including the exhaust system and all electric wiring, shall conform to the requirements of American National Standard Installation of Blower and Exhaust Systems for Dust, Stock, and Vapor Removal or Conveying, Z33.1-1961 (NFPA 91-1961). The blast nozzle shall be bonded and grounded to prevent the build up of static charges. Where flammable or explosive dust mixtures may be present, the abrasive blasting enclosure, the ducts, and the dust collector shall be constructed with loose panels or explosion venting areas, located on sides away from any occupied area, to provide for pressure relief in case of explosion, following the principles set forth in the National Fire Protection Association Explosion venting Guide. NFPA 68-1954.

4.4 Dust Containment

4.4.1 Blast-cleaning enclosure

4.4.1.1 Blast-cleaning enclosures shall be exhaust ventilated in such a way that a continuous inward flow of air will be maintained at all openings in the enclosure during the blasting operation.

4.4.1.2 All air inlets and access openings shall be baffled or so arranged that by the combination of inward air flow and baffling the escape of abrasive or dust particles into an adjacent work area will be minimized and visible spurts of dust will not be observed.

4.4.1.3 The rate of exhaust shall be sufficient to provide prompt clearance of the dust-laden air within the enclosure after the cessation of blasting.


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4.4.1.4 Before the enclosure is opened, the blast shall be turned off and the exhaust system shall be run for a sufficient period of time to remove the dusty air within the enclosure.

4.4.1.5 Safety glass protected by screening shall be used in observation windows, where hard deep-cutting abrasives are used.

4.4.1.6 Slit abrasive-resistant baffles shall be installed in multiple sets at all small access openings where dust might escape, and shall be inspected regularly and replaced when needed.

4.4.1.7 Doors shall be flanged and tight when closed.

4.4.1.8 Door on blast-cleaning rooms shall be operable from both inside and outside, except that where there is a small operator access door, the large work access door may be closed or opened from the outside only.

4.4.2 Abrasive Blasting Rooms

4.4.2.1 Abrasive blasting rooms contain the hazard and protect adjacent workers from exposure. However, such rooms may increase the risk for blasters, since they must work inside the enclosure in high concentrations of hazardous blasting material. Blasting rooms must be ventilated to reduce these concentrations and to increase visibility. A supplied-air respirator is required for any blaster working inside a blasting room.

4.4.3 Portable Blast-Cleaning Equipment

4.4.3.1 Portable blast-cleaning equipment presents particularly serious health problems because engineering controls are rarely used. Curtains can be used as temporary containment structures to reduce the hazard to adjacent workers and the general public. As with abrasive blasting rooms, these structures should be ventilated to reduce concentrations of hazardous materials and to increase visibility. During work inside the containment, a supplied-air respirator is required for the blaster.

4.4.4 Exhaust ventilation system

4.4.4.1 The construction, installation, inspection, and maintenance of exhaust systems shall conform to the principles and requirements set forth in American National Standard Fundamentals Governing the Design and Operation of Local Exhaust Systems, Z9.2-1960, and ANSI Z33.1-1961.

4.4.4.2 When dust leaks are noted, repairs shall be made as soon as possible.

4.4.4.3 The static pressure drop at the exhaust ducts leading from the equipment shall be checked when the installation is completed and periodically thereafter to assure continued satisfactory operation. Whenever an appreciable change in the pressure drop indicates a partial blockage, the system shall be cleaned and returned to normal operating condition.

4.4.4.4 In installation where the abrasive is recirculated, the exhaust ventilation system for the blasting enclosure shall not be relied upon for the removal of fines from the spent abrasive instead of an abrasive separator. An abrasive separator shall be provided for the purpose.

4.4.4.5 The air exhausted from blast-cleaning equipment shall be discharged through dust collecting equipment. Dust collectors shall be set up so


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that the accumulated dust can be emptied and removed without contaminating other working areas.

4.5 Personal Hygiene

4.5.1 The following personal hygiene practices are important elements of any program for protecting workers from exposure to crystalline silica and other contaminants such as lead during abrasive blasting operations.

4.5.1.1 All sandblasters should wash their hands and faces before eating, drinking, or smoking.

4.5.1.2 Sandblasters should not eat, drink, or use tobacco products in the blasting area.

4.5.1.3 Workers should shower before leaving the worksite.

4.5.1.4 Workers should park their cars where they will not be contaminated with silica and other substances such as lead.

4.6 Personal Protective Equipment

4.6.1 Employers must use only respirators approved by NIOSH under 42 CFR part 84 for protecting employees from dusts produced during abrasive-blasting operations.

4.6.2 Abrasive-blasting respirators shall be worn by all abrasive-blasting operators:

4.6.2.1 When working inside of blast-cleaning rooms, or

4.6.2.2 When using silica sand in manual blasting operations where the nozzle and blast are not physically separated from the operator in an exhaust ventilated enclosure, or

4.6.2.3 Where concentrations of toxic dust dispersed by the abrasive blasting may exceed the exposure limits and the nozzle and blast are not physically separated from the operator in an exhaust-ventilated enclosure.

4.6.3 Properly fitted particulate-filter respirators, commonly referred to as dust-filter respirators, may be used for short, intermittent, or occasional dust exposures such as cleanup, dumping of dust collectors, or unloading shipments of sand at a receiving point when it is not feasible to control the dust by enclosure, exhaust ventilation, or other means. The respirators used must be approved by NIOSH under 42 CFR part 84 for protection against the specific type of dust encountered.

4.6.4 Operators shall be equipped with heavy canvas or leather gloves and aprons or equivalent protection to protect them from the impact of abrasives. Safety shoes shall be worn to protect against foot injury where heavy pieces of work are handled.

4.6.5 Equipment for protection of the eyes and face shall be supplied to the operator when the respirator design does not provide such protection and to any other personnel working near abrasive blasting operations.

4.7 Air for abrasive-blasting respirators must be free of harmful quantities of dusts, mists, or noxious gases, and must meet the requirements for supplied-air quality and use.

4.8 Dust shall not be permitted to accumulate on the floor or on ledges outside of an abrasive-blasting enclosure, and dust spills shall be cleaned up promptly. Aisles and walkways shall be kept clear of steel shot or similar abrasive that may create a slipping hazard.


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4.9 The current OSHA permissible exposure limit (PEL) for respirable crystalline silica (quartz) is 100 mg/m3 as an 8-hour time-weighted average (TWA).

4.10 Air Monitoring

4.10.1 Air monitoring should be performed to measure worker exposure to airborne crystalline silica and to provide a basis for selecting engineering controls. Air monitoring should be performed as needed to measure the effectiveness of controls. Air samples should be collected and analyzed according to NIOSH Method Nos. 7500 and 7602 [NIOSH 1984] or their equivalent.

4.11 Respiratory Protection

4.11.1 Respirators should not be used as the only means of preventing or minimizing exposures to airborne contaminants. Effective source controls such as substitution, automation, containment, local exhaust ventilation, and good work practices should be implemented to minimize worker exposure to silica dust. NIOSH prefers such measures as the primary means of protecting workers. However, when source controls cannot keep exposures below the NIOSH REL, controls should be supplemented with the use of respiratory protection during abrasive blasting.

4.11.2 When respirators are used, the following will be implemented:

4.11.2.1 An evaluation of the worker's ability to perform the work while wearing a respirator,

4.11.2.2 Regular training of personnel,

4.11.2.3 Periodic environmental monitoring,

4.11.2.4 Respirator fit testing,

4.11.2.5 Maintenance, inspection, cleaning, and storage, and

4.11.2.6 Selection of proper NIOSH-approved respirators.

4.11.2.7 The respiratory protection program should be evaluated regularly by the employer.

4.12 Medical Monitoring

4.12.1 Medical examinations should be available to all workers who may be exposed to crystalline silica. Such examinations should occur before job placement and at least every 3 years thereafter [NIOSH 1974b]. More frequent examinations (for example, annual) may be necessary for workers at risk of acute or accelerated silicosis. Examinations should include at least the following items:

4.12.1.1 A medical and occupational history to collect data on worker exposure to crystalline silica and signs and symptoms of respiratory disease

4.12.1.2 A chest X-ray classified according to the 1980 International Labour Office (ILO) Classification of Radiographs of the Pneumoconioses [ILO 1981]

4.12.1.3 Pulmonary function testing (spirometry)

4.12.1.4 An annual evaluation for tuberculosis [ATS/CDC 1986]

4.13 Warning Signs

4.13.1 Signs should be posted to warn workers about the hazard and specify any protective equipment required.


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4.14 Training

4.14.1 Workers should receive training that includes the following:

4.14.1.1 Information about the potential adverse health effects of silica exposure

4.14.1.2 Material safety data sheets for silica, alternative abrasives, or other hazardous materials

4.14.1.3 Instruction about obeying signs that mark the boundaries of work areas containing crystalline silica

4.14.1.4 Information about safe handling, labeling, and storage of toxic materials

4.14.1.5 Discussion about the importance of engineering controls, personal hygiene, and work practices in reducing crystalline silica exposure

4.14.1.6 Instruction about the use and care of appropriate protective equipment (including protective clothing and respiratory protection)


5.1 Medical records will be maintained for the duration of the project plus 30 years.

Respiratory protection documentation will be maintained in accordance with Practice 36—Respiratory Protection.


HSE Practice 36 Respiratory Protection

® RESPIRATORY PROTECTION PRACTICE 36 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 The purpose of this Practice is to establish FLUOR ARABIA minimum requirements for developing a Respiratory Protection Program.

2.0 References


2.2 Title 29 Code of Federal Regulations (CFR) Part 1910 Subpart I (1926.134)

2.3 Title 29 Code of Federal Regulations (CFR) Part 1910 Subpart Z (1910.1020)

2.4 Title 30, Part II of the Code of Federal Regulations - NIOSH Approvals for Respirators

2.5 American National Standards Institute - Practices for Respiratory protection Z88.2-1992



3.0 Definitions

3.1 Approved - Tested and listed as satisfactory by the National Institute for Occupational Safety and Health (NIOSH) of the U. S. Department of Health and Human Services.

3.2 Ceiling concentration - The concentration of an airborne substance that shall not be exceeded.

3.3 Competent Person - The person designated must meet two qualifications; 1) they should have an excellent working knowledge of the respiratory protection Practices or methods and 2) should have sufficient authority to promptly prevent and/or correct hazardous conditions.

3.4 Face Piece - That portion of a respirator that covers the wearer's nose and mouth in a half-mask face piece or that covers the nose, mouth, and eyes in a full-face piece. It is designed to make a gas-tight or particle-tight fit with the face and includes the headbands, exhalation valve(s), inhalation valve(s) and connections for an air-purifying device or respirable air source, or both.

3.5 Filter - A media component used in respirators to remove solid or liquid particles from the inspired air.

3.6 Hazardous Atmosphere-An atmosphere that may expose employees to the risk of death, incapacitation, impairment of ability to self-rescue (that is escape unaided), injury or acute illness.

3.7 Immediately Dangerous to Life or Health (IDLH) - Any atmosphere that poses an immediate hazard to life or produces immediate irreversible debilitating effects on health.

3.8 Maximum Use Concentration (MUC) of Filter, Cartridge, or Canister - The maximum concentration of a contaminant for which an air-purifying filter, cartridge, or canister is approved for use.

3.9 Negative Pressure Respirator - A respirator in which the air pressure inside the respirator-inlet covering is positive during exhalation in relation to the air pressure of the outside atmosphere and negative during inhalation in relation to the air pressure of the outside atmosphere.

3.10 Odor Threshold Limit - The lowest concentration of a contaminant in air that can be detected by the olfactory sense (sense of smell).


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3.11 Oxygen Deficiency - The concentration of oxygen, by volume, below which atmosphere supplying respiratory protection must be provided. It exists in atmospheres where the percentage of oxygen, by volume, is less than 19.5 percent.

3.12 Permissible Exposure Limit (PEL) - OSHA's legally established time-weighted average (TWA) concentration of a contaminant that shall not be exceeded.

3.13 Resistance - Opposition to the flow of air, as through a canister, cartridge, particulate filter, orifice, valve, or hose.

3.14 Respirator - a device worn over the mouth or nose for protecting the respiratory tract.

3.15 Service Life - The period of time that a respirator provides adequate protection to the wearer-for example, the period of time that an air-purifying device is effective for removing a harmful substance from inspired air.

3.16 Sorbent - A material which is contained in a cartridge or canister and which removes toxic gases and vapors from inspired air.

3.17 Time -Weighted Average - the average concentration of a contaminant in air during a specific time period.

4.0 Process

4.1 General

4.1.1 In the control of those occupational diseases caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays, or vapors, the primary objective shall be to prevent atmospheric contamination. This shall be accomplished as far as feasible by accepted engineering control measures (for example, enclosure or confinement of the operation, general or local ventilation, and substitution of less toxic materials). When effective engineering controls are not feasible, or while they are being instituted, appropriate respirators shall be used pursuant to this procedure.

4.1.2 Respirators shall be provided when such equipment is necessary to protect the health of the employee. Respirators, which are applicable and suitable for the purpose intended, shall be provided. FLUOR ARABIA shall be responsible for the establishment and maintenance of a respiratory protection program that includes the requirements of this procedure.

4.1.3 Each field site and office facility shall ensure that employees are provided a safe and healthful working atmosphere, free of hazards that could adversely affect their personal health and safety.

4.1.4 It is the policy of FLUOR ARABIA to use the most up-to-date and efficient respiratory protective equipment available and the most effective work methods to eliminate or minimize atmospheric hazards. The latter shall be accomplished by accepted engineering control measures. When effective engineering controls are not feasible, appropriate respirators shall be used according to this procedure.

4.1.5 The voluntary use of respiratory equipment where not required is prohibited without written authorization from FLUOR ARABIA’s Corporate Safety Department.


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4.1.6 The use of employee owned respirators is prohibited.

4.1.7 The use of dust mask is prohibited without written authorization from FLUOR ARABIA’s Corporate Safety Department.

4.1.8 FLUOR ARABIA shall designate a program administrator, at both the corporate and site level, who is qualified by appropriate training or experience to oversee the respiratory protection program and conduct the required evaluations of program effectiveness.

4.1.9 All required training and medical evaluation shall be provided at no cost to the employee.

4.1.10 Every consideration will be given to the use of effective engineering controls to eliminate or reduce exposure to respiratory hazards to the point where respirators are not required. However, when feasible engineering controls are not effective in controlling toxic substances, the company, at no charge, will provide appropriate respiratory protective equipment to the employee.

4.1.11 Employees required to use respiratory protective devices because of exposure to toxic substances will do so as a condition of employment. Employees required to use respirators will be properly fitted, appropriately tested, medically screened, and thoroughly trained in their use.

4.2 Responsibilities

4.2.1.1 The Manager/Supervisor is responsible for implementing and enforcing this procedure and the site respiratory protection program.

4.2.1.2 The Construction HSE Manager is responsible for monitoring compliance with this procedure.

4.2.1.3 The Employee, whose tasks require the use of respiratory equipment, is responsible to use the appropriate type of respiratory equipment.

4.2.1.4 The Subcontractor is responsible for providing FLUOR ARABIA a written respiratory protection program, which, at a minimum, shall meet the requirements of the FLUOR ARABIA program. The subcontractor shall also provide evidence of current respiratory training, medical evaluation, and qualitative or quantitative fit testing for those employees required to use respiratory equipment

4.3 Selection of respirators for routine use

4.3.1 Approved Respirators - Approved or authorized respirators shall be used. Any change or modification, however minor, will void the respirator approval and significantly affect the performance of the respirator.

4.3.2 Selection - Respirator face piece and cartridge selection involves reviewing each operation to (A) determine what hazards may be present (hazard determination) and (B) select which type or class of respirator can offer adequate protection.

4.3.3 If a question exists concerning the type of respirator required, and if the project needs assistance with the hazard determination steps listed below, the home office industrial hygiene staff shall be consulted.


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4.4 Purchase of Approved Equipment

4.4.1 These requirements apply to all NIOSH approved respirators used on FLUOR ARABIA projects. Non-approved “dust masks” may be used on FLUOR ARABIA projects only after a hazard assessment has been conducted and air monitoring has shown only nuisance levels of contaminants. Such air monitoring shall be conducted by the Project HSE Manager (if qualified) or through an independent company specializing in air monitoring. In all cases the non-approved dust masks shall be maintained and issued by the Project HSE Manager.

4.4.2 Regardless of the contaminant type, the requirements contained herein apply.

4.5 Comfort

4.5.1 Once the type of respirator that is applicable and suitable for the purpose intended has been selected, the selection process should give consideration to the fit and comfort of the respirator.

4.6 Medical Assessment Requirements

4.6.1 Prior to issuance and use of respiratory protection devices, a medical evaluation shall be offered to all affected personnel. The medical evaluation shall be under the direct supervision of a licensed physician and shall be provided at no cost to the employee and at a reasonable time and place. The licensed physician shall determine what physiological and psychological conditions are pertinent for the wearing of different types of respirators.

4.6.2 When applicable, medical surveillance, including bioassay, shall be carried out periodically to determine if respirator wearers are receiving adequate respiratory protection. The licensed physician shall determine the requirements of the surveillance program.

4.7 Medical Forms

4.7.1 When conducting the initial medical evaluation, the Medical Questionnaire for Respirator Use (DBN-F26) must be used.

4.7.2 In addition to the standardized questionnaire, the physician must also be furnished with a copy of the latest OSHA Standard governing the type of exposure to which the employee will be subjected. A description of the employee's duties as they relate to the exposure, the anticipated exposure level, a description of the respiratory protective equipment to be used, and any available information from previous medical evaluations of the employee must also be furnished to the physician on the Request for Medical Evaluation for Respirator Use (DBN-F27).

4.7.3 At the conclusion of the evaluation, the physician will submit a written opinion to the Company on the bottom of DBN-F27. This will contain the results of the evaluation and any recommendations from the physician regarding the employee's limitations.

4.7.4 The Company must furnish a copy of the physician’s opinion to the employee, within thirty (30) days of its receipt by the Company.

4.8 Issuing Respirators

4.8.1 Respirators will not be fit tested or issued to individuals who have facial hair (including stubble) or any other condition, which interferes with the sealing surface of the respirator.


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4.8.2 Respirators will not be fit tested nor issued to individuals who have not received appropriate respirator training in addition to fit testing and a medical clearance.

4.9 Fit-Testing Requirements

4.9.1 Respirators will be fitted properly and be tested for their face piece-to-face seal. The two acceptable methods for conducting these tests: qualitative and quantitative fit testing.

4.9.2 The fit test is valid only for respirators of the same model and size tested.

4.9.3 Qualitative fit testing is based on the wearer's subjective response to a challenge atmosphere, of which three popular tests are: the irritant smoke test, the odorous vapor test, and the saccharin solution test.

4.9.3.1 Irritant Smoke Test:

Directing an irritant smoke from a smoke tube towards the respirator being worn performs the Irritant Smoke Test. If the wearer does not detect the irritant smoke, a satisfactory fit is assumed to be achieved. Since this type of test provokes an involuntary response from the employee, it is the preferred testing method when available.

4.9.3.2 Saccharin Solution Test: This test relies on the wearer's ability to taste a saccharin solution sprayed around the outside of the respirator. The test is performed by placing an enclosure over the respirator wearer's head and shoulders and administering the solution from a nebulizer. If the wearer does not react to the chemical, then a satisfactory fit is assumed to be achieved. NOTE: This test is dependent on the wearer's honest indication of taste. There is not an involuntary response. The saccharin solution aerosol QLFT protocol is the only currently available, validated test protocol for use with disposable particulate respirators not equipped with high-efficiency filters.

4.9.3.3 Odorous Vapor Test:

The odorous vapor test relies on the respirator wearer's ability to detect an odorous material, usually isoamyl acetate (banana oil) inside the respirator. The test is performed by placing an isoamyl acetate saturated material near the respirator. If the wearer is unable to smell the chemical, then a satisfactory fit is assumed to be achieved.

4.10 Fit Test Car d

4.10.1 The respirator wearer shall be issued an employee fit test card (DBN-F28) with the following information:

4.10.1.1 Name.

4.10.1.2 Date of fit test.

4.10.1.3 Manufacturer, model, and size of each successfully tested respirator.

4.10.1.4 Name and signature of the person that conducted the test.

4.10.1.5 Fit test challenge agent used.


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4.10.1.6 Fit factor if a quantitative fit test was performed.

4.11 Semi-annual Testing

4.11.1 The qualitative fit test should be repeated at least once every 12 months for routine use.

4.12 Fit Checks

4.12.1 There are two tests that are used in the field to check the seal of the respirator. These are known as the positive and negative fit checks. Each of these two tests must be performed every time a respirator is put on and prior to entering a contaminated area.

4.13 Care and Maintenance

4.13.1 Personnel involved in respirator maintenance must be thoroughly trained. Substitution of parts from different brands or types of respirators invalidates approval of the device. Repairs and adjustments should never be made beyond the manufacturer's recommendations.

4.13.1.1 Cleaning the Respirator

• Respirators must be cleaned and disinfected after each day's use.

• The project shall assign specific individuals to be responsible for the cleaning and disinfecting of respirators. Note: Respirator-freshening wipes are not an adequate

substitute for this cleaning and disinfecting process.

4.13.1.2 Storing the Respirator

• When they are not being used, respirators shall be individually sealed in plastic bags and stored at locations established by project management in order to protect them against dust, sunlight, extreme temperatures, excessive moisture, or damaging chemicals. Respirators should not be stored (thrown) in toolboxes or gang boxes. They shall be stored in such a way, that the face piece and exhalation valve are not distorted.

4.13.1.3 Inspecting the Res pirator

• All respirators shall be inspected by the individual before and after each use, and at least monthly by the user's supervisor to ensure that they are in satisfactory working condition.

4.14 Work Area Surveillance

4.14.1 The Respiratory Protection Standards, 29 CFR 1910.134 and 1926.103 require "appropriate surveillance." This shall include identification of the contaminant(s), nature of the hazard, concentration at the breathing zone, and, if appropriate, biological monitoring.

4.15 For all IDLH atmospheres, the pr oject shall ensure that:

4.15.1 One employee or, when needed, more than one employee is located outside the IDLH atmosphere;

4.15.2 Visual, voice, or signal line communication is maintained between the employee(s) in the IDLH atmosphere and the employee(s) located outside the IDLH atmosphere;


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4.15.3 The employee(s) located outside the IDLH atmosphere are trained and equipped to provide effective emergency rescue;

4.15.4 The Construction HSE Manager must be notified before the employee(s) located outside the IDLH atmosphere enter the IDLH atmosphere to provide emergency rescue;

4.15.5 The authorized employee, once notified, provides necessary assistance appropriate to the situation;

4.15.6 Employee(s) located outside the IDLH atmospheres are equipped with:

4.15.6.1 Pressure demand or other positive pressure SCBAs, or a pressure demand or other positive pressure supplied-air respirator with auxiliary SCBA; and either

4.15.6.2 Appropriate retrieval equipment for removing the employee(s) who enter(s) these hazardous atmospheres where retrieval equipment would contribute to the rescue of the employee(s) and would not increase the overall risk resulting from entry; or

4.15.6.3 Equivalent means for rescue where retrieval equipment is not required.

4.16 Breathing Air Quality and Use

4.16.1 The Construction HSE Manager shall ensure that compressed air, compressed oxygen, liquid air, and liquid oxygen used for respiration accords with the following specifications:

4.16.1.1 Compressed and liquid oxygen shall meet the United States Pharmacopoeia requirements for medical or breathing oxygen; and

4.16.1.2 Compressed breathing air shall meet at least the requirements for Grade D breathing air described in ANSI/Compressed Gas Association Commodity Specification for Air, G-7.1-1989, to include:

4.16.1.3 Oxygen content (v/v) of 19.5-23.5%;

4.16.1.4 Hydrocarbon (condensed) content of 5 milligrams per cubic meter of air or less;

4.16.1.5 Carbon monoxide (CO) content of 10 ppm or less;

4.16.1.6 Carbon dioxide content of 1,000 ppm or less; and

4.16.1.7 Lack of noticeable odor.

4.16.2 The Construction HSE Manager shall ensure that compressed oxygen is not used in atmosphere-supplying respirators that have previously used compressed air.

4.16.3 The Construction HSE Manager shall ensure that oxygen concentrations greater than 23.5% are used only in equipment designed for oxygen service or distribution.

4.17 Program Evaluation

4.17.1 The Construction Manager shall ensure that the Program is periodically evaluated to determine the effectiveness of the Respiratory Protection Program during all phases of operation in which respirators are being used. Frequent walk-through inspections during these activities shall be conducted to monitor and document supervisor and worker compliance with the requirements of the program. In addition to general assessment of the overall Respiratory Protection


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Program, specific evaluations of the respirator cleaning, inspection, maintenance, repair, storage, and use Practices shall be conducted and documented weekly to ensure that the desired results of these operations are consistently achieved.


5.1 Respirator Training Records

5.1.1 Upon completion of the basic Respirator Training Program, the employee will be required to read and sign a Respirator Training & Fit Test Record (DBN-F28) attesting to the fact they have received the basic training program and feel confident in their ability to use the respirator properly.

5.1.2 The signed and dated Respirator Training Record will then become a part of the employees' medical records and will be retained for the same period of time as those records.

5.2 Recordkeeping of Test Results

5.2.1 A summary of the test results for each employee on whom a fit test was conducted, will be documented on the Respirator Training & Fit Test Record (DBN-F28). This record shall also be retained as a medical record.

5.3 Care and Maintenance Records

5.3.1 A written record should be maintained of the Care and Maintenance Program for each project. Information contained on this record should include inspection reports, replacement parts used, dates of repair, cleaning and type of disinfectant used and the names of persons doing the work. The respirator should be identified by manufacturer, model, and approval number. Records shall be retained for a minimum of five years.

5.4 Medical Records

The Company must retain all records pertaining to the employee’s medical examination and evaluation for a period of thirty (30) years plus the duration of employment.


HSE Practice 37 Control of Hazardous Energy

® CONTROL of HAZARDOUS ENERGY (Lockout/Tagout) PRACTICE 37 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

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1.0 Purpose

1.1 This Practice establishes the minimum requirements for the control of hazardous energy sources.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart

3.0 Definitions

3.1 Caution Tag

3.1.1 This tag is used to inform personnel of special precautions or instructions about safe and proper operation of equipment. This tag is not to be used to prevent equipment and systems from being operated.

3.2 Danger Tag

3.2.1 This tag is attached to a switch, circuit breaker, and other electrical controlling devices to warn others that the equipment and/or system has been isolated from its power source (de-energized) and that employees are working on the equipment or system.

3.2.2 This tag is attached to valve handles, applicable circuit breakers, switches, and other operating mechanisms to prevent manipulation or operation of mechanical equipment and pressurized systems during work on them. It shall also be used to secure valves between operational and non-operational sections of a system.

3.3 Energy Sources - any source of energy, i.e., electrical, spring, gravity, hydraulic, pneumatic, chemical, etc.

4.0 Process

Each project shall develop a written plan for the control of hazardous energy sources (Lock-out/Tag-out/Try). Where FLUOR ARABIA shares a site with Client personnel; the FLUOR ARABIA Plan shall compliment the Client program. However, the minimum requirements set forth in this Practice shall be met. Employees shall not be allowed to work on energized systems without written authorization from the Construction Manager and consultation with the Construction HSE Manager.

4.1 General

4.1.1 This Practice specifies methods of controlling hazardous energy sources during construction and maintenance activities involving work on electrical services, facilities, shop equipment, pressurized pipelines, and systems used as service lines for construction. This Practice also covers Practices to be used during start-up phases .

4.1.2 A standard “DANGER - DO NOT OPERATE” tag (DBN-F39) and individually keyed locks will be used by each project.

4.1.3 Tags used will be dated, signed and a description of the work being performed shown on the tag and securely attached to the equipment/lock.

4.1.4 Tags must never be reused, but destroyed immediately upon removal. No alterations to a tag are permitted.

4.1.5 No device shall be operated with a tag or lock attached regardless of circumstances.

4.1.6 No person shall remove another’s tag or lock unless the requirements of 4.6 are adhered to.


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4.1.7 It is the discipline Supervisor’s responsibility to ensure that no work is performed beyond the protection of locks and tags.

4.1.8 Tags required beyond one shift must be replaced by the oncoming shift. In no case will locks and tags be permitted to remain for more than 30 days without another inspection and redating with signatures.

4.1.9 Each person performing work on a system is required to affix a lock and tag on the system even though the equipment or system is already locked out. In these situations, a multiple locking device shall be used.

4.1.10 The program shall be inspected periodically in accordance with Practice 38—Site Safety Inspections.

4.2 Types of Systems Requiring Lock-out/Tag -out

4.2.1 Examples of types of energy sources requiring lock-out/tag-out are as follows:

4.2.1.1 Electrical systems prior to being connected to a power source and energized will be locked out until they are released for service. Any time repairs or modifications are made to electrical systems, either temporary or permanent, they shall be locked out. Locks shall be applied to the main disconnect whenever possible.

4.2.1.2 Pipelines, valves and other such sources that could be inadvertently activated, causing a hazardous condition, shall be locked out and blanked off or otherwise secured to prevent accidental activation.

4.2.1.3 Lines, valves, and similar systems that are being tested pneumatically with gases shall be tagged and/or locked out to prevent accidental discharge of the pressure within the line. In addition, areas affected by the pneumatic test shall be barricaded against entry and the Construction HSE Manager notified before commencement of the test.

4.2.1.4 Sources of energy such as pipelines, valves, and pumps shall be locked, blanked off, and otherwise secured to prevent charging, energizing, or creating any type of hazard to persons working on systems or inside a confined space.

4.2.2 Electrical Operated Systems

4.2.2.1 Whenever work on electrical equipment or services are scheduled, the power source (disconnects, circuit breakers, switches) controlling electrical equipment or systems shall be de-energized.

4.2.2.2 The Electrical Superintendent or their designee will de-energize any power panel(s), distribution panel(s), or equipment controller(s).

4.2.2.3 Completed Danger Tag(s) and locks shall be attached to the controlling device by:

• The person responsible for de-energizing the system, and

• The craft supervisor responsible for this operation

4.2.2.4 Each worker required to work on the de-energized equipment or systems shall ascertain that the craft supervisor's and/or their foreman's complete Danger Tag and lock is attached to the con-trolling device or devices and place their lock and tag on the device before they begin work.


9905-02-000.doc 12/8/2004 3

4.2.2.5 The de-energized equipment or system shall be tested using a volt-meter on the downstream side of the tagged-out controlling device. If the equipment is wired directly to a power panel box and is energized by turning on a push button or butterfly switch on the equipment, the power panel box on the downstream side must be tested using a voltmeter.

4.2.2.6 The Electrical Superintendent or their designee will establish and maintain a lockout log. (DBN-F41)

4.2.2.7 The lockout log shall list craft workers or personnel applying a lock and tag on any power panel, distribution panel, or equipment-controlling device.

4.2.2.8 Each employee shall detail in the lockout log the time of day the lock was applied, the necessity for the lockout, the area or machine where the work is being performed and the approximate length of time that the power panel, distribution panel or equipment controller will be de-energized.

4.2.2.9 When the work is completed, the employees will report this information to the Electrical Superintendent before removing their lock. The employees will log the time the work was completed in the lockout log and the time the lock was removed.

4.2.2.10 The last lock on the lockout device shall not be removed until the power panel, distribution panel, or the Electrical Superintendent inspects the equipment controller.

4.2.2.11 Faceplates, doors, and covers must be installed and in place before the panels are re-energized.

4.2.2.12 The Electrical Superintendent shall notify craft workers in the area that the power panel, distribution panel, or controller is about to be re-energized. The Electrical Superintendent or his designee may then remove that last lock.

4.2.2.13 The Electrical Superintendent or their designee shall check the re-energized power panel, distribution panel or equipment controller for proper operation.

4.2.2.14 The date and time of day when these panels or equipment controllers were restored to service shall be entered in the lockout log.

4.2.2.15 To lock out electrically powered shop equipment to ensure maxi-mum employee safety, a power disconnect switch shall be installed between the main power supply panel and each piece of electrical-ly driven equipment which is directly connected to the power panel box. (This does not apply to equipment, which is equipped with a plug connection, including welding equipment.) This dis connect switch should be located close to the equipment and properly identified. Pushbuttons or butterfly controls of equipment should not be locked out. A short circuit can occur between a locked out pushbutton and relay causing the equipment to be energized with full power. Since some equipment is wired with dual controls and locking out one pushbutton does not render that equipment


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inoperable, after tag and lockout try start buttons to be certain disconnect is complete.

4.2.2.16 Whenever maintenance of shop equipment is required, such as changing the blade of a radial arm saw, the craft operator shall verify that the controlling device (power disconnect) has been tagged and locked out before maintenance work begins.

4.2.3 Construction Equipment or Facilities

4.2.3.1 Electrical Superintendent, or their designee, opens the switch, pulls fuses and places his lock and tag on the equipment and then tries the system.

4.2.3.2 Other employees place their locks and tags on the lockout device.

4.2.3.3 Employees complete lockout log information.

4.2.3.4 Upon completion of the work the employees remove their locks and tags.

4.2.3.5 The Electrical Superintendent or their designee is the last to remove their lock and tag. After assuring that everyone is clear, the Electrical Superintendent or their designee will re -energize the system.

4.2.4 Operating Facilities and Equipment

4.2.4.1 Plant electrician de-energizes the system and demonstrates accuracy to the Electrical Superintendent or their designee.

4.2.4.2 Electrical Superintendent or their designee ascertains that the system is de-energized and places his lock and tag on the lockout device.

4.2.4.3 Other employees working on the system places their locks and tags on the device and completes the lockout log.

4.2.4.4 Upon completion of the work, the Electrical Superintendent or their designee is the last construction personnel to remove their lock and tag in the presence of the Plant Electrician.

4.2.4.5 The Plant Electrician then assumes control of the system.

4.2.5 Mechanical Work

4.2.5.1 Whenever work is scheduled on mechanical equipment or pres-surized systems, controlling devices such as circuit breakers, switches, valve handles, and other operating mechanisms shall be locked and tagged out to prevent their manipulation or operation.

4.2.5.2 Craft workers required to work on equipment or pressurized sys-tems shall determine that the craft supervisor's and their foreman's completed Danger Tag is attached to the controlling device or devices before they begin work. (See 4.2.5.3)

4.2.5.3 Where controlling devices permit, a lock shall be placed on the device by each employee to ensure that the controlling device is not inadvertently energized.

4.2.5.4 De-energized equipment or systems shall be checked or tested to verify that the equipment is inoperable or that the pressurized system has been drained of its contents on the downstream side.


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To prevent harmful exposures, pressurized systems shall then be flushed out with water if liquids are involved or with inert gas if compressed gases are involved.

4.2.5.5 Appropriate air tests shall be conducted whenever pressurized sys-tems have previously contained hazardous gases or liquids, espe-cially if welding and burning operations are involved when the system has been shut down. When isolating a pressurized system, slip-blind blanks and double valves with an open drain cock between valves are preferred over a single shutoff valve.

4.3 Unauthorized Use of a Danger Tag

4.3.1 The standard Danger Tag shall be used only for the purpose of identifying a de-energized piece of equipment or system. It is not to be used as a substitute for a defective tag or a Caution Tag.

4.3.2 A Caution Tag is to be used to inform personnel of special pre cautions or instructions for safe and proper operation of equipment.

4.3.3 Do not use a Caution Tag to warn against operating a system or piece of equip-ment. Only a Danger Tag may be used to prevent the operation of a system or piece of equip ment.

4.4 Unauthorized Removal of a Danger Tag

4.4.1 The unauthorized removal of a Danger Tag from the controlling device of de-energized systems or pieces of equipment shall be grounds for imme diate termination of the employee(s) involved.

4.4.2 The unauthorized operation of a controlling device of a de-energized system or piece of equipment that has been tagged out with a Danger Tag shall be grounds for immediate termination of the employee(s) involved.

4.5 Testing

4.5.1 When the performance of a work activity requires the functional testing of a machine, component, or system, the locks and tags may be temporarily removed in accordance with the tag removal, to perform the test. As a result of the testing, if it is determined that the equipment needs further work, the locks and tags shall be positioned back on to the device. If it is not necessary to replace all the locks and tags, then the unnecessary locks and tags may be returned to the Lockout/Tagout Coordinator. The Construction HSE Manager shall initial the Lockout/Tagout Request in the removal block to indicate that these locks and tags have been removed. When testing has been satisfactorily completed, the locks and tags shall be removed.

4.5.2 Steps to take include, but may not be limited to:

4.5.2.1 Make sure all danger areas are clear of personnel

4.5.2.2 Verify that the main disconnect switch or circuit breaker cannot be moved to the on position.

4.5.2.3 Use a voltmeter or other equipment to check the switch.

4.5.2.4 Press all start buttons and other activating controls on the equipment itself.

4.5.2.5 Shut off all machine controls when the testing is finished.


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4.5.3 When multi-worker or multi-craft situations exist, a multi-lockout tab is to be used. These devices allow for multiple locks for protection of all craft involved. Each lock must be properly tagged.

4.6 Emergency Removal of Employee's Lockout Lock

4.6.1 Lockout/tagout device removal

4.6.1.1 Each lockout/tagout device shall be removed from each energy-isolating device by the employee who applied the device. When the employee who applied the lockout/tagout device is not avail-able to remove it, the device may be removed only after the following steps have been completed:

• The craft supervisor and general foreman/foreman shall verify that the employee who applied the lockout/tagout device is not at the facility or available to return.

• The craft supervisor and general foreman/foreman shall make a reasonable effort to contact the employee to inform him or her that the lockout/tag-out device must be removed. The employee shall return to the project, without pay, to remove the lock if possible.

• The craft supervisor and the general foreman/foreman must "walked-down" the entire system to verify it is safe to start the system.

• The craft supervisor and general foreman/foreman shall com-plete an "Emergency Lockout Device Removal" form (DBN-F42) and present it to the project superintendent and the Construction HSE Manager for approval to re move the lock.

Note: If the Project Superintendent or the Construction HSE Manager is absent, the Construction Manager assumes their signature authority. If the Construction Manager is also absent then the designees that have received signature authority by designation may sign the "Emergency Lock-out Device Removal" form only after contacting the person they are receiving this signature authority from and that person has granted verbal permission to do so.

• The craft supervisor and/or general foreman/foreman shall en-sure that the employee whose lock was removed has been notified prior to returning to work on the system.

4.7 Training

4.7.1 Personnel shall receive Lockout/Tagout Training to include the following minimum requirements:

4.7.1.1 Personnel shall receive Lockout/Tagout Training as required by the OSHA Standard for Control of Hazardous Energy Sources.

4.7.1.2 Notify all affected employees that a lock out/tag out system is to be utilized on the project.

4.7.1.3 Maintain a list of the names and job titles of all employees who are authorized to lock out/tag out the specified machine or equipment.


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4.7.1.4 A written record must be maintained of all employees who have been educated in the company or projects lock out/tag out program.

4.7.1.5 Retraining of all affected employees will be conducted and documented when there is a change in:

4.7.1.5.1. Assignments

4.7.1.5.2. Machines

4.7.1.5.3. Equipment

4.7.1.5.4. Processes

4.7.1.5.5. When lock out/tag out inspections reveal a need, or supervision sees a need

4.7.1.5.6. New hazards or changes in the energy control procedure.


The Lockout Log shall be maintained in the Electrical Departments files for the duration of the project with a copy provided to the Construction HSE Manager on a weekly basis.


HSE Practice 38 Site Safety Inspections

® SITE SAFETY INSPECTIONS PRACTICE 38 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1. Purpose 1.1. The purpose of this Practice is to provide the minimum requirements for conducting regular

inspections to ensure that standards are being followed and work area hazards are being effectively controlled.

2. References

2.1. Title 29 Code of Federal Regulations Part 1926 Subpart C (1926.20) 3. Definitions

3.1. Competent Person - a person capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. The Project HSE Manager and the Construction Manager shall designate the competent person.

3.2. Combustible Material - liquids, solids, or gases that are relatively difficult to ignite and that burn relatively slowly (such as paper, wood, etc.)

4. Process

4.1. Daily Site Inspections 4.1.1. All Project Supervisors shall conduct daily safety inspections and record their findings

on the Project “Blue Cards” (DBN-F8). The “Blue Cards” will be turned in to the HSE Department for input into the Project HSE Management System. They shall also see that unsafe acts/conditions are corrected immediately.

4.2. Weekly Supervisor’s Site Inspection

4.2.1. Each project/area superintendent shall lead a formal written HSE inspection of his work area each week. The inspection team shall consist of the project/area superintendent, general foremen, the subcontractor supervisor, and the Project HSE Manager.

4.2.2. The Project “Blue Cards” shall be used to document this inspection. The “Blue Cards” will be turned in to the HSE Department for input into the Project HSE Management System.

4.3. Weekly Site Safety Committee Inspection 4.3.1. The Site Safety Committee shall conduct an inspection at least every two weeks. The

inspection team shall consist of one member of Management (superintendent or subcontract administrator), one supervisor (foreman), and at least on management representative from each subcontractor. The Safety Committee Chairperson shall assign the members of the Safety Committee inspection team on a rotating basis.

4.3.2. The members of the inspection team shall use the Project “Blue Cards to document this inspection. ”. The “Blue Cards” will be turned in to the HSE Department for input into the Project HSE Management System.

4.4. Monthly Construction Manager’s Inspection

4.4.1. On a monthly basis, the Construction Manager, the Project HSE Manager, the area superintendent, and one member of the Safety Committee shall conduct an additional compliance inspection using the Project “Blue Cards. The results shall be discussed at the Safety Committee meeting as well as the Supervisor’s Safety Meeting, and a copy shall be forwarded to the Corporate Director of Occupational Safety.

5. Record Retention 5.1. Site Safety Inspection forms shall be filed in the project EH&S files for the duration of the

project. 5.2. Daily HSE Reports (DBN-F40) shall be routed as follows:

5.2.1. Construction Manager

® SITE SAFETY INSPECTIONS PRACTICE 38 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 2

5.2.2. Site HSE files 5.3. Output from the Project HSE Management System shall be distributed as follows:

5.3.1. Construction Manager 5.3.2. HSE Manager 5.3.3. Site Supervisors

5.3.4. Site Safety Committee 5.3.5. Home Office Construction Manager or Manager of Projects

5.3.6. Site HSE files


HSE Practice 39 Safety Committee Meeting/Walkthrough

® SAFETY COMMITTEE MEETING/WALK-THROUGH PRACTICE39

DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to involve the direct work force in recognizing and correcting unsafe acts, unsafe conditions and provide a communication link with management to help build safe attitudes throughout the project.

2.0 References


3.0 Definitions

3.1 None

4.0 Process

4.1 Requirements

4.1.1 Members of the Project HSE Committee are assigned by the Construction Manager (CM) and the Construction HSE Manager. The Project HSE Committee shall consist of Management and Craft personnel. The ratio shall be, as a minimum, one management person to four craft people. The craft persons shall be encouraged to take an active roll in promoting and monitoring project HSE.

4.1.2 The Project HSE Committee will meet once a week, preferably on the same day at the same time.

4.1.3 The Project HSE Committee reviews significant near misses, recordables, and lost-time incidents and discusses them to determine if further corrective action is necessary.

4.1.4 The Project HSE Committee reviews and discusses findings from the weekly Site Inspection and any other inspections conducted during the previous week, and recommends corrective measures to management.

4.1.5 The Project HSE Committee discusses employee HSE concerns and suggestions and offers solutions or implements suggestions.

4.1.6 The Project HSE Committee discusses jobs planned for the coming month, particularly HSE issues to be addressed with craft employees.

4.1.7 The Project HSE Committee offers topics for discussion at weekly toolbox meetings.

4.2 Committee Membership

4.2.1 Chairperson (may be a supervisor or a craft person)

4.2.1.1 Conducts one Project HSE Committee meeting each week.

4.2.1.2 Develops a written agenda for the meeting.

4.2.1.3 Leads the HSE committee meeting, following the agenda and encouraging open discussion.

4.2.1.4 Designates at least one committee member per month to participate in the Constructions Manager’s Site Inspection.

4.2.1.5 Communicates HSE concerns to project management.

4.2.1.6 Starts meetings on time and limits length of meeting to 1 hour.

4.2.2 Recorder

4.2.2.1 Takes minutes of Project HSE Committee meetings.

® SAFETY COMMITTEE MEETING/WALK-THROUGH PRACTICE39


9905-02-000.doc 12/8/2004 2

4.2.2.2 Ensures minutes are typed and distributed. (DBN-F29)

4.2.3 Committee Member (craft employee or supervisor/manager)

4.2.3.1 Attends and actively participates in Project HSE Committee meetings.

4.2.3.2 Communicates HSE concerns to the work force.

4.2.3.3 Sets an example of safe work habits and follows HSE regulations.

4.2.3.4 Assists with incident investigations at the request of the CM and HSE committee chairperson.

4.2.3.5 Each person will be assigned as a member for at least two months with a rotation set up that will not have a majority of the members rotating at one time.

4.3 Distribution of Minutes

4.3.1 Project HSE Committee meeting minutes shall be distributed as follows:

4.3.1.1 Original to Construction Manager

4.3.1.2 Copy to each committee member

4.3.1.3 Copy to Corporate Director HSE.


A copy of the minutes of each HSE Committee meeting shall be maintained on file in the HSE Office for the duration of the project.


HSE Practice 40 Site Specific Rigging Inspection


HSE Practice 41 Incident Investigation

® INCIDENT INVESTIGATION PRACTICE 41 DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 1

1 Purpose 1.1. The purpose of this Practice is to provide the requirements for making appropriate

investigation of accidents/incidents. 2 References

2.1. Title 29 Code of Federal Regulations (CFR) Part 1926

2.2. Title 29 CFR Part 1910 2.3. Title 29 CFR Part 1904 2.4. Exxon Mobil Corporation Illness, Injury, and Hazard Loss Reporting Guide

3 Definitions

Category Description Level of Investigation Incident Any situation where serious safety related

consequences occurs or were likely to occur. Formal investigation required.

Injury / Illness Any event where individuals suffered an injury or illness as defined in the Exxon Mobil Injury and Illness reporting guidelines.1

Formal investigation required.

Near Miss Any situation in which an ongoing sequence of events was prevented from developing to a level where serious consequences were likely to occur, or where in addition to corrective action carried out on the spot further action is required.

Formal investigation not normally required. Appropriate level of investigation by supervisor and / or Safety Team.

Observation An observed behavior or situation that was corrected on the spot where serious consequences were unlikely to occur.

Not normally investigated. Data analyzed on a monthly basis.

4 Process

4.1. Requirements

4.1.1. When an accident/incident occurs, the primary focus shall be obtaining appropriate treatment for injured people and securing the scene to prevent additional hazards or injuries.

4.1.2. Once the injured personnel have been cared for and the scene has been secured, it will be necessary to initiate a formal investigation the accident/incident to determine the extent of damage, causal factors, and corrective actions to be implemented.

4.1.3. The investigation team will be comprised of the following personnel: - The FLUOR ARABIA supervisor/superintendent for the work - A member of the sub contractor management team

- The FLUOR ARABIA HSE Manager or FLUOR ARABIA Safety Supervisor if delegated by the FLUOR ARABIA HSE Manager

- The Yanpet HSE Manager (participation at Yanpet’s discretion)

4.2. Fatality, Hospitalization, Debilitating Injury 4.2.1. Upon notification to the Home Office, arrangements will be made, as necessary, to

conduct a formal accident/incident investigation with the assistance of the Corporate Director of Occupational HSE.

1 Exxon Mobil will use the “Exxon Mobil Corporation Illness, Injury, and Hazard Loss Reporting Guide

for their own determination of illness/injury recordability for the project. FLUOR ARABIA will follow OSHA-Recordkeeping for Occupational Injuries and Illnesses to determine recordability for the project. Any discrepancies in recordability will be resolved at the time of the investigation.


HSE 12/8/2004 2

4.2.2. The accident/incident scene shall be secured as quickly after the accident/incident as possible in order to preserve all evidence. Measures to secure the scene may include:

• Erecting barricades

• Monitoring the accident/incident scene 24 hours a day by security personnel

• Restricting access to authorized personnel only

4.2.3. The investigation team shall make a sketch of the area indicating the location of the injured person, equipment being used, material in the area, people in the area, and shall include any other pertinent information. Photographs shall be taken of the area and equipment and shall show different angles of the accident/incident scene.

4.2.4. Witnesses to the accident/incident shall be taken to a secluded area, prevented from conversing amongst themselves, kept separate from the general population, and given a witness statement form to complete. It is essential that witness statements be taken as soon after the accident/incident as possible, while the facts of the accident/incident are still clear in their minds.

4.2.5. When an accident/incident occurs, an investigation shall be conducted. For accidents/incidents other than a fatality, hospitalization, or debilitating injury, site personnel will typically conduct the investigation; however, if assistance from the Home Office is deemed necessary a request shall be made immediately.

4.2.6. The purpose of the accident/incident investigation is to ensure that the acts and conditions that contributed to the accident/incident have been eliminated or controlled.

4.2.7. Accidents/Incidents on FLUOR ARABIA projects are varied and all shall be investigated. The level of investigation will depend on the degree of injury or the severity of the accident/incident.

4.3. Accident/Incident Investigations 4.3.1. Formal Accident/Incident Investigations shall be conducted for the following types of

accidents/incidents: Ø Recordable injuries/illnesses. Ø Utility damage.

Ø Fires. Ø Vehicle/equipment accidents/incidents.

4.3.2. First-aid cases and near misses shall be investigated to the extent necessary to determine the root cause, ancillary causal factors, and determine whether lessons learned from the accident/incident are applicable to other tasks, work groups, or projects to prevent a similar accident/incident from occurring again.

4.3.3. The FLUOR ARABIA Formal Near Miss/Investigation Form shall be used as outlined in the project specific HSE Plan and as outlined below. This form is a multi-page form and the investigation team shall determine which pages require completion. In general, the Form shall be completed as follows:

4.3.3.1. Page one will be completed for all accidents/incidents. 4.3.3.2. The Employee Statement shall be completed for accidents/incidents

involving an FLUOR ARABIA employee.

4.3.3.3. The Foreman’s statement will be completed for accidents/incidents involving FLUOR ARABIA workers or work areas.

4.3.3.4. All witnesses to any accident/incident shall complete the Witness Statements.


HSE 12/8/2004 3

4.3.3.5. The Vehicle/Equipment Accident page shall be completed for accident/incidents involving vehicles and/or equipment whether owned by the company or a third party.

4.3.3.6. The Environmental or Chemical Hazard form shall be completed for accident/incidents involving spills or releases of chemicals or employee exposure to hazardous chemicals.

4.3.3.7. The Utility Damage page shall be completed for accidents/incidents involving damage to utilities controlled by the company or a third party.

4.3.3.8. The Project HSE Manager’s Summary and Construction Manager’s Concurrence shall be completed for all accident/incidents.

4.3.4. The Project HSE Manager shall prepare a Summary of Lessons Learned. This summary shall include: 4.3.4.1. A brief description of the accident/incident (use employee

classification, and not names)

4.3.4.2. The root cause of the accident/incident. 4.3.4.3. The contributing cause(s) of the accident/incident. 4.3.4.4. The corrective actions to be implemented.

4.3.4.5. The lessons learned from this accident/incident applicable to other activities and projects. Note: The FLUOR ARABIA Formal Investigation Form may be used by the subcontract administrator to assist subcontractors in conducting an adequate investigation of accidents/incidents involving subcontract employees.

4.3.5. The investigation shall be completed within five (5) working days of the accident/incident.

4.3.6. A copy of the completed investigation form shall be forwarded to the Corporate Occupational HSE Manager.

4.3.7. Following review by the Corporate Occupational HSE Manager, the completed investigation shall be filed in the project HSE files.

4.3.8. The Corporate Occupational HSE Manager shall be responsible for the distribution of the Summaries of Lessons Learned to the rest of the organization.

5 Record Retention

5.1. All accident/incident records, photographs and statements shall be maintained in the project HSE files for the duration of the project.

Upon completion of a project all accident/incident records, photographs and statements shall be forwarded to the Corporate Occupational HSE Manager for appropriate storage.


HSE Practice 42

Flagman & Traffic Vest

® FLAGMEN & TRAFFIC VEST PRACTICE DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

HSE 12/8/2004 1

1.0 Purpose

1.1 The purpose of this Practice is to specify the minimum requirements for flagmen and the use of traffic vests wherever a hazardous condition exists and a need is indicated for using such equipment to adequately reduce the hazard to personnel, visitors, and/or subcontractors.

2.0 References

2.1 Title 29 Code of Federal Regulations (CFR) Part 1926 Subpart P (1926.651)

2.2 American National Standards Institute D - 6.1 (current issue) - Manual of Uniform Traffic Control Devices for Streets and Highways



3.0 Definitions

3.1 None

4.0 Process

4.1 Requirements

4.1.1 Whenever employees are required to work in the immediate vicinity of moving traffic, all personnel must wear, as a minimum, a fluorescent orange or red traffic safety vest. If such activities are conducted at night, the vests shall be reflective.

4.1.2 Whenever it is necessary for equipment to cross railroads, public roads or heavily traveled roads within plants at least one flagman shall be used during crossings.

4.1.3 If hoisting equipment must cross under overhead electrical lines and it is possible for the boom to contact or be in close proximity to the line then a flagman shall be used to eliminate the potential for contact.

4.1.4 If the flagman will be hand signaling then he shall use red flags at least eighteen (18) inches square. In periods of darkness red lights shall be used.

4.1.5 In general, whenever signs or barricades do not provide adequate protection then flagmen should be used.

4.1.6 Signaling direction by flagmen should conform to American National Standards Institute D-6.1 - Current Issue, Manual of Uniform Traffic Control Devices for Streets and Highways.


None


HSE SECTION II.

PROJECT FORMS


DBN-F8 Blue Card

® BLUE CARD DBN – 1 Turnaround

Yanpet, Yanbu Saudi Arabia DBN-F8 (Blue Card)

9905-02-000.doc 12/8/2004 1

Date Reported by Time Group Observed Area Office Furnace Utilities Ethylene Polymers Glycol W’House Explain what your observation / concern is, and what action you have taken Return this form to YEP DBN-1 Safety Team Y

EP

DB

N-1

Saf

ety

Obs

erva

tion

Action Fixed on the spot, no further action required.

Further Action Required—See Reverse

Front Side of Card

Action Required Actionee

YE

P D

BN

-1 S

afet

y O

bser

vatio

n

Back Side of Card


DBN-F9 Barricade Tag

® BARRICADE TAG DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F9

9905-02-000.doc 12/8/2004 1

FLUOR ARABIA BARRICADE TAG

________________________________________________________________ UNIT:________________________________________________________ LOCATION:__________________________________________________ ________________________________________________________________ DATE ERECTED:_____________________________________________ ________________________________________________________________ DESCRIPTION OF HAZARD(S): ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ________________________________________________________________

HAZARD LEVEL

DO NOT ENTER

ENTER ONLY WITH AUTHORIZATION OF THE SUPERVISOR WHOSE NAME APPEARS BELOW AND AFTER MEETING THE PRECAUTIONS LISTED BELOW. ________________________________________________________________________________________________________________________________________________________________________________________________

ENTER WITH CAUTION ________________________________________________________________ ISSUED BY:

__________________________________________________ FLUOR ARABIA SUPERVISOR

______________________________

Method to Contact Supervisor (Phone #, Pager #, Radio Channel, etc.)


DBN-F10 Ladder Inspection Checklist

® LADDER INSPECTION CHECKLIST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F10

9905-02-000.doc 12/8/2004 1

SAFETY INSPECTION FOR LADDERS - MONTHLY

REGULATION : All ladders shall be maintained in good condition at all times. The use of ladders with broken or missing rungs or steps; broken or split siderails or other faulty or defective construction are prohibited. When ladders with defects are detected, they shall be immediately withdrawn from service. Compliance with these regulations are required by Occupational Safety and Health regulations for Construction Part 1926 Subpart X.

INSTRUCTION : All ladders shall be inspected monthly. Those that are discovered to have a defect shall be tagged "UNSAFE DO NOT USE" and removed from the work area for repair or destruction. Those that are in good condition shall be color coded with the safety color codes of the mo nth. Color code tape shall be placed (one wrap) on the right side rail between the third and fourth rungs or steps. The effective date for color codes shall be the first work day of each month. Complete this inspection form by placing a check under “OK” if the ladder meets requirements of the regulation or a check under “NO” if the ladder is defective and removed from service. Ladders must have an I.D. number.

COLOR CODE FOR THE MONTH: _________ INSPECTION BY: ______________________________ DATE: ____________

TYPE OR

DESCRIPTION STEP

LADDER SINGLE

LADDER EXTENSION

LADDER SECTIONAL

LADDER TRESTLE LADDER

EXTENSION TRESTLE LADDER

JOB MADE LADDER

I..D. NUMBER OK NO OK NO OK NO OK NO OK NO OK NO OK NO

® LADDER INSPECTION CHECKLIST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F10

9905-02-000.doc 12/8/2004 2

TYPE OR DESCRIPTION

STEP LADDER

SINGLE LADDER

EXTENSION LADDER

SECTIONAL LADDER

TRESTLE LADDER

EXTENSION TRESTLE LADDER

JOB MADE LADDER

I..D. NUMBER OK NO OK NO OK NO OK NO OK NO OK NO OK NO


DBN-F11 Powered Aerial Work Platform Checklist

® POWERED AERIAL WORK PLATFROM CHECKLIST

DBN – 1 Turnaround Yanpet, Yanbu Arabia

DBN-F11

9905-02-000.doc 12/8/2004 1

MAKE MODEL DATE

ABB # THIRD PARTY # SERIAL #

GENERAL GOOD DEFECT N/A GROUND CONTROL GOOD DEFECT N/A Overall Condition Starter & Choke Placards Control Switches Operation & Safety Manual Emergency Power Lubrication Manual Descent Guards (Fan, Brake, Muffler,Etc.) BOOM & PLATFORM CHASIS Boom Pivot Point Wheels & Lug Nuts Lift Cylinder & Pins Frame Scope Cylinder & Pins Power Train Boom Sections Turntable & Pinion Platform Pivot & Pins Drive Brakes Platform Pivot Cylinder Tie Rods & Linkage Platform Rotation & Pins Outriggers Platform Rotation Cylinder Extending Axle Platform Assembly Oscillating Axle Hoses & Cables ROTATING SUPERSTRUCTURE PLATFORM CONTROLS Cowling & Latches Emergency Stop Switch Counterweight Starter & Choke Crankcase Oil Lever Control Switches Crankcase Oil Gaskets Control Levers Crankcase Oil Filters Foot Switches Pulleys & Belts 1. Activates Platform Controls Mufflers & Exhaust System 2. Deactivates Starter Switch Air Filter Emergency Power Hydraulic Pump & Drive Capacity Indicator Hydraulic Tank & Oil Level Low Speed Travel Limit Switch Hydraulic Oil Filter Hydraulic Lines & Couplings Fuel Tank ____________________________________ _______ Battery SIGNATURE DATE


DBN-F12 Forklift Inspection Checklist

® FORKLIFT INSPECTION CHECKLIST


DBN-F12

9905-02-000.doc 12/8/2004 1

Make: _____________ Model: _____________ Serial No: _________ Week Ending: ______________

Sun. Mon. Tues. Wed. Thurs. Fri. Sat.

Forks Hoist chains & cylinder Brakes - Drum Brakes - Carrier Brakes - Emergency Tires Hydraulic System Mirrors (Rear-view) Exhaust System Operator’s controls Fire extinguisher Headlights (if used inside or at night)

Back-up alarm Horn Seat belt Initials & badge # of inspector Other: These items shall be checked prior to each shift’s use. Report ALL items in need of repair to the equipment superintendent at the time of inspection. Return the completed sheet to the Equipment Superintendent and Safety Department at the end of the week.

To be completed by the mechanic:

Date reported Repairs Made: Date Repaired

Signature of the Equipment Superintendent: _________________________________________________


DBN-F13 Harness Inspection Checklist


DBN-F14 Assured Equipment Grounding Inspection Checklist

® ASSURED EQUIPMENT GROUNDING INSPECTION CHECKLIST


DBN-F14

9905-02-000.doc 12/8/2004 1

COLOR CODE:__________________________________ MONTH:____________________________________ INSPECTOR:______________________________________________________

TYPE OF EQUIPMENT

I.D. NUMBER TYPE OF TEST DATE TESTED INSPECTION RESULTS

VISUAL INSPECTION (CORD INSULATION, PLUG,

ETC.)

COMMENTS//REMARKS

CONT. GRND. COND.

OK TO REPAIR

GOOD CONDITION

WORN CONDITION


DBN-F15 Excavation Permit

® EXCAVATION PERMIT DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F15

9905-02-000.doc 12/8/2004 1

Date: ________________________ Time: __________________ Expiration Date: _________________________

Job description/location/work order number (Be specific.) _______________________________________________________________________________________________________________________________

Have the individuals assigned to this task been trained in excavation safety? Yes No

Before Trenching and Excavating

Soil Classification ________________ Distance in feet to utilities, buildings, footings, or pilings Type C ________________ Distance in feet to sources of vibrations Type B Yes No Have the owners of utilities been notified, if applicable? Type A Yes No Has the ground been disturbed previously? Stable ________________ List the allowable slope.

Indicate if the items below are: necessary, adequate, and/or available. necessary adequate available personal protective equipment(be specific) ________ ________ _______ shoring material ________ ________ _______ signs, barricades ________ ________ _______ machinery ________ ________ _______

Check known obstructions: electrical telephone water sewer steam alarm drain process footings pilings concrete encasement other (specify) _____________________________________

Excavation method: Backhoe Hand dig Ditchwitch Other (specify): _____________________

Precautions to be taken: de-energize lines ground tools insulate operator

Trenching and Excavating Checklist

Size of the excavation: Depth __________ Width _______ Length _____Protective system used for excavation: Are ground conditions changing (particularly after rainfall)? Yes No Sloping Is there a concern for the development of a hazardous atmosphere? Yes No Shoring Ensure that the shoring and/or sloping remains adequate as excavation progresses. Indicate the shoring method used and applicable appendix. What method shall be used for entry and exit: stairway ladder ramp [ ] App. C - Timber shoring Has there been a change in vehicular and machinery operation patterns? ________ [ ] App. E-Alternative to timber shore Is water removal equipment needed ______ available ______ and operable_______ [ ] App. F-Selection of protect system Are portable trench boxes or trench shields adequate? Yes No [ ] Pre-designed shoring Note: Protection for excavations greater than 20 feet deep (shoring, benching, and sloping designs) shall be developed by a registered professional engineer.

Signatures and Dates Excavation

Competent Person Client Representative (if applicable)

FAL Supervisor FAL EH&S Professional Registered Professional Engineer (if applicable)

Signature

Date

Electrical Superintendent

Pipe Superintendent Equipment Superintendent

Field Engineer Other: ____________________

Signature

Date

Note: Each individual signing above is entitled to a copy of this permit, if desired.


DBN-F16 Daily Excavation Inspection Checklist

® DAILY EXCAVATION INSPECTION CHECKLIST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F16

9905-02-000.doc 12/8/2004 1

Name of Excavation Competent Person: _____________________________________________________ Date of Inspection: ________________________ Excavation/Trench location: _______________________________________________________________ ______________________________________________________________________________________ Depth: ________________ Width: ______________ Date Opened: _____________________

Soil classification: A B C

Indicate, by marking the test below, how the classification was made.

Manual test(s) Cohesive Cohesive Granular unfissured fissured a) plasticity ________ _______ ________ b) dry strength ________ _______ ________ c) thumb penetration ________ _______ ________ d) pocket penetrometer ________ _______ ________ e) other ________ _______ ________

Visual test(s) Do as many as possible Cohesive Soil Granular Soil a) Spoil pile Remains in clumps Breaks up easily b) Trench Side Stands vertical for over 2 hours Sloughs into trench

The excavation is properly (circle one): Shored (indicate the type of shoring) closed open wood

metal Sloped/benched (indicate the slope) vertical sides 3/4:1 1:1

1 1/2: 1 2:1 Excavation Checklist: Morning Mid-Day Afternoon Time: _________ ________ _________ Weather: _________ ________ _________ Was atmospheric testing required? yes no yes no yes no Was atmospheric testing done? yes no yes no yes no Is the spoil pile back 3’ from the edge? yes no yes no yes no Have surface encumbrances been removed? yes no yes no yes no Are there any signs of sloughing or cave-in? yes no yes no yes no Is there water accumulation in the bottom? yes no yes no yes no

® DAILY EXCAVATION INSPECTION CHECKLIST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F16

9905-02-000.doc 12/8/2004 2

Are there vibration sources near the excavation? yes no yes no yes no Is there adequate access/egress (ladder, ramp, etc.) yes no yes no yes no Has the soil been disturbed previously? yes no yes no yes no Sides yes no yes no yes no Top yes no yes no yes no If the excavation is over 20 feet deep, have engineering designs been documented and complied with? yes no yes no yes no


DBN-F17 Rope, Sling & Shackle Inspection Checklist

® ROPE, CABLE, SLING AND SHACKLE INSPECTION CHECKLIST


DBN-F17

9905-02-000.doc 12/8/2004 1

PROJECT NAME: PROJECT No.: INSPECTED BY: DATE OF INSPECTION MONTH: COLOR CODE RESPONSIBLE SUPERVISOR: INSTRUCTIONS: Inspect monthly using the codes noted below for identification and disposition. LEGEND: Use the following codes: S = Satisfactory DD = Defective/Destroy N/A = Not Applicable

Type of Sling

and Size I. D. No. Broken

Wires Reduction in Diameter due

to Wear

Kinking, Crushing,

Bird Caging

Heat, Mechanical or Chemical

Damage

Shackles - Cracked, Worn

or Spread

Shackle Pin - Cracked, worn

or Bent

Hooks - Cracked or

Worn

Nylon Slings -

Broken or Worn

Stitches

Nylon Slings -

Worn or Damaged


DBN-F18 Monthly Crane Inspection Checklist

® MONTHLY CRANE INSPECTION CHECKLIST

DBN-1 Turnaround Yanpet, Yanbu saudi Arabia

DBN-F18

9905-02-000.doc 12/8/2004 1

TYPE OF CRANE

CRANE ENGINE MANUFACTURER

CARRIER ENGINE SERIAL NUMBER

MANUFACTURER

CRANE ENGINE SERIAL NUMBER PROJECT

MODEL NUMBER

CARRIER NUMBER LOCATION

SERIAL NUMBER

CARRIER ENGINE MANUFACTURER DATE INSPECTED

MARK ONE IN/OUT COMMENTS

GOOD FAIR REPAIR

Carrier For Truck Crane Horn Windshield and Wiper Glass Fire Extinguisher Lights (Head Lights, Tail, Stop, Etc) Mirrors Turn Signals Gauges Outrigger (Beams And Boxes) Jacks, Pads Cracks Bent Leakage Controls Locks Steering Brakes Clutch Drive Shaft and "U" Joints Transmission Transfer Case Differential Fluid Levels and Condition Front Axle(s) Intermediate Axle(s) Rear Axle(s) Springs and Shocks Locking Devices Backup Alarm Tires Recommended Inflation Pressure Excessive Wear Damage Lug Nuts Wheels and Rims Engine



DBN-F18

9905-02-000.doc 12/8/2004 2

TYPE OF CRANE



MANUFACTURER


MODEL NUMBER


SERIAL NUMBER



GOOD FAIR REPAIR

Performance Fan Belts Batteries Radiator and Cooling System Hoses Fluid Levels and Condition

Under Carriage On Crawler Crane Tracks (Excessive Wear) Crawler Pads Crawler Pad Bolts Crawler Pad Connection Pins Pin Keeper Bolts Rollers (Top and Bottom) Front Tumbler Drive Tumbler Tumbler Bearings Drive Chain Chain Sprockets Adjustment Track Drive Chain Travel Locks/Brakes Bolts (General) Fluid Levels and Condition

General Appearance Panels and Hood, Etc. Paint Structural

Superstructure Load Rating Chart and Decals Signal Horn Glass Windshield Wiper Outrigger Controls and Locks Controls and Labels Catwalk and Handrails (Holds) Gantry System



DBN-F18

9905-02-000.doc 12/8/2004 3

TYPE OF CRANE



MANUFACTURER


MODEL NUMBER


SERIAL NUMBER



GOOD FAIR REPAIR

Counterweight Hooks and Bolts

Turntable Circle Gear Bull Gear Hook Rollers Mounting Bolts Warpage Bearings Locking Device

Wire Rope (Load, Whip, Boom Hoist, Pendant) Correct Size and Length Reeving In Compliance With Mfr. Specs. Spooling Properly On Drums Broken Wires Kinks, Birdcaging, Mashed Corrosion Other Damage Excessive Wear

Load Block And Hooks Deformation: 15% Excess Of Normal Throat Opening MYre Than 10 Degrees Twist From Plane Of Unbent Hook

Cracks Wedge Sockets Safety Latches Hook Connection

Sheaves Boom Bent/Warpage/Rust Cracks (Metal and Welds) Wear Pads and Adjustment Sheaves Boom Stops Gantry and Sheaves Jib And Pins

Jib Stops Bent/Warpage/Rust



DBN-F18

9905-02-000.doc 12/8/2004 4

TYPE OF CRANE



MANUFACTURER


MODEL NUMBER


SERIAL NUMBER



GOOD FAIR REPAIR

Cracks (Metal and Welds) Sheaves Pendants and Pins Inside Upper Structure A. Oil Levels and Condition 1. Engine 2. Torque Converter 3. Gear and Chain Drive 4. Hydraulic System B. Cooling System 1. Coolant, Level Protection and Condition 2. Heat Exchangers 3. Hoses, Fan Belts 4. Pressure Test C. Electrical 1. Mounting 2. Wiring 3. Switches 4. Battery - Charge and Condition D. General Repairs 1. Leaks 2. Adjustment 3. Brakes 4. Clutches 5. Pawls 6. Pins and Linkage 7. Rust and Corrosion 8. Structure Defects: a. Cracks (Metal and Welds) b. Bent/Warpage/Rust c. Guards In Place

Operator's Position Glass Door and Cab General Appearance Control Labels Load Chart



DBN-F18

9905-02-000.doc 12/8/2004 5

TYPE OF CRANE



MANUFACTURER


MODEL NUMBER


SERIAL NUMBER



GOOD FAIR REPAIR

Controls: A. Engine B. Electrical C. Hydraulic D. Other Heater Defroster Horn and Backup Alarm Warning Devices Limit Switches Windshield Wiper Gauge And Indicators: A. Hydraulic Pressure B. Air Pressure C. Oil Pressure D. Temperature Operation: A. Swing B. Boom C. Winch D. Telescope E. Travel F. Outrigger G. Steering Fire Extinguisher 5bc Rating Operator Parts Service Manual

Lubrication And Service Engine And Drive Chain Structure And Components Hydraulic System

Safety Devices Malfunction Over Their Full Range Any Significant Inaccuracies Load Indicator Overload Cutoff Boom Angle Indicator



DBN-F18

9905-02-000.doc 12/8/2004 6

TYPE OF CRANE



MANUFACTURER


MODEL NUMBER


SERIAL NUMBER



GOOD FAIR REPAIR

Signal Horn (Upper And Lower) Back-Up Alarm Automatic Boom Kickout Anti-Two-Blocking Device

General Overall Cleanliness Operator Manual Service Books

SIGNATURE (FLUOR INSPECTOR)

DATE


DBN-F19 Daily Crane Inspection Checklist

® DAILY CRANE INSPECTION CHECKLIST


DBN-F19

9905-02-000.doc 12/8/2004 1

PROJECT NAME PROJECT NO./CONTRACT NO. DATE

MANUFACTURER MODEL NUMBER SERIAL NO. EQUIPMENT NO.

INSPECTED BY APPROVED BY

GOOD REPAIR NOT

APPL. COMMENTS All Control Mechanisms

Maladjusted

Excessive Wear

Hydraulic System

Level Of Oil And Condition

Filters

Hoses And Connections

Electrical Apparatus

Excessive Deterioration

Malfunctioning

Engines

Fluid Levels And Condition

Air System And Pressure

Air Filter

Belts

Batteries

Cab

Glass

Signal Horn

Windshield Wiper

Operational Aids Anti-Two-Block/LMI Console

Gauges And Warning Lights

Lights

Mirrors

Bubble Level

Load Chart

Fire Extinguisher

Brakes And Clutches

Tires Or Tracks

Wire Rope

Condition - Damage

Connections, Sockets, Clips

Reeving

® DAILY CRANE INSPECTION CHECKLIST


DBN-F19

9905-02-000.doc 12/8/2004 2

GOOD REPAIR NOT

APPL. COMMENTS

Hooks, Block And Ball

Cracks (Metal And Welds)

Excessive Wear

Bent/Warpage/Rust

Sockets And Hook Connection Latch Drums Locking Devices/Dogs Brakes Minimum 3 Wraps Of Rope Boom And Jib Pendant Lines Sheaves Bent Lattices Or Cords Automatic Stops Limiting Devices Angle Indicator All Safety Devices Anti-Two-Block/LMI Components Overhead Crane Travel Warning Device OVERALL CLEANLINESS


DBN-F20 Critical Lift Permit

® CRITICAL LIFT PERMIT


DBN-F20

9905-02-000 12/8/2004 1

1. PROJECT 2. JOB NUMBER 3. DATE OF LIFT 4. AREA OR LOCATION

5. CRANE MANUFACTURER 6. MODEL NUMBER 7. CRANE INSPECTION DATE 8. WEATHER CONDITIONS

9. DESCRIPTION OF LOAD 10. BOOM LENGTH 11. BOOM ANGLE _________ PICK _______SET

12. JIB LENGTH

13. OFFSET/TYPE ___________TO #_____________

14. MAXIMUM OPERATING RADIUS

15. DEGREE OF SWING 16. WILL JIB BE USED? YES NO

17. LENGTH OF JIB 18. CRANE MANUFACTURERS RATED CAPACITY

A. COMPONENT WEIGHTS WEIGHT (LBS.) 1. JIB __________________________ 2. WEIGHT OF BALL AND HOOK (JIB POINT) __________________________ 3. UPPER BOOM POINT (FROM CAPACITY CHART IF NOTED) __________________________ 4. WEIGHT OF BALL AND HOOK (UPPER BOOM POINT) __________________________ 5. LOAD BLOCK __________________________ 6. TOTAL WEIGHT WIRE ROPE BENEATH LOWER, UPPER AND JIB POINT __________________________ 7. WEIGHT AND DESCRIPTION OF SLINGS _______EA. ________LENGTH __________________________ _______EA. ________LENGTH __________________________ 8. WEIGHT AND DESCRIPTION OF SHACKLES _______EA. ________LENGTH __________________________ _______EA. ________LENGTH __________________________ 9. WEIGHT OF SPREADER BAR __________________________ 10. WEIGHT OF OTHER MISCELLANEOUS RIGGING __________________________

B. TOTALS 1. TOTAL COMPONENT WEIGHT (ADD A.1.THRU A.10.) __________________________ 2. WEIGHT OF LOAD TO BE LIFTED __________________________ 3. TOTAL ERECTION LOAD WEIGHT (ADD B.1. AND B.2.) __________________________

C. PERCENTAGE OF CAPACITY

1. MAXIMUM OPERATING CAPACITY ____________’___________”_ 2. CRANE CAPACITY AT ABOVE RADIUS ______________________LBS 3. LOAD PERCENTAGE OF CRANE CAPACITY (LINE B.3. DIVIDED BY C.2.) ________________________%

OTHER CONSIDERATIONS CRANE SET UP LEVEL

YES NO SOIL COMPACTION _________% IF TOTAL ERECTION WEIGHT EXCEEDS 70% OF CRANE CAPACITY, MATS MUST BE USED OVER WELL COMPACTED SOIL.

TYPE OF SOIL

SIGNATURES EQUIPMENT SUPERVISOR: CRAFT SUPERVISOR:

__________________________________________________ __________________________________________________ CRANE OPERATOR: SITE SAFETY MANAGER:

__________________________________________________ __________________________________________________ RIGGING SUPERVISOR: PROJECT CONSTRUCTION MANAGER:

__________________________________________________ __________________________________________________


DBN-F21 Rigging & Lift Plan

® RIGGING & LIFT PLAN


DBN-F21

9905-02-000.doc 12/8/2004 1

Location:___________________________________________________________________________ Date of Lift:___________________

Load Description:____________________________________________________________________________________________________

Does this lift involve the lifting of personnel? Yes No (If Yes, LGH TP 6404-23.000 - Personnel Hoisting)

Lift description:_____________________________________________________________________________________________________

A. WEIGHT B. JIB

1. Weight of Equipment ____________lb. Erected Stowed

2. Weight of Headache Ball ____________lb. 1. Length of Jib _______________

3. Weight of Load Block ____________lb. 2. Angle of Jib _______________

4. Weight of Lifting Bar ____________lb. 3. Rated Capacity of Jib (From Chart)

5. Weight of Slings & Shackles ____________lb. C. SIZING OF SLINGS/SHACKLES

6. Weight of Jib ____________lb. 1. Sling Selection

7. Weight of cable (Load Fall) ____________lb. a. Type of Arrangement _______________

8. Allowance for Unaccounted Material in Equipment (10% of Equip. Weight)

____________lb

b. Number of Slings in Hookup _______________

9. No. of People Lifted x 250lb. ____________lb. c. Sling Length _______________

10. Other ____________________________ ____________lb. d. Rated Capacity of Slings _______________

TOTAL WEIGHT 2. Shackle Selection

Source of Load Weight:____________________________________ a. Capacity (tons) _______________

Weight Verified By:______________________________________ b. Number of Shackles _______________

D. CRANE E. CRANE PLACEMENT

1. Type of Crane _____________________________________ 1. Smooth Solid Foundation in Area? Yes No

2. Crane Capacity _____________T If No Explain:_______________________________________

3. Lifting Arrangement ___________________________________________________

a. Max. Distance Center load to Center Pin ______________ ___________________________________________________

b. Length of Boom ______________ 2. Electrical Hazards in Area? Yes No

c. Angle of Boom at Pickup ______________ If Yes Explain:_______________________________________

d. Angle of Boom at Set ______________ ___________________________________________________

4. Rated capacity of crane under most severe lifting conditions: ___________________________________________________

1. Over Rear ____________lb. 3. Obstructions/Obstacles to Lift/Swing? Yes No

2. Over Front ____________lb. If Yes Explain:______________________________________

3. Over Side ____________lb. __________________________________________________

5. Rated Capacity of Crane for Lift ____________lb. ___________________________________________________

6. Max. Load on Crane ____________lb. F. CABLE

7. Lift is ___% of Crane’s Rated Capacity ______________ 1. Number of Parts of Cable. _______________

2. Size of Cable

______________

® RIGGING & LIFT PLAN


DBN-F21

9905-02-000.doc 12/8/2004 2

G. PRE - LIFT CHECK LIST

1. CRANE(S)

1.1. Mechanical Condition checked & O.K Yes No 1.9. Load Block per Rigging Sketch. Yes No

1.2. Fuel level checked and O.K. Yes No 1.10. Load line reaving per Rigging Sketch. Yes No

1.3. Wire rope condition checked & O.K. Yes No 1.11. Counterweights per Rigging Load Charts. Yes No

1.4. Load charts checked. Yes No 1.12. Block pinned? Yes No

1.5. Load Charts in crane(s). Yes No 1.13. Operator qualified and certified? Yes No

1.6. Crane(s) rating per Rigging Sketch. Yes No 1.14. Swing clearances adequate? Yes No

1.7. Boom(s) per Rigging Sketch. Yes No 1.15. Head room adequate? Yes No

1.8. Outriggers fully extended. Yes No 1.16 Experienced rigger. Yes No

2. RIGGING

2.1. Rigging installed per Rigging Sketch. Yes No 2.3. Sling Proof Load Cert (1½“ ∅ & larger only Yes No

2.2. Rigging Specialties approved. Yes No 2.4. Shackle NDT Test(100T & larger only) Yes No

3. GENERAL

3.1. Lift Weight per Rigging Sketch Yes No 3.6. Prerequisites Complete per Rigging Sketch Yes No

3.2. Ground Preparations Suitable. Yes No 3.7. Shims/Slide Plates Set to Elevation. Yes No

3.3. Crane Mats as Required. Yes No 3.8. Anchor Bolt Pattern Verified. Yes No

3.4. Lifting Attachments Checked. Yes No 3.9. Prelift Meeting Complete. Yes No

3.5.-Signal Man Assigned and Briefed. Yes No 3.10.Weather/Wind Conditions.______________________________

4. NOTES

5. Crane Inspected By:__________________________________________________________ Date:____________________________

6. Functional Test of Crane By:___________________________________________________ Date:____________________________

SPECIAL INSTRUCTIONS OR RESTRICTIONS FOR CRANE, RIGGING, LIFT, ETC ._____________________________________

__________________________________________________________________________________________________________________

• MULTIPLE CRANE LIFTS REQUIRE A SEPARATE LIFT PLAN FOR EACH CRANE.

• ANY CHANGES IN THE CONFIGURATION OF THE CRANE, PLACEMENT, RIGGING, LIFTING SCHEME. ETC. OR

CHANGES IN ANY CALCULATIONS REQUIRE THAT A NEW LIFT PLAN BE DEVELOPED. NOTE: SKETCH MUST BE ATTACHED SHOWING DIAGRAM OF CRANE AND LOAD PLACEMENT AND RIGGING CONFIGURATION. ______________________________ _________ ______________________________ __________ SIGNATURE OF CONSTRUCTION MANAGER DATE SIGNATURE - OF EH&S PROFESSIONAL DATE ____________________________________________ _____________ ____________________________________________ _______________ SIGNATURE OF RIGGING SUPERINTENDENT DATE SIGNATURE - OF FIELD ENGINEER DATE ____________________________________________ _____________ ____________________________________________ _______________ SIGNATURE OF OWNER (IF REQUIRED) DATE OTHER (AS REQUIRED) DATE


DBN-F22 Authorization for Use Of Suspended Personnel Hoisting Platform

® AUTHORIZATION for USE OF SUSPENDED PERSONNEL HOISTING PLATFORM DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F22

9905-02-000.doc 12/8/2004 1

Lift Weight Summary

___________________ __________________ ____________________ Test lift weight Actual lift weight Crane capacity at farthest

most point of lift

The managers and supervisors indicated on the attached lift plan have determined that it is necessary to use a Suspended Personnel Hoisting Platform. A pre-lift meeting was held on ____________________(date) to discuss the safe execution of a personnel lift at ____________________________________(location) for ________________ _______________________________________________________(task requiring the lift). This meeting was attended by the undersigned: Construction Manager: _________________________________________________________ Rigging Superintendent: ________________________________________________________ Operator: ____________________________________________________________________ Signal person: ________________________________________________________________ Person(s) to be lifted: __________________________________________________________ __________________________________________________________ Others: ______________________________________________________________________ ____________________________________________________________________________

Date:__________________ Time: _______________ Project #: _________________ Based upon the evaluation of alternate methods, FLUOR ARABIA. has determined that it is necessary to us a personnel hoisting platform for the task described above. The evaluation, a formal lift plan, and the record of a pre-lift meeting have been provided. Authorization for the use of the Suspended Personnel Hoisting Platform is hereby granted provided that the Construction Manager ensures that the lift plan and all Federal, State, local, and client requirements are met. Project Director:___________________________________________________


DBN-F23

Justification for Use of Suspended Personnel Hoisting Platform

® JUSTIFICATION FOR USE OF SUSPENDED PERSONNEL HOISTING PLATFORM DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F23

9905-02-000.doc 12/8/2004 1

Justification for the use of a Suspended Personnel Hoisting Platform

Prior to using a suspended personnel hoisting platform, FLUOR ARABIA requires that all other methods be evaluated. If an alternated method is available and feasible, without regard to time and/or costs, then that method shall be used. If no other method is available and feasible, then a lifting plan must be developed and submitted (along with this evaluation) to the Project Director for authorization of the use of the suspended personnel hoisting platform. Evaluate each of the methods listed below. If the method cannot be used, explain why: Ladders: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Scaffolds: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Boom Lift(s): ________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________ Vertical (Scissor) Lift(s): ________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________


DBN-F24

Equipment Operator License Record

® EQUIPMENT OPERATOR LICENSE RECORD


DBN-F24

9905-02-000.doc 12/8/2004 1

Name: Number:

Badge number:

Local address: Local phone number:

Permanent address: Permanent phone number:

Sex: M F Birthdate:

Hair Color Eye Color Height

Weight

Date of last physical exam: Wear prescription glasses: Yes No

Equipment License Record Card Number Type of equipment Capacity Name/Title of Licensing

Official Expiration

Date

Comments:

I have personally provided instruction and the above named operator has displayed a thorough knowledge of the operation and safety procedures to be followed when operating the aforementioned equipment. Competent Person Name Date:

Witness’ name

Competent Person’s Signature Witness’ signature


DBN-F25

PPE Training Record

® PPE TRAINING RECORD DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F25

9905-02-000.doc 12/8/2004 1

Project Name:

Project Location:

Project No.:

Type of PPE Covered:

Date Of Training:

EMPLOYEES TRAINED

Certified By: Title:


DBN-F26

Medical Questionnaire for Respirator Use

® MEDICAL QUESTIONAIRE FOR RESPIRATOR USE


DBN-F26

HSE 12/8/2004

1

Have you ever worn a respirator before? Yes No When? ______________ What type? SCBA Half Face Dust Full Face Air Line If Yes, describe any apparent difficulties noted with the use of the respirator:_________________________

_______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ Have you had or do you now have any of the following? 1 Lung Disease Yes No 2. Persistent Cough Yes No 3. Heart trouble Yes No 4. Shortness of breath Yes No 5. History of fainting or seizures Yes No 6. High blood pressure Yes No 7. Diabetes Yes No 8. Fear of tight or enclosed spaces Yes No 9. Sensation of smothering Yes No 10. Heat exhaustion or heat stroke Yes No 11. Ruptured ear drums Yes No 12. Defective vision/blurred vision Yes No 13. Defective hearing Yes No 14. Contact lenses or glasses Yes No 15. Other conditions that might interfere with respirator use or result in limited work ability? Yes No 16. Are you taking any medications? Yes No If Yes, what is the dosage and how many per day? ________________________ * Please explain any and all “YES” answers; __________________________________________________

______________________________________________________________________________________ ______________________________________________________________________________________ I understand that failure to advise my employer of a medical condition may result in harm to me during my respirator use. Employee Signature:________________________________ Witness:__________________________

Name: ____________________________________ Social Security #: ________ - _______ - _________

Project Name: ______________________________ Project #: __________________________________

Date: _______________ Age: ________________ Height: _____________ Weight: _____________


DBN-F27 * Reserved - Not Used


DBN-F28

Respirator Fit Test Card

® RESPIRATOR FIT TEST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F28

HSE 12/8/2004 1

Employee Name:_______________________________________ Date:__________________ (Last, First, MI)

Craft or job title: ______________________ BADGE #:_______________

Project name: ________________________________ Project #: ____________________________

I received basic respirator training consisting of the following elements:

° The reasons for requiring respiratory protection.

° The nature, extent, and effects of respiratory hazards to which I may be exposed.

° An explanation of why engineering controls are not being applied or are not adequate and of what effort is

being made to reduce or eliminate the need for respirators.

° An explanation of why a particular type of respirator has been selected for a specific respiratory hazard.

° An explanation of the operation, and the capabilities and limitations, of the respirator selected.

° Instruction in inspecting, donning, checking the fit of, and wearing the respirator.

° An opportunity to handle the respirator, learn how to don and wear it properly, check its seals, and wear it in

a safe atmosphere.

° An explanation of how to maintain and store the respirator.

° Instructions in how to recognize and cope with emergency situations.

° Instructions as needed for special respirator use.

° Regulations concerning respirator use.

I was also given the opportunity to wear the respirator described below in a test atmosphere in order to test the fit of the respirator.

Brand:______________________________________ Model:________________________ Size:________________

Half Mask Full Face Air Purifying PAPR

Escape Airline SCBA

Fit Test Results

Qualitative Parameter

Positive/Negative Pass Fail Isoamyl acetate Pass Fail

Irritant Smoke Pass Fail Saccharin solution Pass Fail

Quantitative Fit Factor:_______________ Pass Fail

Person administering test: __________________________________________________________ Date:________________

Employee acknowledgement of training and fit test: ___________________________________________________________Date:________________


DBN-F29

HSE Committee Minutes

® HSE COMMITTEE MINUTES


DBN-F29

9905-02-000.doc 12/8/2004 1

Project Name:

Description of Project:

MOM-

Written By:

Date of Meeting:

Date of Report:

Page 1 of

Purpose of Meeting:

Location of Meeting:

Job No.:

Attended By: Distribution: ATTENDEES +

Item Discussion Action By Date Needed


DBN-F30

Job Hazard Analysis

® JOB HAZARD ANALYSIS


DBN-F30

9905-02-000.doc 12/8/2004 1

Date Prepared/Revised: Strike out as appropriate JHA No.

Permits Required: ¨ YES ¨ NO Date Issued:

Prepared By (Names of Team Members):

Authorized By: (Supervisor) Name: Signature:

Job Description/Location: Isolation Required: ¨ YES ¨ NO

Specify:

TEAM MEMBERS UNDERTAKING THE WORK

We have been instructed in this JHA Procedure and understand that failure to comply with the instructions may lead to disciplinary action

Surname: Signature: Date:




DBN-F30

9905-02-000.doc 12/8/2004 2


SEQUENCE OF BASIC JOB STEPS HAZARDS CONTROLS/RECOMMENDED SAFE WORK PROCEDURE

Break the job down into steps. Each of the steps should

accomplish some major task and be logical.

Identify the hazards associated with each step. Examine each

hazard to find possibilities that could lead to an incident

Using the first two columns as a guide, decide what actions are

necessary to eliminate then control the hazards that could lead

to an incident.



DBN-F30

9905-02-000.doc 12/8/2004 3


DBN-F31

Safety Task Assignment

® SAFETY TASK ASSIGNMENT

DBN-F31 DBN – 1 Turnaround

Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

AREA__________ FOREMAN_____________________________ DATE_____________ BEGINNING TIME__________________ EXPIRATION TIME_________________________ DESCRIPTION OF WORK__________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________ NAME OF ATTENDANT(if required)_______________________________________NAME OF FIRE WATCH(if required)___________________________________________________________

A. Safety Response Assembly Point: H. Tools, Material & Equipment Required: ________________________________________ Primary:_________________________________________________________________ ___________________________________ ________________________________________ Secondary_____________________________________________________________ ___________________________________ ________________________________________ Wind Direction_________________________________________________________ ___________________________________ ________________________________________ B. Atmosphere Monitoring Required Yes No N/A ___________________________________ ________________________________________ Comb. Gas/Flamm. Vapor Test Reading_____________ ___________________________________ ________________________________________ Oxygen Concentration Reading_____________ I. Potential Hazards _____________________________________________________________ Hazardous/Toxic Gas Test Reading_____________ ______________________________________________________________________________ C. Safety Checklist Requirements - (see attached checklist for items checked below) _____________________________________________________________________________ Access Yes No _____________________________________________________________________________ Electrical Yes No J. Action Taken to Eliminate Hazards ______________________________________________ Excavation Yes No ______________________________________________________________________________ Hazards (body) Yes No ______________________________________________________________________________ Permits Yes No ______________________________________________________________________________ Hazards (environmental) Yes No K. Other Special Precautions _____________________________________________________ Equipment/Lifting Yes No ______________________________________________________________________________ Overhead Work Yes No ______________________________________________________________________________ Process/Equipment Yes No L. Work Crew Sign - Off _______________________________________ Tools Yes No _____________________________________ _______________________________________ Personal Protective Equipment Yes No _____________________________________ _______________________________________ Stand-By Person Yes No _____________________________________ _______________________________________ Welding/Burning Yes No _____________________________________ _______________________________________ Hazard Yes No _____________________________________ _______________________________________ G. Permits Required Foreman’s Signature _ ______________________________________ Hot Work Yes__________ No_____________ Lockout/Tagout Yes__________ No_____________ Excavation Yes__________ No_____________ Confined Space Yes__________ No_____________ Other(specify) __________________________________________________ _________________________________________________

Note: This STA is valid only for the activity, date and time specified. This STA shall be posted at the work site during the work activity. If the terms noted change, work must be stopped and the STA re-issued. Fire and/or Emergency Alarm automatically invalidate the permit. When the work is complete or the STA expires, return the STA to the HSE office marked complete.

Note: Check off and discuss all pertinent items for the attached checklist that apply to the scope of work being performed. The items that are checked should be discussed with the crew who is performing the work activity to ensure that they understand the safety requirements necessary to safely perform this task.

® SAFETY TASK ASSIGNMENT

DBN-F31 DBN – 1 Turnaround

Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 2

ACCESS ____ Scaffold (properly inspected) ____ Scaffold(complete handrails, toeboards, solidly decked) ____ Ladder (Condition, secured, placement) ____ Walkways ELECTRICAL ____ Lockout/tagged (Try start/stop Switch) ____ Disconnected (if required) ____ Properly Grounded ____ Good Condition EXCAVATION ____ Properly Shored/Sloped ____ Escape Ladder Provided ____ Competent Person on Site ____ Entry Permit Required ____ Soil Typed/Documented ____ Daily Inspection (Documented) ____ Barricaded Properly EMERGENCY DEPT. LOCATIONS ____ Fire Monitors located at _______________________ ____ Fire Extinguishers located at _______________________ ____ Safety Shower located at _______________________ HAZARDS (body) ____ Fall Potential ____ Pinch Points ____ Electrical Shock ____ Housekeeping ____ Slip/Trip (Cords, Pipe, etc.) ____ Flying Particles ____ Thermal Burns ____ Sharp Objects PERMITS ____ Signed at Jobsite ____ Proper Permit Displayed ____ All Conditions Met ____ Properly Signed

HAZARDS (environmental) ____ Airborne Particulates (Fumes, Mists) ____ Heat Stress (Hot/Cold Surfaces) ____ Materials ____ Adequate Lighting ____ Noise ____ Access/Egress Radiation From: ____ Radiography ____ Other Source EQUIPMENT/LIFTING ____ Operator Certified/Licensed ____ Good Equipment Condition ____ Backup Warning Device ____ Forklift ____ Manlift ____ Boom Truck ____ Crane ____ Load Charts ____ Position ____ Proper Riggings ____ Chainfall ____ Lashing Required ____ Personnel Basket Permit OVERHEAD WORK ____ Barricades/Tags ____ Signs ____ Hole Cover ____ Handrail ____ Grating Secured ____ Fall Protection In Place ____ Life Lines Properly Installed PROCESS/EQUIPMENT ____ Valves Blocked In ____ Tags Hung ____ Equipment Cleared ____ Blinds Installed and Tagged ____ Blind List ____ Hazcom Summary TOOLS ____ Current Inspection ____ Proper Tools ____ Good Tools Condition ____ Tool Use Instructions

PERSONAL PROTECTIVE EQUIPMENT ____ Hardhat ____ Safety Glasses ____ Mono Goggles ____ Ear Protection ____ Face Shield/Burning Goggle ____ Proper Type Respirator ____ Fresh Air ____ Gloves ____ Safety-Toe Shoes ____ Metatarsal Guards ____ Rubber Boots ____ Other Safety Footwear ____ Fire Retardant Clothing ____ Slicker Suit ____ Acid Suit ____ Safety Harness/Lanyard ____ Other (List) _______________________ STAND-BY PERSON ____ Confined Space Entry (Hole-Watch) ____ Fresh Air Work (Bottle Watch) ____ Fire Watch ____ Electrical ____ Traffic Flagman WELDING ____ Flashburns ____ Combustibles ____ Spark Containment ____ Shields ____ Grounding ____ Water Hose ____ Fire Extinguishers (Inspected/Near by) ____ Fire Blanket ____ Cylinders Secured ____ Cylinder Caps in Place HAZARDS ____ Hygiene ____ Chemical Burns ____ Skin/Eyes ____ Flammable ____ Inhalation ____ Skin Contamination


DBN-F32

Daily Tool-Box Meeting Report

® DAILY TOOL-BOX MEETING REPORT


DBN-F32

9905-02-000.doc 12/8/2004 1

Project name: YEP DBN-1 Project number:___________________ Craft: Foreman conducting the meeting: Location of the meeting: Date of meeting: ___________________ Time of Meeting:________________ Topics discussed: Environment, Health and/or Safety questions, concerns or recommendations expressed during the meeting: Action taken regarding the issues listed above: All personnel in attendance shall sign this report. (Names and badge numbers of those present at the meeting) Route the report to the following individuals for review and signature: GeneralForeman: _____________________________________________________________________ Superintendent: ________________________________________________________________________ Construction HSE Manager: ______________________________________________________________


DBN-F33

Chemical Inventory

® CHEMICAL INVENTORY


DBN-F33

9905-02-000.doc 12/8/2004 1

Trade Name Chemical Name Manufacturer’s Name Quantity on Hand Storage Location Use/Application

Date Compiled: _______________________________________ Signature: ______________________________________________________________ Project Name: ________________________________________ Project Number: ___________________________________________________________


DBN-F34

Formal Near Miss/Incident Investigation Report

® FORMAL NEAR MISS/INCIDENT INVESTIGATION REPORT

DBN – 1 Turnaround

Yanpet, Yanbu Saudi Arabia DBN-F34

9905-02-000.doc 12/8/2004 1

The HSE Professional shall complete page one 1. Indicate the type of incident:

Near miss First-aid

Non-recordable w/c Recordable

Restricted work day case (estimate the number of restricted days)___________________

Lost work day case (estimate the number of lost days)_______________________

Property damage < $5,000 Property damage > $5,000

Vehicle accident Fire

2. Number of employees involved in the incident: ________________________________________

3. List the name, sex and age of the employees involved:

NAME AGE SEX NAME AGE SEX

4. List the names of witnesses:

NAME NAME




9905-02-000.doc 12/8/2004 2

Formal Investigation Report Date: _______________________ Location: ____________________

Employee Statement Project No.: __________________ Project Name: ________________

Describe the incident in your own words (state what happened, how it happened, why it happened, and how this incident could have been prevented): __________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________________________

________________________________________________

My statement in this report is true and correct to the best of my knowledge and memory. ___________________________________________ Badge # __________ Employee’s printed name ___________________________________________ Date: _____________ Signature ___________________________________________ Date: _____________ Witness of signature




9905-02-000.doc 12/8/2004 3

Formal Investigation Report Date:______________________ Location:___________________

Foreman’s Statement (Page 1 of 2) Project Number:_____________ Project Name:_______________

What was your location at the time of the incident?______________________________________________ _______________________________________________________________________________________

Was a JPSA completed for this task? Yes No

Did the employee participate in the JPSA? Yes No

What did the employee do or fail to do that contributed to this incident (explain in detail)? ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

What was the employee’s assigned occupation at the time of the incident? ___________________________

What is the employee’s experience in this occupation? ___________________________________________

Is this his/her regular occupation? Yes No

If no, what is the employee’s regular occupation and what is his/her experience?

Regular Occupation_________________________ Years of Experience____________________________

What did someone else do or fail to do that contributed to this incident (explain in detail)? ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Did any adverse conditions (weather, extended work shifts, defective tools/equipment or missing protective measures) contribute to this incident? Yes No

(If Yes, explain.)

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Do you think that this incident could have been prevented? Yes No (If yes explain how)

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________




9905-02-000.doc 12/8/2004 4

Describe the incident in your own words (state how the incident happened, what happened, why it happened; use the space on the back for a diagram):

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Foreman’s Recommended Corrective Action:

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

My statement in this report is true and correct to the best of my knowledge and memory.

Signature: ____________________________________________ Date: _____________________

Foreman’s printed name: _____________________________________

General Foreman’s/Superintendent’s Recommendations for Corrective Action: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

_________________________________________ _____________________________________________

GF’s Signature Date Supt.’s Signature Date

Corrective Action Taken and Date Implemented:

_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________

Followup/verification of Corrective Action:

___________________________________________ _______________________________________

Safety Department Representative Date




9905-02-000.doc 12/8/2004 5

Formal Investigation Report Date: _____________________ Location: __________________

Witness Statement Project #: __________________ Project Name: ______________ Describe the incident in your own words (state what happened, how it happened, why it happened, and how it could have been prevented): _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ My statement in this report is true and correct to the best of my knowledge and memory. _______________________________________________ Date: _______________________ Signature _______________________________________________ Date: _______________________ Witness of signature




9905-02-000.doc 12/8/2004 6

Formal Investigation Report Date: ______________________ Location: ___________________ Complete this page for Vehicle Accidents Project No.: _________________ Project Name: ________________ 1. Was the employee authorized to drive at the time of the accident? Yes No 2. If yes, by whom? __________________________________________________________________ 3. Complete the following information: ABB Lummus Global Inc Third Party Type of vehicle ______________________ ____________________ Vehicle license number ______________________ ____________________ Name of driver ______________________ ____________________ Employee SS no. & employer ______________________ ____________________ Personal address ______________________ ____________________ Personal phone no. ______________________ ____________________ Driver license no. & state ______________________ ____________________ Type of license ______________________ ____________________ Date of expiration ______________________ ____________________ Damages done (details) ______________________ ____________________ ______________________ ____________________ ______________________ ____________________ 4. Was a police report filed for this accident? Yes No 5. Was a citation issued? Yes No 6. If Yes, who received it? _____________________________________________________________ 7. What was the citation for? ___________________________________________________________ _________________________________________________________________________________ For Subcontractor Employees, non-employees and third party vehicle accidents: Employer’s name: ________________________________________________________________________ Employer’s phone number: ________________________________________________________________ Employer’s address ______________________________________________________________________ Insurance company name: _________________________________________________________________ Policy number: __________________________________________________________________________ Insurance Co. address: ____________________________________________________________________ Insurance Co. phone number: ______________________________________________________________

Supervisor’s signature: ___________________________________Date: ______________________

Provide a diagram of the accident: (attach diagram on additional pages)

Formal Investigation Report Date: _________________ Location: ______________ For Environmental or chemical hazard incidents Project No: ____________ Project Name: __________ Product or chemical spilled: ________________________________________________________________

Estimated amount spilled or discharged: ______________________________________________________

Were ABB Lummus Global Inc. employees present? Yes No

Was exposure monitoring warranted for this incident? Yes No (If No, explain) ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Was exposure measured for ABB Lummus Global Inc. employees? Yes No What instruments/methods were used to measure exposure? ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Note: Attach calibration records, monitoring results, etc.

Attach a diagram (on separate sheets) of personnel locations, the release site, and the monitoring locations.

Were the authorities notified of the incident? Yes No N/A

When was notification made? (Date and Time)_________________________________________________




9905-02-000.doc 12/8/2004 7

Who was notified? (Persons Name, Title, Agency) ______________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________

What instructions did the agency provide upon notification? ______________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ Who made the notification? ________________________________________________________________ Corrective action planned and/or taken: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ _______________________________________________________________________________________

Supervisor’s signature: _________________________________________ Date: ________________




9905-02-000.doc 12/8/2004 8

Formal Investigation Report Date: ______________________ Location: __________________ For Utililty damage Project No.: ___________________

Project Name: _________________

Name of utility company/telephone: _______________________________________________________________________________________ Building site, Bldg. no., and grid location (if known) _______________________________________________________________________________________ Utility damaged (specify type) _______________________________________________________________________________________ Who caused the damage? ______________________________________________________________________________________________________________________________________________________________________________ Damage occurred whicle excavating: By hand By machine Other (describe) __________________________________ _______________________________________________________________________________________ Supervisor’s signature: _____________________________________ Date: ________________




9905-02-000.doc 12/8/2004 9

Formal Investigation Report Date:________________________ Location:_____________________ HSE Professional’s Summary Project No.____________________ Project Name:_________________ Are there written rules or regulations concerning this job? Yes No

Were these rules or regulations being followed? Yes No

Was the employee instructed in these rules or regulations? Yes (attach document.) No

Was a permit required for this job? Yes (attach a copy) No What was the root cause of this incident? _____________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________

What were the contributing causes of this incident? _____________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________

What corrective action(s) do you recommend to prevent a recurrence of this incident? __________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________

HSE Professional’s Signature: _____________________________________ Date: ________________

Construction Manager’s Concurrence:

Action Taken/Planned: Assigned To: Target Completion Date:

Construction Manager’s Signature: __________________________________ Date: __________

Forward a copy of the completed investigation form to the home office HSE Department for the preparation of a Summary of Lessons Learned for distribution throughout the organization.


DBN-F40

Daily Safety Report

® DAILY SAFETY REPORT


DBN-F40

9905-02-000.doc 12/8/2004 1

DATE PAGE OF

DAILY HSE REPORT Project Name:

STA No. Project No.

Area: SAT SUN MON TUE WED THU FRI

Work Performed:

Safety Inspection Items ( Corrective Action ) Interface Problems

Comments/Recommendations

EH&S Professional’s Signature: _________________________ Construction Manager’s signature: ________ File in project EH&S files


DBN-F41

Green Lift Checklist

® GREEN LIFT CHECKLIST DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F41

9905-02-000.dco 12/8/2004 1

PROJECT DATE DESCRIPTION OF LOAD CRANE MODEL WEIGHT OF LOAD BOOM LENGTH WEIGHT OF RIGGING AN D CRANE BLOCK

JIB LENGTH

TOTAL ERECTION LOAD MAXIMUM RADIUS OF LIFT PERCENT CRANE CAPACITY AT MAXIMUM LIFT RADIUS

CRANE CAPACITY AT MAXIMUM RADIUS OF LIFT RADIUS

RIGGING GEAR REQUIRED – SIZE AND CAPACITY

Shackles Spreader Slings Tailing Hook-Up

LOAD AND LIFTING LUG

1. Has the weight of the load been documented or accurately calculated?

2. Are all items that will be lifted with the equipment included in the weight?

3. Have the lifting lugs that will be used to lift the load been designed for that purpose?

4. Will the lifting lugs be used with the correct shackle?

5. Will the lifting lugs be loaded only in the strong direction(s) of the lug?

6. Are the lifting lugs visibly free of defects or damage?

7. Has the load been checked for loose or unsecured items that might fall off during the lift?

8. For a one-crane lift, will the crane hook be over the center of gravity at the initial pick?

RIGGING GEAR

9. Have the capacities of the slings and shackles been checked for the load?

10. Have the slings and shackles been visually inspected for defects or damage?

11. Have the sling angles been considered when checking the capacity of the slings and shackles?

12. Has the center of gravity been considered when checking the capacities of the sling and shackles?

CRANE

13. For a crane that HAS a load-indicating device with overload cut -off, is the total load less than 90% of the allowable crane capacity?

14. For a crane that does NOT have a load indicating device with overload cut -off, is the total load less than 80% of the allowable crane capacity?

15. Has the crane received a daily inspection and operational check by the operator?

16. Is the crane set up according to the manufacturer’s specifications?

17. Do approved crane mats support the crane? 18. If the lift involves more than one crane, can it be made without any possibility of one of the cranes being overloaded?

19. Has the soil been inspected and determined to be adequate?

LIFT

20. Has the radius of the lift been checked by a tape measure? 21. Is the lift area free of operating process equipment, piping, or live electrical lines?

22. Has the area under the lift been barricaded or everyone warned to stay away?

23. Is the wind less than 20 miles per hour?

24. If there is a possibility for boom or equipment interference, has a rigging layout or clearance study been made?

25. Has one person been designated “Signalman-in-Charge” for the lift?

APPROVALS

FIELD RIGGER RESPONSIBLE FOR LIFT

DATE RIGGING SUPERINTENDENT (IF REQUIRED) DATE

NOTE!!! All questions should be answered yes, no , or n/a (not applicable). The Rigging Superintendent must approve any checklist item answered “no”.


DBN-F42

Lift Classifications

® LIFT CLASSIFICATIONS


DBN-F42

9905-02-000.doc 12/8/2004 1

5.1 NON-ENGINEERED LIFTS 5.2 ENGINEERED LIFTS:

LIFT CATEGORY “A” Lifts “B” Lifts “C” Lifts

VERTICAL VESSELS Less than 30T Less than 8 feet diameter

30T to 100T Greater than 8 feet diameter

100T to 600T Greater than 600T

OTHER EQUIPMENT & STRUCTURES Less than 60T Greater than 60T 100T to 600T Greater than 600T

CHART CAPACITY Up to 80% crane capacity without (LID)* Up to 90% crane capacity with (LID)*

More than 80% crane capacity w/o load indicating device (LID)* More than 90% crane capacity w/ load indicating device(LID)*

TRANSPORTATION Less than 60T Greater than 60T PERMITS AND/OR DRAWINGS REQUIRED

None Green Lift Checklist Required

Engineered Design and Drawing Required

STIPULATIONS Less than 5T Less than 50% crane capacity

Greater than 5T Greater than 50% crane capacity Over energized electrical lines Lifted by 2 or more cranes

Over 20 tons and in a structure or over operating processes Non-ferrous material Lifts by 2 cranes in which the load can be transferred between the cranes

RESPONSIBILITY

LIFT LUG DESIGN Fluor Rigging department must approve or design all lift lugs for loads over 10 tons as stipulated in this practice. DESIGN OR LAYOUT: (INCLUDES LAYOUT, GEAR, AND CONFIGURATION)

Qualified Field Rigger Qualified Field Rigger Rigging Supervisor, Fluor Rigging Engineer or Subcontractor

Fluor Rigging Engineer or Subcontractor

Fluor Rigging Engineer or Subcontractor

CHECKER AND REVIEWER: (INCLUDES CHECKING DESIGN OR LAYOUT AND LIFT SET UP)

Qualified Field Rigger Qualified Field Rigger Fluor Rigging Engineer

Checker: Fluor Rigging Engineer Reviewer: Fluor Rigging Engineer

Checker: Fluor Rigging Engineer Reviewers: Two Fluor lead Rigging Engineers, Optional 3rd party Consultant

REVIEWER: (FINAL RESPONSIBILITY)

Qualified Field Rigger Jobsite Rigging Supervisor

Jobsite Rigging Supervisor Fluor lead Rigging Engineer and Site Manager

Rigging Manager, Site Manager, Project Manager


DBN-F43

Safety Violation Notification Form

® SAFETY VIOLATION NOTIFICATION FORM


DBN-F43

9905-02-000.doc 12/8/2004 1

Job No.: Date:

Location: Craft Title:

Employee: Date of Hire:

Description of infraction and suggested corrective actions:

Construction HSE Manager:

Date:

Has the employee been warned about this action before? Yes No If "Yes", how? Written Reprimand Oral Warning:

By Whom? Date:

My signature hereupon does not necessarily signify my agreement with the above, but attests that I have read and understood the seriousness of this report. A repetition of this action or other acts of similar nature may result in a more serious corrective action and/or termination of employment.

Employee Signature: Date: Employee Comments:

Const. Manager: Date:


DBN-F44

Rigging Data Sheet

® RIGGING DATA SHEET DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F44

9905-02-000.doc 12/8/2004 1


DBN-F45 Transportation Drawing

® TRANSPORTATION DRAWING DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

DBN-F45

9905-02-000.doc 12/8/2004 1

® HSE PRACTICE INDEX BY NUMBER DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

PROJECT PRACTICES

Practice No. Title

1 Roles & Responsibilities 2 Subcontractors Responsibilities 3 Work Area Hazard Assessment 4 Safety Education & Training 5 Safety Task Assignment 6 Emergency & Contingency Planning 7 Hazard Communication 8 Safety Violation Notification System 9 Personal Protective Equipment 10 Housekeeping 11 Sanitation & Potable Water 12 Illumination 13 Materials Storage & Handling 14 Barricading 15 Ladders 16 Scaffold Safety 17 Powered Aerial Work Platforms 18 Forklifts & Powered Industrial Trucks 19 Fall Protection 20 Steel Erection 21 Hand Tools 22 Power Tools 23 Powdered Actuated Tools 24 Electrical Safety 25 Excavation & Trenching 26 Confined Space Entry 27 Rope Chain & Sling Inspection 28 Mobile, Overhead & Gantry Cranes 29 Rigging / Lifting Plans 30 Personnel Hoisting 31 Welding, Cutting & Heating 32 Fire Protection & Prevention 33 Heat Stress Prevention 34 Operator Licensing 35 Abrasive Blasting 36 Respiratory Protection 37 Control of Hazardous Energy 38 Site Safety Inspections 39 Safety Committee Meeting/Walkthrough 40 Site specific Rigging Inspection 41 Incident Investigation 42 Flagman & Traffic Vest

® HSE PRACTICE INDEX BY ALPHA DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

PROJECT PRACTICES

Practice No. Title

35 Abrasive Blasting 14 Barricading 26 Confined Space Entry 37 Control of Hazardous Energy 24 Electrical Safety 6 Emergency & Contingency Planning 25 Excavation & Trenching 19 Fall Protection 32 Fire Protection & Prevention 42 Flagman & Traffic Vest 18 Forklifts & Powered Industrial Trucks 21 Hand Tools 7 Hazard Communication 33 Heat Stress Prevention 10 Housekeeping 12 Illumination 41 Incident Investigation 15 Ladders 13 Materials Storage & Handling 28 Mobile, Overhead & Gantry Cranes 34 Operator Licensing 9 Personal Protective Equipment 30 Personnel Hoisting 23 Powdered Actuated Tools 22 Power Tools 17 Powered Aerial Work Platforms 36 Respiratory Protection 29 Rigging / Lifting Plans 1 Roles & Responsibilities 27 Rope Chain & Sling Inspection 39 Safety Committee Meeting/Walkthrough 4 Safety Education & Training 5 Safety Task Assignment 8 Safety Violation Notification System 11 Sanitation & Potable Water 16 Scaffold Safety 38 Site Safety Inspections 40 Site specific Rigging Inspection 20 Steel Erection 2 Subcontractors Responsibilities 31 Welding, Cutting & Heating 3 Work Area Hazard Assessment

® HSE PRACTICE INDEX BY NUMBER DBN – 1 Turnaround Yanpet, Yanbu Saudi Arabia

9905-02-000.doc 12/8/2004 1

PROJECT FORMS

Form No. Title DBN-F8 Blue Card DBN-F9 Barricade Tag DBN-F10 Ladder Inspection Checklist DBN-F11 Powered Aerial Work Platform Checklist DBN-F12 Forklift Inspection Checklist DBN-F13 Harness Inspection Checklist DBN-F14 Assured Equipment Grounding Inspection Checklist DBN-F15 Excavation Permit DBN-F16 Daily Excavation Inspection Checklist DBN-F17 Rope, Sling & Shackle Inspection Checklist DBN-F18 Monthly Crane Inspection Checklist DBN-F19 Daily Crane Inspection Checklist DBN-F20 Critical Lift Permit DBN-F21 Rigging & Lift Plan DBN-F22 Authorization for Use Of Suspended Personnel Hoisting Platform DBN-F23 Justification for Use of Suspended Personnel Hoisting Platform DBN-F24 Equipment Operator License Record DBN-F25 PPE Training Record DBN-F26 Medical Questionnaire for Respirator Use DBN-F27 Respirator Fit Test DBN-F29 HSE Committee Minutes DBN-F30 Job Hazard Analysis DBN-F31 Safety Task Assignment DBN-F32 Daily Tool-Box Meeting Report DBN-F33 Chemical Inventory DBN-F34 Formal Near Miss/Incident Investigation Report DBN-F40 Daily Safety Report DBN-F41 Green Lift Checklist DBN-F42 Lift Classifications DBN-F43 Safety Violation Notification Form DBN-F44 Rigging Data Sheet DBN-F45 Transportation Drawing


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DBN-1 HSE TA Site Safety Plan_0