February 1993 - Construction Safety Manual: Table of Contents Page 1

SAUDI ARAMCO CONSTRUCTION SAFETY MANUAL

PREFACE Dhahran, Saudi Arabia

February, 1993

The purpose of the Saudi Aramco Construction Safety Manual (CSM) is to prevent injury, loss of life, and damage to assets. This is the fourth revision of the CSM. Since its 1974 introduction, the Construction Safety Manual has provided safety criteria for all construction work performed by Saudi Aramco and its contractors.

Many of the requirements in this manual detail the need for Saudi Aramco services or equipment. Where references indicate that certain equipment (fall protection, safety shoes, etc.) should be provided or services rendered (bio-monitoring, etc.), the intent is that contractors must provide equivalent equipment or services (as approved by Saudi Aramco) from their own resources.

The construction industry functions in a dynamically changing work environment in which updating of equipment and standards is a continuous process resulting from changes in operating variables, regulatory requirements, and safety practices. Although this manual has been updated to reflect the latest Saudi Aramco and construction industry practices, as time goes on there may be a need to consider new procedures, standards, or operating conditions. Such new developments, including potential conflicts with existing provisions, should be referred to the Loss Prevention Department for resolution. The Loss Prevention Department will issue interim revisions or updates where appropriate.

Good loss prevention is an integral part of good project management. For our projects and maintenance programs to proceed safely, all Saudi Aramco and contractor personnel involved in construction activities, whether management or line employees, need to understand and follow the provisions in this Manual. Only with the active commitment of everyone can we ensure that Saudi Aramco maintains the safest possible work environment.

Senior Vice President, Engineering and Project Management

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I. Administration.................................................................................30

1.0 SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM......................................31 1.1 Loss Prevention Policy Implementation.................................................................31

1.1.1 Compliance With Construction Requirements .......................................31 1.1.2 Operating Standards and Instructions.....................................................31 1.1.3 Personal Protection.....................................................................................31 1.1.4 Inspection ....................................................................................................31 1.1.5 Education and Training..............................................................................32 1.1.6 Motivation and Recognition .....................................................................32 1.1.7 Job Placement ..............................................................................................32 1.1.8 Response to Accidental Occurrences......................................................32 1.1.9 Contractor Safety ........................................................................................32 1.1.10 Off-The-Job Safety......................................................................................32 1.1.11 Traffic Safety................................................................................................32 1.1.12 Accountability.............................................................................................33 1.1.13 Compliance Reviews ...................................................................................33

1.2 Saudi Aramco Loss Preve ntion Requirements For Contractors.......................33 1.2.1 Non-Compliance..........................................................................................33 1.2.2 Assistance....................................................................................................33 1.2.3 Standards and Instructions .......................................................................34

1.3 Contractor's Loss Prevention Program.................................................................34 1.3.1 Written Program..........................................................................................34 1.3.2 Hazard Identification Plan..........................................................................35 1.3.3 Safety Supervisor........................................................................................35 1.3.4 Safety Discussion .......................................................................................35

2.0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT SERVICES ....................................36 2.1 Loss Prevention Program.........................................................................................36 2.2 Program Management Services ..............................................................................37 2.3 Program Maintenance Services ..............................................................................38

3.0 ACCIDENT INVESTIGATION, ANALYSIS AND REPORTING..............................................39 3.1 Reports Required by Saudi Aramco........................................................................39 3.2 Accident Investigation ...............................................................................................40

3.2.1 Responsibilities for Investigation.............................................................40 3.2.1.1 Supervisor/Safety Representative............................................40 3.2.1.2 Project Manager..........................................................................40

3.3 Cases to be Investigated.............................................................................................41 3.4 Accident Investigation Guidelines...........................................................................41 3.5 Accident Analysis ....................................................................................................41

3.5.1 Classification................................................................................................41

4.0 RESPONSIBILITIES FOR SAFETY...............................................................................................45 4.1 Contractor Senior Management..............................................................................45 4.2 Design Engineer.........................................................................................................45 4.3 Contractor's Safety Officer......................................................................................45 4.4 Construction Manager/Superintendent.................................................................46 4.5 Site Safety Supervisor ...............................................................................................47 4.6 Equipment Manager/Supervisor ..............................................................................47 4.7 Engineer/Supervisor..................................................................................................47

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4.8 Foreman........................................................................................................................47 4.9 Worker.........................................................................................................................48

5.0 EMERGENCY PROCEDURES .........................................................................................................49 5.1 Action to be Taken......................................................................................................49 5.2 Contact After Office Hours ......................................................................................49 5.3 Help in an Emergency................................................................................................49

6.0 SAFETY TRAINING...........................................................................................................................51 6.1 Safety Training for Supervisors..............................................................................51 6.2 Safety Training for Workmen.................................................................................51

6.2.1 Integrated Practices ....................................................................................51 6.2.2 Specialized Training....................................................................................52 6.2.3 Use of Persuasion .......................................................................................52 6.2.4 Course Requirements..................................................................................52

6.3 Scope of Training .......................................................................................................53 6.3.1 Safety Training Topics For Supervisors ..................................................54 6.3.2 Induction Safety Topics For Workmen ...................................................55

7.0 SITE PLANNING AND HOUSEKEEPING.....................................................................................57 7.1 Initial Planning ...........................................................................................................57

7.1.1 Hazard Identification Plan..........................................................................57 7.1.2 Loss Prevention Program...........................................................................58 7.1.3 Protection of Employees and Equipment.................................................58 7.1.4 Transportation.............................................................................................58 7.1.5 Lifting Equipment........................................................................................58 7.1.6 Demolition ....................................................................................................58 7.1.7 Excavations ..................................................................................................58 7.1.8 Scaffolding ...................................................................................................58

7.2 Site Layout...................................................................................................................59 7.2.1 Site Accommodation...................................................................................59 7.2.2 Adequate Access Roads ...........................................................................59 7.2.3 Project Sign ..................................................................................................59 7.2.4 Safe Means of Access and Egress ...........................................................60 7.2.5 Parking Facilities..........................................................................................60 7.2.6 Drainage........................................................................................................60 7.2.7 Vehicle / Heavy Equipment Paths On Site Vs Pedestrian

Paths..............................................................................................................60 7.2.8 Sand...............................................................................................................60 7.2.9 Fire Prevention.............................................................................................60 7.2.10 Site Illumination...........................................................................................60

7.3 Storage Areas .............................................................................................................60 7.4 Welfare Facilities.......................................................................................................61 7.5 Good Housekeeping....................................................................................................61 7.6 Construction Sites and Materials Storage Yards ................................................62

8.0 FIRST AID ...........................................................................................................................................65 8.1 Provision of First Aid Facilities...............................................................................65 8.2 First Aid Attendants...................................................................................................66 8.3 First Aid Facilities At Work Site............................................................................67 8.4 Labor And Workmen Law.........................................................................................69

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9.0 PERSONAL PROTECTIVE EQUIPMENT.....................................................................................71 9.1 Head Protection...........................................................................................................72 9.2 Eye and Face Protection.............................................................................................72

9.2.1 Eye Protection from Impact........................................................................73 9.2.2 Eye Protection from Radiant Energies......................................................73 9.2.3 Face Protection............................................................................................73

9.3 Hand Protection ..........................................................................................................73 9.4 Foot Protection............................................................................................................73 9.5 Hearing Protection.....................................................................................................74

9.5.1 Ear Plugs.......................................................................................................74 9.5.2 Ear Muffs ......................................................................................................74

9.6 Fall Restraining/Arresting Devices .......................................................................74

10.0 BREATHING APPARATUS .........................................................................................................81 10.1 Selection of Equipment ..............................................................................................81

10.1.1 Requirements For Use................................................................................82 10.1.2 Misuse ..........................................................................................................82 10.1.3 Hazardous Substances ...............................................................................83 10.1.4 Contaminants ...............................................................................................83

10.2 Respiratory Protective Devices................................................................................83 10.2.1 Air Purifying Respirators ...........................................................................83

10.2.1.1 Gas Masks ....................................................................................83 10.2.1.2 Chemical Cartridge Respirators .................................................84 10.2.1.3 Particulate Filter Respirators (Dust Respirators)....................84

10.2.2 Supplied Air Respirators ............................................................................84 10.2.2.1 Air Line Respirators ....................................................................84 10.2.2.2 Abrasive Blasting Respirators ..................................................85 10.2.2.3 Air Supplied Suits .......................................................................85

10.2.3 Self Contained Breathing Apparatus (SCBA).........................................85 10.3 Training .......................................................................................................................86 10.4 Safety Precautions .....................................................................................................86

10.4.1 Air Compressors..........................................................................................86

11.0 FIRE PREVENTION.......................................................................................................................89 11.1 Before the Job Starts .................................................................................................89 11.2 Layout ...........................................................................................................................90 11.3 Equipment Protection.................................................................................................90 11.4 Control of Ignition Sources ......................................................................................91 11.5 Flammable Liquids 91

11.5.1 Storage..........................................................................................................91 11.5.2 Handling of Flammable Liquids.................................................................92 11.5.3 Ventilation ....................................................................................................92

11.6 Combustible Materials ..............................................................................................92 11.7 Housekeeping..............................................................................................................92 11.8 Emergency Equipment ...............................................................................................92

11.8.1 Water-Type Fire Extinguisher...................................................................93 11.8.2 Carbon Dioxide Type Extinguisher...........................................................93 11.8.3 Dry Chemical Type Extinguisher...............................................................93 11.8.4 Pressurized Water.......................................................................................93

11.9 Reporting a Fire..........................................................................................................94 11.10 End-of-Shift Checks...................................................................................................94

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12.0 RADIO COMMUNICATIONS .....................................................................................................96 12.1 Equipment.....................................................................................................................97

12.1.1 Remote Control Unit ...................................................................................97 12.2 Safe Operation ............................................................................................................97 12.3 Radio Phrases .............................................................................................................97 12.4 Phonetic Alphabet.......................................................................................................98 12.5 International Communications Union Agreement ...............................................99

12.5.1 Monitoring of Circuits ................................................................................100 12.5.2 Secrecy Act..................................................................................................100 12.5.3 Penalties........................................................................................................100

12.6 Message Priorities for Company Operations .......................................................100 12.7 Distress Messages .....................................................................................................102

12.7.1 MAYDAY.....................................................................................................102 12.7.2 Urgency Signal............................................................................................103 12.7.3 Priority Traffic ..............................................................................................104

13.0 TRANSPORTATION ......................................................................................................................105 13.1 Driver Requirements .................................................................................................105 13.2 Driver's Responsibilities ..........................................................................................105 13.3 Motor Vehicle Regulations: Saudi Arab Government and Saudi

Aramco.........................................................................................................................107 13.4 Vehicle Condition.......................................................................................................107 13.5 Driver Training ..........................................................................................................109 13.6 Enforcement of Safe Driving Practices ..................................................................109 13.7 Action Taken After a Saudi Aramco Motor Vehicle Accident...........................110

13.7.1 Emergencies .................................................................................................110 13.7.2 Remain at Scene...........................................................................................110

13.8 Passenger Seating and Seat Belts ..........................................................................111 13.9 Desert Driving ............................................................................................................111

13.9.1 Stay With Vehicle........................................................................................111 13.9.2 Sand Tires.....................................................................................................111

13.10 Vehicle Admittance to Restricted Areas................................................................112 13.11 Operation of Motor Vehicles Within Saudi Aramco Communities ..................112

13.11.1 Seat Belts ......................................................................................................112 13.11.2 Traffic Regulations......................................................................................112

14.0 AIRCRAFT OPERATION...............................................................................................................113 14.1 General Operating Responsibilities .......................................................................113

14.1.1 Captain/Pilot.................................................................................................113 14.1.2 Camp Supervisors .......................................................................................113

14.2 Passenger Briefing/Instructions, General (All Aircraft Types)......................114 14.3 Transportation of Dangerous Goods .......................................................................115 14.4 Hours of Operation for Single-Engine Helicopters .............................................115 14.5 General Precautions for Helicopters......................................................................115

14.5.1 Life Vests ......................................................................................................115

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II. General And Civil...........................................................................116

1.0 WORK PERMIT SYSTEM................................................................................................................117 1.1 Definitions ...................................................................................................................117

1.1.1 Restricted Areas ..........................................................................................117 1.1.2 Issuer (Operation Supervisors).................................................................118 1.1.3 Receiver (Authorized Craftsmen)..............................................................118 1.1.4 Work Permit..................................................................................................118

1.2 Issuance and Approval ...............................................................................................118 1.2.1 Power Distribution Department Clearances ............................................119

1.3 Precautions..................................................................................................................119 1.3.1 Checklist.......................................................................................................119 1.3.2 Clear Area.....................................................................................................119 1.3.3 Work Stoppage............................................................................................110

1.4 Handling of Issued Work Permit............................................................................119 1.5 Closing Out and Filing the Permit..........................................................................120 1.6 Certification ................................................................................................................120 1.7 12 Rules on Work Permit Procedure ....................................................................120 1.8 Hold Tags and Multiple Lockouts............................................................................120

2.0 EXCAVATIONS, TRENCHING AND SHORING.........................................................................125 2.1 Before Work Starts ...................................................................................................128 2.2 Work Permit...............................................................................................................128

2.2.1 Excavation near Saudi Telephone Cables................................................128 2.3 Underground Obstructions.......................................................................................129 2.4 General Precautions ..................................................................................................129

2.4.1 Shoring Protective Systems .......................................................................129 2.4.2 Personnel Protection...................................................................................129 2.4.3 Inspection.....................................................................................................130 2.4.4 Clearance ......................................................................................................130 2.4.5 Mechanical Excavator.................................................................................130 2.4.6 Walkways.....................................................................................................130

2.5 Access and Egress......................................................................................................130 2.6 Hazardous Atmospheres and Materials .................................................................130

2.6.1 Ventilation 101 2.6.1.1 Hazardous Atmospheres............................................................131 2.6.1.2 Emergency Rescue Equipment..................................................131

2.6.2 Exhaust Gases ..............................................................................................131 2.6.3 Organic Lead................................................................................................131

2.7 Edge Protection, Markers and Fixed Lighting......................................................132 2.8 Roads, Streets, and Sidewalks .................................................................................132 2.9 Backfilling...................................................................................................................132 2.10 Borrow Pits..................................................................................................................133

3.0 DEMOLITION.....................................................................................................................................153 3.1 Before Work Starts ...................................................................................................154

3.1.1 Responsible Supervisor .............................................................................154 3.1.2 Original Drawings........................................................................................154 3.1.3 Disconnections............................................................................................154 3.1.4 Adjacent Structures and Public Areas.....................................................154 3.1.5 Barricades/Signs..........................................................................................154

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3.2 Method of Demolition.................................................................................................154 3.2.1 Demolition of Equipment Containing PCB: Polychlorinated

Biphenyl (ASKAREL).................................................................................155 3.2.2 Demolition Of Buildings With Asbestos / Insulation

Materials .......................................................................................................155 3.3 Stability During Demolition.....................................................................................155 3.4 Working Place Clearance........................................................................................155

3.4.1 Access ..........................................................................................................155 3.4.2 Glass Removal..............................................................................................155

3.5 Structural Steel Removal..........................................................................................155 3.6 Tanks, Vessels and Pipe Work (Explosion Prevention)......................................156

3.6.1 Welding and Hot Cutting...........................................................................156 3.6.2 Cold Cutting.................................................................................................156 3.6.3 Steaming and Ventilation ...........................................................................156 3.6.4 Residue Cleaning.........................................................................................166

3.7 Protective Clothing and Equipment.........................................................................156 3.8 Mechanical Equipment Guards ................................................................................157

4.0 ASBESTOS AND OTHER FIBERS.................................................................................................158 4.1 Types of Asbestos .......................................................................................................158 4.2 Health Risks................................................................................................................158 4.3 Before Work Starts ...................................................................................................159

4.3.1 Air Sampling.................................................................................................159 4.3.2 Job Details ....................................................................................................159 4.3.3 Chest X-rays ................................................................................................159

4.4 Storage and Transportation......................................................................................159 4.5 Work Area...................................................................................................................160 4.6 Handling and Use........................................................................................................160

4.6.1 Wetting/Ventilation ....................................................................................160 4.6.2 Cutting ..........................................................................................................160 4.6.3 Protective Equipment..................................................................................160

4.7 Protective Clothing ....................................................................................................160 4.7.1 Types ............................................................................................................160 4.7.2 Contamination..............................................................................................161 4.7.3 Review...........................................................................................................161

4.8 Respiratory Equipment..............................................................................................161 4.8.1 Type ..............................................................................................................161 4.8.2 Use.................................................................................................................161 4.8.3 Care................................................................................................................161

4.9 Washing and Changing Facilities...........................................................................161 4.10 Disposal of Waste Asbestos Materials/Clothing..................................................162 4.11 Cleanliness of Work Areas and Equipment ..........................................................162

5.0 WELDING, CUTTING, AND BRAZING.........................................................................................163 5.1 Gas Welding: Oxy-Acetylene Equipment and Use...............................................163

5.1.1 Gases .............................................................................................................163 5.1.2 Color Coding of Cylinders .........................................................................164 5.1.3 Storage Of Cylinders..................................................................................164 5.1.4 Handling of Cylinders.................................................................................165 5.1.5 Inspecting Equipment.................................................................................166 5.1.6 Faults.............................................................................................................167 5.1.7 Fuel Gas and Oxygen Manifolds...............................................................169

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5.2 Electric Arc Welding.................................................................................................169 5.2.1 Voltage..........................................................................................................169 5.2.2 Welding Connections.................................................................................169

5.3 Protective Measures ..................................................................................................171 5.4 Welding and Cutting: Tanks, Vessels and Drums .............................................173 5.5 Confined Spaces..........................................................................................................173 5.6 Personnel Protection.................................................................................................173 5.7 Health Hazards ............................................................................................................174

5.7.1 Radiant Energy ............................................................................................174 5.7.2 Respiratory Effects......................................................................................174

6.0 EXPLOSIVE MATERIALS ...............................................................................................................176

7.0 PILING OPERATIONS......................................................................................................................177 7.1 Before Work Starts ...................................................................................................177

7.1.1 Cranes ...........................................................................................................178 7.1.2 Pile Gates ......................................................................................................178 7.1.3 Inspection.....................................................................................................178 7.1.4 Wedges .........................................................................................................178 7.1.5 Timber Block................................................................................................178 7.1.6 Ground Support ...........................................................................................179

7.2 Driving Piles ...............................................................................................................179 7.2.1 Pitching.........................................................................................................179 7.2.2 Driving ..........................................................................................................179

7.3 Pile Extraction.............................................................................................................179 7.4 General Precautions ..................................................................................................180

8.0 ROADWORKS ...................................................................................................................................181 8.1 General .........................................................................................................................181 8.2 Street and Road Construction, Excavations, and Maintenance Traffic

Controls........................................................................................................................182

9.0 WORKING PLACES, LADDERS, AND SCAFFOLDING..........................................................183 9.1 Working Places, General .........................................................................................184

9.1.1 Falls ...............................................................................................................184 9.1.2 Access and Egress......................................................................................184 9.1.3 Lighting.........................................................................................................184 9.1.4 Prevention of Falls ......................................................................................184 9.1.5 Ramps............................................................................................................184 9.1.6 Falling Material............................................................................................185 9.1.7 Hot Surfaces.................................................................................................185 9.1.8 Slipping and Tripping.................................................................................185 9.1.9 Roof Work....................................................................................................185 9.1.10 Insecure Structures .....................................................................................185 9.1.11 Work Over Water........................................................................................186

9.2 Ladders and Stepladders ...........................................................................................186 9.2.1 Selection .......................................................................................................186 9.2.2 Condition......................................................................................................187 9.2.3 Position.........................................................................................................187 9.2.4 Use.................................................................................................................188 9.2.5 Stepladders...................................................................................................190 9.2.6 General..........................................................................................................190

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9.3 Scaffolding Components............................................................................................191 9.4 Requirements Common to All Scaffoldi ng ............................................................195

9.4.1 Foundations .................................................................................................195 9.4.2 Posts ..............................................................................................................195 9.4.3 Runners.........................................................................................................197 9.4.4 Bearers ..........................................................................................................197 9.4.5 Board Bearers...............................................................................................197 9.4.6 Bracing..........................................................................................................198 9.4.7 Ties ................................................................................................................198 9.4.8 Platform Units ..............................................................................................199 9.4.9 Guardrail Systems and Toeboards............................................................200 9.4.10 Access ..........................................................................................................200 9.4.11 Scaffold Ladders..........................................................................................200

9.4.11.1 Portable Straight and Extension Ladders.................................200 9.4.11.2 Vertical Ladder.............................................................................200

9.4.12 Workmanship...............................................................................................202 9.4.13 Inspections...................................................................................................202

9.5 Fabricated Tubular Frame and System Scaffolding .............................................202 9.6 Tube and Coupler Scaffolds ......................................................................................204

9.6.1 Independent Tied Scaffold ........................................................................204 9.6.2 Light Duty Tube and Coupler Scaffolds..................................................204

9.6.2.1 Design, Loading and Dimensions.............................................204 9.6.2.2 Platform.........................................................................................204 9.6.2.3 Limitations....................................................................................205

9.6.3. Medium Duty Tube and Coupler Scaffold ..............................................205 9.6.3.1 Design, Loading, and Dimensions............................................205 9.6.3.2 Platform.........................................................................................205 9.6.3.3 Limitations....................................................................................205 9.6.3.4 Bearers ..........................................................................................206

9.6.4 Heavy Duty Tube and Coupler Scaffolds ...............................................206 9.6.4.1 Design, Loading and Dimensions.............................................206 9.6.4.2 Platform.........................................................................................206 9.6.4.3 Limitations....................................................................................206 9.6.4.4 Bearers ..........................................................................................206

9.7 Free-Standing Tower Scaffolds ................................................................................207 9.7.1 General Requirements .................................................................................207 9.7.2 Design, Loading and Dimensions.............................................................207 9.7.3 Runners and Bearers...................................................................................207 9.7.4 Bracing..........................................................................................................207 9.7.5 Ties ................................................................................................................207 9.7.6 Platform.........................................................................................................208 9.7.7 Access ..........................................................................................................208 9.7.8 Limitations....................................................................................................208

9.8 Mobile Tower Scaffolds .............................................................................................208 9.8.1 Foundations .................................................................................................208 9.8.2 Operation......................................................................................................208 9.8.3 Limitations....................................................................................................209

9.9 Scaffolds for Tanks and Vessels .............................................................................209 9.9.1 Bracket Scaffolds.........................................................................................209

9.10 Special Scaffolds .........................................................................................................210 9.11 Scaffold Terminology.................................................................................................210

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10.0 HAND TOOLS AND POWER TOOLS........................................................................................221 10.1 Hand Tools, General...................................................................................................222

10.1.1 Quality...........................................................................................................222 10.1.2 Cleanliness ...................................................................................................222 10.1.3 Repair and Storage......................................................................................222 10.1.4 Selection .......................................................................................................222 10.1.5 Electrical Risks .............................................................................................222

10.2 Individual Hand Tools, Precautions.........................................................................222 10.2.1 Screwdrivers.................................................................................................222 10.2.2 Hammer.........................................................................................................223 10.2.3 Chisels ...........................................................................................................223 10.2.4 Picks and Shovels .......................................................................................223 10.2.5 Spanners and Wrenches ............................................................................223 10.2.6 Pipe Wrenches.............................................................................................223 10.2.7 Pliers ..............................................................................................................224 10.2.8 Jacks ..............................................................................................................224 10.2.9 Hacksaws......................................................................................................224 10.2.10 Hand saws ....................................................................................................224

10.3 Power Tools, General.................................................................................................224 10.3.1 Quality...........................................................................................................224 10.3.2 Repair and Storage......................................................................................225

10.4 Pneumatic Tools .........................................................................................................225 10.4.1 General..........................................................................................................225 10.4.2 Individual Tools, Precautions ...................................................................225

10.4.2.1 Jack Hammer and Concrete Breakers........................................225 10.4.2.2 Rock Drill ......................................................................................226 10.4.2.3 Grinding Machine........................................................................226

10.5 Cartridge Operated Tools .........................................................................................231 10.5.1 General..........................................................................................................231 10.5.2 Storage..........................................................................................................231 10.5.3 Selection and Training of Personnel ........................................................231 10.5.4 Personal Protective Equipment .................................................................232 10.5.5 Issue and Returns .......................................................................................232 10.5.6 Work Permits................................................................................................232 10.5.7 Use.................................................................................................................232 10.5.8 Maintenance and Repair ............................................................................234

10.6 Electrically Operated Tools ......................................................................................235 10.6.1 General..........................................................................................................235 10.6.2 Maintenance and Storage..........................................................................236 10.6.3 Personal Protective Equipment .................................................................236 10.6.4 Individual Tools, Precautions ...................................................................236

10.6.4.1 Grinders.........................................................................................236 10.6.4.2 Drills ..............................................................................................237 10.6.4.3 Saws ..............................................................................................237 10.6.4.4 Radial Saws ..................................................................................237

11.0 PAINTS AND COATINGS .............................................................................................................250 11.1 Flammability Hazards of Coating Materials..........................................................250

11.1.1 Flammable Materials ...................................................................................250 11.1.2 Flash Point (Definition)..............................................................................250 11.1.3 Flammable (Explosive) Limits (Definition)...............................................250 11.1.4 Fire Precautions...........................................................................................251

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11.2 Health Hazards Associated With Paints ................................................................251 11.2.1 Toxic Materials ............................................................................................251 11.2.2 Dermatitic Materials ....................................................................................252 11.2.3 Prevention of Health Hazards....................................................................252

11.3 Ventilation in Confined Spaces................................................................................252 11.4 Surface Preparation...................................................................................................253

11.4.1 Abrasive Blast Cleaning.............................................................................254 11.4.2 Hydroblast and Steam Cleaning................................................................254 11.4.3 Hand and Power Tool Cleaning ................................................................254 11.4.4 Chemical Cleaning.......................................................................................255 11.4.5 General Safety in Surface Preparation......................................................255

11.5 Personal Protective Equipment................................................................................256 11.6 Paint Application ........................................................................................................258

11.6.1 Paint Materials .............................................................................................258 11.6.2 General Safety In Paint Application .........................................................258

11.7 Scaffolding and Ladders ............................................................................................259 11.8 Tarring Operations....................................................................................................259 11.9 General Safety for Paints and Coatings.................................................................259

12.0 CONCRETE, CONCRETE FORMS, AND SHORING...............................................................259 12.1 General .........................................................................................................................262 12.2 Reinforcing Steel .......................................................................................................262 12.3 Bulk Concrete Handling ...........................................................................................262 12.4 Concrete Placement...................................................................................................262

12.4.1 Concrete Mixers...........................................................................................262 12.4.2 Guardrails ......................................................................................................262 12.4.3 Bull Floats.....................................................................................................262 12.4.4 Powered Concrete Trowels ........................................................................263 12.4.5 Concrete Buggies ........................................................................................263 12.4.6 Pumpcrete Systems .....................................................................................263 12.4.7 Concrete Buckets ........................................................................................263 12.4.8 Discharging on Slope .................................................................................263 12.4.9 Back-Up Man, Truck Spotter.....................................................................263 12.4.10 Pneumatic Hose...........................................................................................263

12.5 Vertical Shoring.........................................................................................................263 12.5.1 General Requirements .................................................................................263 12.5.2 Tubular Welded Frame Shoring................................................................264

12.6 Forms and Shoring.....................................................................................................264 12.6.1 General Provisions ......................................................................................264 12.6.2 Vertical Slip Forms .......................................................................................265 12.6.3 Tube and Coupler Shoring.........................................................................265 12.6.4 Single Post Shores ......................................................................................266

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III. Mechanical Equipment And Materials.........................................267

1.0 CRANES AND LIFTING EQUIPMENT...........................................................................................268 1.1 Competent Person ......................................................................................................269 1.2 Saudi Aramco Crane Operations (General Requirements)...............................269 1.3 Saudi Aramco Crane Operator Qualifications .....................................................270 1.4 Special Crane Operating Procedures ....................................................................270 1.5 Effect of Wind Speeds on Crane Operations .........................................................270 1.6 Overhead Power Lines...............................................................................................270

2.0 SLINGS AND LIFTING GEAR (RIGGING)....................................................................................275 2.1. Safe Working Load (SWL).......................................................................................275 2.2. Chain Slings................................................................................................................276

2.2.1 Grades ...........................................................................................................276 2.2.2 Repairs ..........................................................................................................276

2.3 Wire Rope Slings.......................................................................................................276 2.4 Synthetic Webbing Slings........................................................................................277

2.4.1 Removal from Service .................................................................................277 2.4.2 Repaired Slings............................................................................................277

2.5 Synthetic and Natural Fiber Rope Slings ..............................................................278 2.6 Care of Slings .............................................................................................................279 2.7 Hooks............................................................................................................................279 2.8 Spreader Bars .............................................................................................................280 2.9 Eyebolts And Safety Hoist Rings .............................................................................280 2.10 Shackles.......................................................................................................................281 2.11 Rigger...........................................................................................................................281

3.0 MECHANICAL EQUIPMENT...........................................................................................................287 3.1 Operators .....................................................................................................................288

3.1.1 Qualifications...............................................................................................288 3.1.2 Licensing Requirements .............................................................................288

3.2 Machinery Guards......................................................................................................289 3.2.1 Multi-Piece Tire Rims and Locking Rings ...............................................289

3.3 General Requirements ..............................................................................................289 3.4 Compressors ...............................................................................................................290 3.5 Concrete Mixers and Batching Plants ...................................................................291 3.6 Dumpers and Dump Trucks .....................................................................................292 3.7 Excavators ....................................................................................................................293 3.8 Fork Lift Trucks ........................................................................................................294 3.9 Generators ...................................................................................................................295 3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders .......................................296 3.11 Woodworking Machinery.........................................................................................296

4.0 MATERIALS HANDLING.................................................................................................................298 4.1 Planning .......................................................................................................................298 4.2 Machine Transport.....................................................................................................299

4.2.1 Dumpers........................................................................................................299 4.2.2 Tractors and Trailers...................................................................................300 4.2.3 Conveyor Belts and Monorails .................................................................300 4.2.4 Concrete Pumps...........................................................................................300

4.3 Site Stores ...................................................................................................................300

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4.4 Manual Handling ........................................................................................................301

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IV. Electrical And Radiation ..............................................................305

1.0 ELECTRICITY.....................................................................................................................................306 1.1 Voltage..........................................................................................................................307 1.2 Temporary Installations ............................................................................................307 1.3 Hand Tools and Lighting ...........................................................................................308 1.4 Work on Live Equipment...........................................................................................309 1.5 Overhead and Underground Cables.........................................................................310 1.6 Overhead Power Transmission and Distribution.................................................311

1.6.1 Initial Inspections, Tests, or Determinations..........................................311 1.6.2 De-energizing Lines and Equipment.........................................................312 1.6.3 Emergency Procedures and First Aid.......................................................312 1.6.4 Night Work...................................................................................................312 1.6.5 Work Near/Over Water..............................................................................312 1.6.6 Hydraulic Fluids ..........................................................................................313 1.6.7 Live-Line Tools (Hot Sticks)......................................................................313 1.6.8 Material Handling........................................................................................313

1.6.8.1 Unloading.....................................................................................313 1.6.8.2 Pole Hauling.................................................................................313 1.6.8.3 Storage..........................................................................................313 1.6.8.4 Framing .........................................................................................313 1.6.8.5 Attaching the Load.....................................................................314

1.6.9 Grounding for Protection of Workers ......................................................314 1.6.9.1 Isolation and Voltage Testing...................................................314 1.6.9.2 Applying and Removing Grounds............................................314 1.6.9.3 Grounding Distance....................................................................314 1.6.9.4 Removal of Grounds for Testing Purposes .............................314 1.6.9.5 Grounding Electrode...................................................................314 1.6.9.6 Grounding Cables And Clamps.................................................314

1.6.10 Overhead Lines............................................................................................315 1.6.10.1 Metal Tower Construction.........................................................315 1.6.10.2 Stringing/Remo ving De-energized Conductors......................317 1.6.10.3 Stringing Adjacent to Energized Lines ....................................318

1.6.11 Underground Lines .....................................................................................319 1.6.11.1 Work in Manholes ......................................................................320 1.6.11.2 Trenching and Excavating .........................................................320

1.6.12 Construction in Energized Substations ...................................................321 1.6.12.1 Barricades and Barriers...............................................................321 1.6.12.2 Control Panels ..............................................................................321 1.6.12.3 Mechanized Equipment..............................................................321 1.6.12.4 Substation Fences.......................................................................321

1.7 Electric Shock.............................................................................................................322

2.0 IONIZING RADIATION....................................................................................................................325 2.1 Methods of Protection Against Radiation ..............................................................325

2.1.1 Distance........................................................................................................325 2.1.2 Time...............................................................................................................325 2.1.3 Shielding.......................................................................................................326

2.2 Classification of Personnel and Exposure Limits ................................................326 2.2.1 Radiation Workers ......................................................................................326 2.2.2 Non-Radiation Workers .............................................................................326

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2.2.3 Exposure Limits............................................................................................326 2.3 Responsibilities for Safe Handling .........................................................................327

2.3.1 Contractor.....................................................................................................327 2.3.2 Competent Person.......................................................................................327 2.3.3. Radiographer................................................................................................327

2.4 Shipping and Transportation....................................................................................328 2.5 Storage Areas .............................................................................................................328

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V. Chemicals And Operations ............................................................330

1.0 LIQUEFIED PETROLEUM GASES..................................................................................................331 1.1 General .........................................................................................................................331 1.2 Storage .........................................................................................................................332 1.3 Handling of Cylinders................................................................................................332 1.4 Leakage........................................................................................................................333 1.5 Transportation ............................................................................................................334 1.6 Operation .....................................................................................................................334 1.7 Action in Case of Fire................................................................................................335 1.8 Bulk Installations.......................................................................................................336 1.9 First Aid.......................................................................................................................336

2.0 PLANT OPERATIONS......................................................................................................................337 2.1 Additional Information On Saudi Aramco Instructions and

Standards .....................................................................................................................337 2.1.1 General Instruction Manual.......................................................................338 2.1.2 Producing Instruction Manual..................................................................338 2.1.3 Refinery Instruction Manual.....................................................................338 2.1.4 Saudi Aramco Engineering Standards .....................................................338

2.2 Work Permit System.................................................................................................338 2.3 Operation of Plant Equipment ..................................................................................338 2.4 Shutdown and Maintenance in Plant Operations..................................................339 2.5 Commissioning ...........................................................................................................339 2.6 Emergency Procedures: Saudi Aramco Disaster Plan ......................................339

2.6.1 Gas Release Emergency Procedures.........................................................340

3.0 PRESSURE TESTING........................................................................................................................341 3.1 Preparation..................................................................................................................342

3.1.1 SAES-A-004 (Pressure Testing)................................................................342 3.1.2 Supports .......................................................................................................342 3.1.3 Vents and Drains.........................................................................................343 3.1.4 Valves............................................................................................................343 3.1.5 Pipings And Joints ......................................................................................343 3.1.6 Vacuums .......................................................................................................343

3.2 General Requirements ..............................................................................................343 3.3 Test Liquid...................................................................................................................344

4.0 CHEMICALS .......................................................................................................................................346 4.1 Hazard Identification System...................................................................................347 4.2 Health Hazards ............................................................................................................348

4.2.1 Inhalation Pathway Hazard ........................................................................348 4.2.2 Skin Hazards.................................................................................................349 4.2.3 Hazards of Swallowing Chemicals ............................................................349

4.3 Emergency Treatment ...............................................................................................349 4.3.1 Artificial Respiration...................................................................................349 4.3.2 First Aid ........................................................................................................349 4.3.3 Showers and Eyewash Fountains.............................................................349

4.4 Fire Hazards ................................................................................................................351 4.5 Reactivity Hazards ......................................................................................................351 4.6 Transportation, Storage and Disposal ....................................................................351

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4.6.1 Transportation.............................................................................................351 4.6.2 Storage..........................................................................................................352 4.6.3 Containers ....................................................................................................352 4.6.4 Disposal........................................................................................................352

4.7 Work on Equipment Which Has Contained Tetraethyl Lead (Organic Lead Compounds)......................................................................................354 4.7.1 Introduction .................................................................................................354 4.7.2 Precautions...................................................................................................355

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VI. Marine...........................................................................................359

1.0 COFFERDAMS ...................................................................................................................................360 1.1 Design...........................................................................................................................360 1.2 Before Work Starts ...................................................................................................360 1.3 Construction................................................................................................................360 1.4 Potential Hazards .......................................................................................................361

1.4.1 Structural Collapse......................................................................................361 1.4.2 Overhead Loads ..........................................................................................361 1.4.3 Dislodgment of Struts and Wales.............................................................361

1.5 Inspection.....................................................................................................................361 1.6 Leaks ............................................................................................................................362

2.0 MARINE OPERATIONS ...................................................................................................................363 2.1 Other Publications .....................................................................................................363 2.2 General .........................................................................................................................364 2.3 Behavior on Floating Craft .......................................................................................364 2.4 Preparation for Transportation by Sea...................................................................364 2.5 Tide and Sea Effects ...................................................................................................365 2.6 Care of Tools and Equipment....................................................................................365 2.7 Housekeeping..............................................................................................................365

3.0 DIVING OPERATIONS....................................................................................................................367 3.1 Employment of Qualified Divers ..............................................................................367 3.2 Diving Equipment........................................................................................................368

3.2.1 Compressors ................................................................................................368 3.2.2 Reserve Air Supply .....................................................................................369 3.2.3 Bail-Out Equipment.....................................................................................369 3.2.4 Maintenance ................................................................................................369

3.3 Safeguards ...................................................................................................................370 3.4 Physical Fitness..........................................................................................................374 3.5 Medical Diving Emergencies: Procedures and Responsibilities......................375

3.5.1 Sports Divers ...............................................................................................375 3.5.2 Commercial Divers.......................................................................................375 3.5.3 Coordinator, Diving Emergencies .............................................................375 3.5.4 Diving Medical Team..................................................................................375 3.5.5 Marine Department .....................................................................................376

3.6 Personnel Transfer at Sea........................................................................................376

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Appendix A...........................................................................................379

INDEX TO APPENDIX A..........................................................................................................................380

A.1 PROJECT MANAGEMENT AND CONTRACTOR'S SAFETY COMPETITION SITE REGISTRATION FORM.................................................................................................................381

A.2 CONTRACTOR SAFETY COMPETITION, RULES OF COMPETITION..............................382

A.3 Saudi Aramco Safety, Health and Environmental Requirements ..............................................387 1. Compliance With Safety Rules - Schedule 'D' ....................................................387 2. Deviations From Safety Rules ..................................................................................387 3. Failure To Comply......................................................................................................387 4. Saudi Aramco Assistance.........................................................................................387 5. Loss Prevention Program.........................................................................................388 6. Work Permits .............................................................................................................388 7. Welding And Cutting Equipment.............................................................................388 8. Personal Protective Equipment................................................................................388 9. Tools And Portable Power Tools..............................................................................388 10. Cartridge Operated Tools .........................................................................................379 11. Ladders .........................................................................................................................389 12. Scaffolding ...................................................................................................................389 13. Electrical Installations And Equipment..................................................................389 14. Cranes And Rigging Equipment..............................................................................389 15. Mechanical Equipment...............................................................................................389 16. Saudi Aramco Plant Operations ..............................................................................390 17. Transportation ............................................................................................................390 18. Injury And Damage Reporting .................................................................................390 19. Excavations...................................................................................................................391 20. Work Over Or Adjacent To Water.........................................................................391 21. Fire Prevention ...........................................................................................................391 22. Formwork.....................................................................................................................391 23. Ionizing Radiation ......................................................................................................391 24. First-Aid Facilities .....................................................................................................391 25. Handling, Transportation And Disposal Of Hazardous Materials And

Waste ............................................................................................................................392 26. Explosives .....................................................................................................................393 27. Sandblasting ................................................................................................................393

A.4 HAZARD IDENTIFICATION PLAN (HIP) ....................................................................................394 HAZARD IDENTIFICATION PLAN:......................................................................................395

I. Conduct Hazards Identification Review. .................................................395 II. List Potential Hazards.................................................................................395 III. Hazard Classification ..................................................................................395 IV. Corrective Action........................................................................................396

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Appendix B: Emergency/Disaster Planning And Response ...............398

B.1 SEARCH AND RESCUE PROCEDURES.......................................................................................399

B.2 EMERGENCY/DISASTER PLANNING AND RESPONSE.........................................................400 B.2.1 General Provisions.....................................................................................................401 B.2.2 Definitions ...................................................................................................................401 B.2.3 Plan Development Action Items ...............................................................................407

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Appendix C: Fire Safety Checklist For Evaluating Construction Materials Store Yard.....................................................427

C.1 Fire Safety Checklist For Evaluating Construction Materials Store Yard.............................428

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Appendix D: Saudi Aramco Crane Safety Handbook ........................432

D.1 Crane Safety Handbook .....................................................................................................................433

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Appendix E: Suggestion Form ............................................................434

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Appendix F: Distribution Form...........................................................436

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Appendix G: Sanitary Code ................................................................438

Implementing The Saudi Aramco Sanitary Code - GI 151.006..........................................................439

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Appendix H: General Instructions Master Index ...............................440

General Instructions (GI) Master Index.................................................................................................441

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Appendix I: List Of Figures ................................................................445

List Of Figures ...........................................................................................................................................446

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Appendix J: List Of Tables .................................................................449

List Of Tables...................................................