JOB SAFETY ANALYSIS

MANUALDoc No MRT-FRM-609-JSA-001-Rev 01

Table of Contents

SECTION 1A - CONFINED SPACES2

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT8

SECTION 1C- WELDING CUTTING AND BRAZING13

SECTION 1D - PRESSURE TESTING23

Section 1E - Blasting amp Painting25

Table 1 A - Ventilation Requirements for Confined Spaces30

Table 1B ndash PPE to be worn or used during Blasting and Coating31

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor33

INJURY REPORTING amp RECORDKEEPING38

INCIDENT ACCIDENT REPORT39

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 1 of 41

SECTION 1A - CONFINED SPACESWork in confined spaces kills many people every year across a wide range of industries from those involving complex plant through to simple storage vessels and above ground storage tanks In addition a number of people are seriously injured Those killed include not only people working in the confined space but those who try to rescue them without proper training and equipment The following information is aimed at all JampP and its subcontractor employees who carry out work in confined spaces and forms part of the companyrsquos policy and commitment to ensure the safety of its workers

11 What is a confined space

A confined space can be any space of an enclosed nature where there is a risk of death or serious injury from hazardous substances or dangerous conditions (eg lack of oxygen) Some confined spaces are fairly easy to identify eg enclosures with limited openings

- Storage Tanks

- Silos

- Reaction Vessels

- Enclosed Drains

- Sewers

Others may be less obvious but can be equally dangerous for example

- Open ndashtopped chambers

- Vats

- Combustion chambers in furnaces etc

- Ductwork

- Unventilated or poorly ventilated rooms

It is not possible to provide a comprehensive list of confined spaces Some places may become confined spaces when work is carried out or during their construction fabrication or subsequent modification

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 2 of 41

12 What are the Dangers from Confined Spaces

Dangers can arise in confined spaces because of

- Lack of oxygen

This can occur

- Where there is a reaction between soils and the atmosphere

- Following the action of ground water on chalk and limestone which can produce carbon dioxide and displace normal air

- In shipsrsquo holds freight containers lorries etc as a result of cargo reacting with oxygen inside the space

- Inside steel tanks and vessels when rust forms

- Poisonous gas fumes or vapour

This can

- Build up in sewers and manholes and in pits connected to the system

- Enter tanks or vessels from connecting pipes

- Leak into trenches and pits in contaminated land such as old refuse tips and old gas works

- Liquids and solids which can suddenly fill the space or release gases into it when disturbed Free flowing solids such as grain can also partially solidify or bridge in silos causing blockages which can collapse unexpectedly

- Fire and explosions (eg from flammable vapours excess oxygen etc)

- Residues left in tanks vessels etc or remaining on internal surfaces which give off gas vapours

- Dust may be present in high concentrations etc in flour silos

- Hot conditions leading to a dangerous increase in body temperature

Some of the above conditions may already be present in the confined space However some may arise through the work being carried out or because of ineffective of plant nearby eg leakage from a pipe connected to a confined space The enclosure and working space may increase other dangers arising through the work being carried out for example

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 3 of 41

- Machinery being used may require special precautions such as provision of dust extraction for a portable grinder or special precautions against electric shock

- Gas fume or vapour can arise from welding or by use of volatile and often flammable solvents adhesives etc

- If access to the space is through a restricted entrance such as a manhole escape or rescue in an emergency will be more difficult (see Emergency procedures)

13 COMPANY POLICY

The Site HSE Officer with the support of the Branch HSE Representative shall carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety For work in confined spaces this means identifying the hazards present assessing the risks and determining what precautions to take In most cases the assessment will include consideration of

- The task

- The working environment

- Working materials and tools

- The suitably of those carrying out the task

- Arrangements for rescue

Appoint a competent person to supervise all work to be carried out in confined spaces and ensure that employees are adequately trained and instructed If the assessment identifies risks of serious injuries from work in confined spaces such as the dangers highlighted above the following Confined Space Procedures must apply

14 Confined Space Procedures

Check if the work can be done another way so that entry or work in confined spaces is avoided Better work planning or a different approach can reduce the need for confined space working Check if the intended work is really necessary or could the following be considered

- Modify the confined space itself so that entry is not necessary

- Have the work done from outside for example

- Blockages can be cleared in silos by use of remotely operated rotating flail devices vibrators or air purgers

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 4 of 41

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Table of Contents

SECTION 1A - CONFINED SPACES2

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT8

SECTION 1C- WELDING CUTTING AND BRAZING13

SECTION 1D - PRESSURE TESTING23

Section 1E - Blasting amp Painting25

Table 1 A - Ventilation Requirements for Confined Spaces30

Table 1B ndash PPE to be worn or used during Blasting and Coating31

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor33

INJURY REPORTING amp RECORDKEEPING38

INCIDENT ACCIDENT REPORT39

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 1 of 41

SECTION 1A - CONFINED SPACESWork in confined spaces kills many people every year across a wide range of industries from those involving complex plant through to simple storage vessels and above ground storage tanks In addition a number of people are seriously injured Those killed include not only people working in the confined space but those who try to rescue them without proper training and equipment The following information is aimed at all JampP and its subcontractor employees who carry out work in confined spaces and forms part of the companyrsquos policy and commitment to ensure the safety of its workers

11 What is a confined space

A confined space can be any space of an enclosed nature where there is a risk of death or serious injury from hazardous substances or dangerous conditions (eg lack of oxygen) Some confined spaces are fairly easy to identify eg enclosures with limited openings

- Storage Tanks

- Silos

- Reaction Vessels

- Enclosed Drains

- Sewers

Others may be less obvious but can be equally dangerous for example

- Open ndashtopped chambers

- Vats

- Combustion chambers in furnaces etc

- Ductwork

- Unventilated or poorly ventilated rooms

It is not possible to provide a comprehensive list of confined spaces Some places may become confined spaces when work is carried out or during their construction fabrication or subsequent modification

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 2 of 41

12 What are the Dangers from Confined Spaces

Dangers can arise in confined spaces because of

- Lack of oxygen

This can occur

- Where there is a reaction between soils and the atmosphere

- Following the action of ground water on chalk and limestone which can produce carbon dioxide and displace normal air

- In shipsrsquo holds freight containers lorries etc as a result of cargo reacting with oxygen inside the space

- Inside steel tanks and vessels when rust forms

- Poisonous gas fumes or vapour

This can

- Build up in sewers and manholes and in pits connected to the system

- Enter tanks or vessels from connecting pipes

- Leak into trenches and pits in contaminated land such as old refuse tips and old gas works

- Liquids and solids which can suddenly fill the space or release gases into it when disturbed Free flowing solids such as grain can also partially solidify or bridge in silos causing blockages which can collapse unexpectedly

- Fire and explosions (eg from flammable vapours excess oxygen etc)

- Residues left in tanks vessels etc or remaining on internal surfaces which give off gas vapours

- Dust may be present in high concentrations etc in flour silos

- Hot conditions leading to a dangerous increase in body temperature

Some of the above conditions may already be present in the confined space However some may arise through the work being carried out or because of ineffective of plant nearby eg leakage from a pipe connected to a confined space The enclosure and working space may increase other dangers arising through the work being carried out for example

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 3 of 41

- Machinery being used may require special precautions such as provision of dust extraction for a portable grinder or special precautions against electric shock

- Gas fume or vapour can arise from welding or by use of volatile and often flammable solvents adhesives etc

- If access to the space is through a restricted entrance such as a manhole escape or rescue in an emergency will be more difficult (see Emergency procedures)

13 COMPANY POLICY

The Site HSE Officer with the support of the Branch HSE Representative shall carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety For work in confined spaces this means identifying the hazards present assessing the risks and determining what precautions to take In most cases the assessment will include consideration of

- The task

- The working environment

- Working materials and tools

- The suitably of those carrying out the task

- Arrangements for rescue

Appoint a competent person to supervise all work to be carried out in confined spaces and ensure that employees are adequately trained and instructed If the assessment identifies risks of serious injuries from work in confined spaces such as the dangers highlighted above the following Confined Space Procedures must apply

14 Confined Space Procedures

Check if the work can be done another way so that entry or work in confined spaces is avoided Better work planning or a different approach can reduce the need for confined space working Check if the intended work is really necessary or could the following be considered

- Modify the confined space itself so that entry is not necessary

- Have the work done from outside for example

- Blockages can be cleared in silos by use of remotely operated rotating flail devices vibrators or air purgers

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 4 of 41

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

SECTION 1A - CONFINED SPACESWork in confined spaces kills many people every year across a wide range of industries from those involving complex plant through to simple storage vessels and above ground storage tanks In addition a number of people are seriously injured Those killed include not only people working in the confined space but those who try to rescue them without proper training and equipment The following information is aimed at all JampP and its subcontractor employees who carry out work in confined spaces and forms part of the companyrsquos policy and commitment to ensure the safety of its workers

11 What is a confined space

A confined space can be any space of an enclosed nature where there is a risk of death or serious injury from hazardous substances or dangerous conditions (eg lack of oxygen) Some confined spaces are fairly easy to identify eg enclosures with limited openings

- Storage Tanks

- Silos

- Reaction Vessels

- Enclosed Drains

- Sewers

Others may be less obvious but can be equally dangerous for example

- Open ndashtopped chambers

- Vats

- Combustion chambers in furnaces etc

- Ductwork

- Unventilated or poorly ventilated rooms

It is not possible to provide a comprehensive list of confined spaces Some places may become confined spaces when work is carried out or during their construction fabrication or subsequent modification

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 2 of 41

12 What are the Dangers from Confined Spaces

Dangers can arise in confined spaces because of

- Lack of oxygen

This can occur

- Where there is a reaction between soils and the atmosphere

- Following the action of ground water on chalk and limestone which can produce carbon dioxide and displace normal air

- In shipsrsquo holds freight containers lorries etc as a result of cargo reacting with oxygen inside the space

- Inside steel tanks and vessels when rust forms

- Poisonous gas fumes or vapour

This can

- Build up in sewers and manholes and in pits connected to the system

- Enter tanks or vessels from connecting pipes

- Leak into trenches and pits in contaminated land such as old refuse tips and old gas works

- Liquids and solids which can suddenly fill the space or release gases into it when disturbed Free flowing solids such as grain can also partially solidify or bridge in silos causing blockages which can collapse unexpectedly

- Fire and explosions (eg from flammable vapours excess oxygen etc)

- Residues left in tanks vessels etc or remaining on internal surfaces which give off gas vapours

- Dust may be present in high concentrations etc in flour silos

- Hot conditions leading to a dangerous increase in body temperature

Some of the above conditions may already be present in the confined space However some may arise through the work being carried out or because of ineffective of plant nearby eg leakage from a pipe connected to a confined space The enclosure and working space may increase other dangers arising through the work being carried out for example

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 3 of 41

- Machinery being used may require special precautions such as provision of dust extraction for a portable grinder or special precautions against electric shock

- Gas fume or vapour can arise from welding or by use of volatile and often flammable solvents adhesives etc

- If access to the space is through a restricted entrance such as a manhole escape or rescue in an emergency will be more difficult (see Emergency procedures)

13 COMPANY POLICY

The Site HSE Officer with the support of the Branch HSE Representative shall carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety For work in confined spaces this means identifying the hazards present assessing the risks and determining what precautions to take In most cases the assessment will include consideration of

- The task

- The working environment

- Working materials and tools

- The suitably of those carrying out the task

- Arrangements for rescue

Appoint a competent person to supervise all work to be carried out in confined spaces and ensure that employees are adequately trained and instructed If the assessment identifies risks of serious injuries from work in confined spaces such as the dangers highlighted above the following Confined Space Procedures must apply

14 Confined Space Procedures

Check if the work can be done another way so that entry or work in confined spaces is avoided Better work planning or a different approach can reduce the need for confined space working Check if the intended work is really necessary or could the following be considered

- Modify the confined space itself so that entry is not necessary

- Have the work done from outside for example

- Blockages can be cleared in silos by use of remotely operated rotating flail devices vibrators or air purgers

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 4 of 41

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

12 What are the Dangers from Confined Spaces

Dangers can arise in confined spaces because of

- Lack of oxygen

This can occur

- Where there is a reaction between soils and the atmosphere

- Following the action of ground water on chalk and limestone which can produce carbon dioxide and displace normal air

- In shipsrsquo holds freight containers lorries etc as a result of cargo reacting with oxygen inside the space

- Inside steel tanks and vessels when rust forms

- Poisonous gas fumes or vapour

This can

- Build up in sewers and manholes and in pits connected to the system

- Enter tanks or vessels from connecting pipes

- Leak into trenches and pits in contaminated land such as old refuse tips and old gas works

- Liquids and solids which can suddenly fill the space or release gases into it when disturbed Free flowing solids such as grain can also partially solidify or bridge in silos causing blockages which can collapse unexpectedly

- Fire and explosions (eg from flammable vapours excess oxygen etc)

- Residues left in tanks vessels etc or remaining on internal surfaces which give off gas vapours

- Dust may be present in high concentrations etc in flour silos

- Hot conditions leading to a dangerous increase in body temperature

Some of the above conditions may already be present in the confined space However some may arise through the work being carried out or because of ineffective of plant nearby eg leakage from a pipe connected to a confined space The enclosure and working space may increase other dangers arising through the work being carried out for example

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 3 of 41

- Machinery being used may require special precautions such as provision of dust extraction for a portable grinder or special precautions against electric shock

- Gas fume or vapour can arise from welding or by use of volatile and often flammable solvents adhesives etc

- If access to the space is through a restricted entrance such as a manhole escape or rescue in an emergency will be more difficult (see Emergency procedures)

13 COMPANY POLICY

The Site HSE Officer with the support of the Branch HSE Representative shall carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety For work in confined spaces this means identifying the hazards present assessing the risks and determining what precautions to take In most cases the assessment will include consideration of

- The task

- The working environment

- Working materials and tools

- The suitably of those carrying out the task

- Arrangements for rescue

Appoint a competent person to supervise all work to be carried out in confined spaces and ensure that employees are adequately trained and instructed If the assessment identifies risks of serious injuries from work in confined spaces such as the dangers highlighted above the following Confined Space Procedures must apply

14 Confined Space Procedures

Check if the work can be done another way so that entry or work in confined spaces is avoided Better work planning or a different approach can reduce the need for confined space working Check if the intended work is really necessary or could the following be considered

- Modify the confined space itself so that entry is not necessary

- Have the work done from outside for example

- Blockages can be cleared in silos by use of remotely operated rotating flail devices vibrators or air purgers

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 4 of 41

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

- Machinery being used may require special precautions such as provision of dust extraction for a portable grinder or special precautions against electric shock

- Gas fume or vapour can arise from welding or by use of volatile and often flammable solvents adhesives etc

- If access to the space is through a restricted entrance such as a manhole escape or rescue in an emergency will be more difficult (see Emergency procedures)

13 COMPANY POLICY

The Site HSE Officer with the support of the Branch HSE Representative shall carry out a suitable and sufficient assessment of the risks for all work activities for the purpose of deciding what measures are necessary for safety For work in confined spaces this means identifying the hazards present assessing the risks and determining what precautions to take In most cases the assessment will include consideration of

- The task

- The working environment

- Working materials and tools

- The suitably of those carrying out the task

- Arrangements for rescue

Appoint a competent person to supervise all work to be carried out in confined spaces and ensure that employees are adequately trained and instructed If the assessment identifies risks of serious injuries from work in confined spaces such as the dangers highlighted above the following Confined Space Procedures must apply

14 Confined Space Procedures

Check if the work can be done another way so that entry or work in confined spaces is avoided Better work planning or a different approach can reduce the need for confined space working Check if the intended work is really necessary or could the following be considered

- Modify the confined space itself so that entry is not necessary

- Have the work done from outside for example

- Blockages can be cleared in silos by use of remotely operated rotating flail devices vibrators or air purgers

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 4 of 41

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

- Inspection sampling and cleaning operations can often be done from outside the space using appropriate equipment and tools

- Remote cameras can be used for internal inspections of vessels If you cannot avoid entry into a confined space make sure that you have a safe system in place for working inside the space Use the results of the risk assessment to help identify the necessary precautions to reduce the risk of injury This will depend on the nature of the confined space the associated risk and the work involved Make sure that the safe system of work including the precautions identified is developed and put into practice Everyone involved will need to be properly trained and instructed to make sure they know what to do and how to do it safely The following checklist is not intended to be exhaustive but includes many of the essential elements to help prepare a safe system of work

Appointment of a supervisor

- Supervisors should be given the responsibility to ensure that the necessary precautions are taken to check safety at each stage and may need to remain present while work is underway

Are persons suitable for the work

- Do they have sufficient experience of the type of work be carried out and what training have they received Where risk assessment highlights exceptional constraints as a result of the physical layout are individuals of suitable build

- The competent person may need to consider other factors e g concerning claustrophobia or fitness to wear breathing apparatus and medical advice on an individualrsquos suitability may be needed

Isolation

- Mechanical and electrical isolation of equipment is essential if it could otherwise operate or be operated inadvertently If gas fume or vapour could enter the confined space physical isolation of pipe work etc needs to be made In all cases a check should be made to ensure isolation is effective

Cleaning before entry

- This may be necessary to ensure fumes do not develop from residues etc while the work is being done

Check the size of the entrance

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 5 of 41

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

- Is it big enough to allow workers wearing all necessary equipment to climb in and out easily and provide ready access and egress in an emergency For example the size of the opening may mean choosing airline-breathing apparatus in place of self-contained equipment which is more bulky and therefore likely to restrict ready passage

Provision of ventilation

- You may be able to increase the number of openings and therefore improve ventilation Mechanical ventilation may be necessary to ensure an adequate supply of fresh air This is essential where portable gas cylinders and diesel fuelled equipment are used inside the space because of the dangers from build-up of engine exhaust Warning carbon monoxide in the exhaust from petrol-fuelled engines is so dangerous that the use of such equipment in confined spaces should never be allowed

Testing the air

- This may be necessary to check that is free from both toxic and flammable vapours and that it is fit to breathe A competent person using a suitable gas detector which is correctly calibrated should carry out testing Where the risk assessment indicates that conditions may change or as a further precaution continuous monitoring of air may be necessary

Provision of special tools and lighting

- Non-sparking tools and specially protected lighting are essential where flammable or potentially explosive atmospheres are likely In certain confined spaces (eg inside metal tanks) suitable precautions to prevent electric shock include use of extra low voltage equipment (typically less than 25V) and where necessary residual current devices

Provision of breathing apparatus

- This is essential if the air inside the confined space cannot be made fit to breathe because of gas fume or vapour present or lack of oxygen Never try to lsquosweetenrsquo the air in a confined space with oxygen as this can greatly increase the risk of fire or explosion

Preparation of emergency arrangements

- This will need to cover the necessary equipment training and practice drills 1048707 Provision of rescue harnesses Lifelines attached to harnesses should run back to a point outside the confined space

Communications

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 6 of 41

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

- An adequate communications system is needed to enable communication between people inside and outside the confined space and to summon help in an emergency

Check how the alarm is raised

Is it necessary to station someone outside to keep watch and to communicate with anyone inside raise the alarm quickly in an emergency and to take charge of the rescue procedures

Is a lsquopermit- to- workrsquo necessary

- A permit-to-work ensures a formal check is undertaken to ensure all the elements of a safe system of work are in place before people are allowed to enter or work in a confined space It is also a means of communication between site management supervisors and those carrying out the hazardous work Essential features of a permit-to-work are

a Clear identification of who may authorize particular jobs (any limits to their authority) and who is responsible for specifying the necessary precautions (eg isolation air testing emergency arrangements etc)

b Provision for ensuring that subcontractors engaged to carry out work are included

c Training and instruction in the issue of permits

d Monitoring and auditing to ensure that the system works as intended

15 Emergency Procedures

When things go wrong people may be exposed to serious and immediate danger Effective arrangements for raising the alarm and carrying out rescue operations in an emergency are essential Contingency plans will depend on the nature of the confined space the risks identified and consequently the likely nature of an emergency rescue Emergency arrangements will depend on the risks You should consider

Communications

- How can an emergency be communicated from inside the confined space to people outside so that rescue procedures can start Do not forget night and shift work weekends and times when the premises are closed eg holidays Also consider what might happen and how the alarm can be raised

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 7 of 41

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Rescue and resuscitation equipment

- Provision of suitable rescue resuscitation equipment will depend on the likely the emergencies identified Where such equipment is provided for use by rescuers training in correct operation is essential

Capabilities of rescuers

- There must be properly trained people sufficiently fit to carry out their task ready at hand and capable of using any equipment provided for rescue eg breathing apparatus lifelines and fire-fighting equipment Rescuers also need to be protected the cause of the emergency

Shut down

- It may be necessary to shut down adjacent plant before attempting emergency rescue

First-aid procedures

- Trained first aiders need to be available to make proper use of any necessary first aid equipment provided

SECTION 1B - PERSONAL PROTECTIVE EQUIPMENTWhen a hazardous situation is recognized steps should be taken to eliminate the hazard by engineering controls Should it prove impractical to eliminate the hazard and then personal protective equipment must be used that meets the requirements of ANSI or equivalent standards When it has been decided that personal protective equipment is required steps must be taken to select the proper type of equipment and ensure that the supervisor instructs his employees in the use and care of that equipment in accordance with the instructions provided by the manufacturer

INSTRUCTIONS AND STANDARDS

Safety Health and Environmental Requirements

OSHA

Code of Federal Regulations 1910 1915 and 1926

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 8 of 41

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

ASTM D120E1-87 Standard Specifications for Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 871-89 Practice for Occupational and Educational Eye and Face Protection

ANSI Z 891-86 Personnel Protection - Protective Headgear for Industrial Workers - Requirements

11 Head Protection

Safety hats or helmets are rigid headgear made of materials designed to protect the head from impact flying particles electric shock etc Each helmet consists of a shell a suspension cradle and a chinstrap

111

Employees working in areas where there is danger of head injury from impact from falling or flying objects or from electrical shock and burns shall be protected by protective helmets as per ANSI referenced standards or equivalent

112

The suspension cradle gives a helmet its impact distribution qualities It is therefore essential that it be properly adjusted to the wearers head so there is a gap of at least one and a half inches between the top of the suspension cradle and the helmet shell

113

Ancillary equipment such as earmuffs welderrsquos shields etc can be obtained to fit on helmet shells Holes should not be drilled into helmet to facilitate use of such equipment as this can seriously impair both the mechanical strength and the electrical resistance of the helmet

114

Safety hats or helmets shall not be painted

115

The complete helmet should be cleaned regularly with soap and water Helmets should be scrapped following any penetration high impact or subjection to extreme heat

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 9 of 41

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

116

All persons at all times when on a construction job site in an operating plant area should wear a safety helmet or whenever there are overhead hazards Metal hard hats do not afford proper impact or electrical protection and therefore are prohibited from all Site work areas

12 Eye and Face Protection

Protection of the eyes and face from injury by physical or chemical agents or light radiation is of prime importance in an industrial environment The type of protection selected will depend on the hazard but it should be borne in mind that all eye protection and most face protection devices must be considered as optical instruments They must be selected fitted and used with regard to both the type of hazard and the optical condition of the user The wearing of contact lenses is not recommended in areas where eye protection is required

121 Eye Protection from Impact

Factors to be considered in selecting impact resistant eye protection include the degree of protection required and the comfort provided as required by ANSI or equivalent requirements

Four basic types of protection are

1 Spectacles used for protection against frontal impact When fitted with side shields they afford limited protection against side impact and should not be worn while driving if they interfere with peripheral vision

2 Flexible fitting goggles A flexible frame surrounding the lens gives protection against flying objects

3 Cushion fitting goggles A rigid plastic frame surrounding the lens and a separate cushioned fitting surface on the facing contact area gives protection against flying objects

4 Chipping goggles Separate rigid plastic eyecups with lens Designed in two shapes one for individuals who do not wear spectacles and one to fit over prescription spectacles

122 Eye Protection from Radiant Energies

In addition to damage from physical and chemical agents the eyes are vulnerable to the effects of radiant energy such as that produced during welding Visible and non-visible bands of the light

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 10 of 41

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

spectrum can produce harmful effects upon the eyes and special attention must be paid to the selection of eye protection from these hazards

123 Face Protection

Face shields protect the face and neck from flying particles sprays of hazardous liquids splashes of molten metal and hot solutions Where required safety spectacles and chemical goggles shall be worn under the face shield

13 Hand Protection

The kind of gloves used depends primarily upon the material or equipment being handled and can be resistant against one or more of the following heat acid caustic slipping wear fire oil sharp edges general wear and tear cold etc Gloves should not be used near moving machinery as they can be caught and trap the hand before it can be withdrawn from the glove

14 Foot Protection

Foot protection used must be manufactured to the referenced ANSI standard Z41-83 (or its equivalent) Safety footwear is available in many styles with special soles to resist oil abrasion heat and other abuses to which the footwear may be subjected Comfort is particularly important for the wearer so safety footwear must fit properly Approved safety footwear is sturdy work shoes with leather uppers andor leather composition with steel toecaps Soles and heels are non-slip type Fashion type shoes with canvas nylon andor other soft composition uppers or soles are not considered safety shoes and are not approved

15 Hearing Protection

Increasing attention is being paid to the problem of excessive noise in industry Noise can be defined as any unwanted sound The intensity of noise is commonly expressed in terms of decibels (dB) and measured by a sound level meter Medical authorities state that continual exposure to noise levels above 90 dB for an eight-hour day five-day workweek may endanger a persons hearing The safe period of exposure to a noise level is inversely proportional to the level of the noise Hearing loss will result from over-exposure to excessive noise levels Only after engineering and mechanical methods of reducing noise levels have been explored should consideration be given to providing hearing protection to individual workmen Whenever it is infeasible to reduce the noise levels or duration of exposure to within the limits hearing

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 11 of 41

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

protection devices shall be provided and used There are two types of hearing protection available namely the plug type and the cup (or muff) type The proper individual fitting of both types of hearing protection is critical as any sound leakage can seriously impair efficiency of these devices

151 Ear Plugs

Earplugs are placed into the canal of the outer ear Materials used for these plugs are rubber plastic wax foam or Swedish wool Disposable types are preferred as they give good protection and are very sanitary

152 Ear Muffs

Earmuffs cover the external ear to provide an acoustic barrier The effectiveness of earmuffs varies considerably due to differences in manufacturer size shape seal material shell mass and type of suspension Head size and shape can also affect their performance Liquid or grease filled cushions between the shell and the head are more effective than plastic or foam filled types but they would present material leakage problems

The use of hearing protection devices shall be properly evaluated to ensure that the selected devices give the necessary noise attenuation and protection

16 Fall RestrainingArresting Devices

There are several types of fall restraining devices used throughout the construction industry The two most commonly used ones are the full body safety harness and the safety belt Harnesses are used for above groundwork where fall restraining and arresting protections is required Safety belts are used to restrain the wearer at his place of work Safety belts should not be used as part of the fall arrest system

161

Full body harnesses are required when working in areas with no guard rails at heights above 182 meters (6 feet) or for potential falls of six feet or greater Exceptions shall require the review and concurrence of the Project Manager and the Branch HSE Officer

162

Special attention should be given to achieve a snug fit of the safety harness as it is easy for a man to slip through sound but badly adjusted equipment and fall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 12 of 41

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

163

No fall restraining or arresting device is any stronger than the point of attachment Therefore all users should be carefully instructed in the importance of a firm anchorage16 fall restraining arresting devices must be stored in clean and dry conditions away from sunlight and must be thoroughly inspected both on issue and at the start of each shift

164

Fall protection devices shall be capable of supporting a minimum dead weight of 2450 kilograms (5400 pounds) (Refer to OSHA 29 CFR 191066 Appendix C - 1991) The maximum length of standard lanyards shall be limited to provide for a fall of no greater than 182 meters (6 feet) except in the case of mechanical fall arresting devices which have been reviewed and received concurrence by the Project Manager and the Branch HSE Officer The lanyard shall have a minimum breaking strength of 2450 kilograms (5400 pounds) All fall arrestingrestraining devices and hardware shall be manufactured to ANSI or equivalent standards

165

During all operations conducted from a personnel platform (man basket) at any height above ground level fall protection devices (lanyards) shall be secured to an anchorage point or a structural member located on the basket which can support a minimum dead weight of 2450 kilograms (5400 pounds)

Note All personal protective equipment shall meet ANSIOSHA or their equivalent requirements Any worker 182 m above ground without the protection of a guardrail system or in a confined space shall wear a full body harness and standard lanyard Respiratory protection shall be used anytime workers could inhale air contaminants exceeding permissible exposure limits (PEL) and when an oxygen deficient atmosphere could be encountered Breathing quality air shall be supplied to the worker through the use of an air fed hood or self-contained breathing apparatus

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 13 of 41

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

SECTION 1C- WELDING CUTTING AND BRAZINGThis section outlines the principals involved and the precautions to be taken in gas welding cutting and brazing and electric arc welding operations Weldingcutting are safe operations if carried out in the correct manner Where equipment is defective or there is no well-arranged well-lit or properly ventilated working place hazards can arise

INSTRUCTIONS AND STANDARDS

American National Standards

ANSI Z491 Safety in Welding and Cutting

ANSI Z871 Practice for Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

11 Gas Welding Oxy-Acetylene Equipment and Use

Personnel working with welding equipment shall be trained competent and provided with personal protection equipment Welding goggles helmets screens forced ventilation and similar equipment shall be provided to all workers and to trainees in the immediate area

111 Gases

Oxygen (O2) is odourless It can promote rapid combustion therefore grease and oil must never be used near oxygen as this could cause fire Oxygen cylinders or apparatus shall not be handled with oily hands or gloves A jet of oxygen must never be permitted to strike an oily surface greasy clothes or enter fuel oil or other storage tanks Acetylene (C2H2) has a distinct odor often likened to that of garlic or sour apples

It is combustible when mixed with air over a wide range (25 - 81) Acetylene burned with oxygen can produce a higher flame temperature than any other commercial gas Acetylene becomes unstable at pressures above 103 kPa (15 psig) which means it may explode Under no conditions shall acetylene be generated piped (except in approved cylinder manifolds) or utilized at a pressure in excess of 15-psi gauge pressure Inside the cylinder acetylene is dissolved in acetone to prevent internal explosion therefore it is essential that acetylene cylinders be stored handled and used in the vertical position to prevent the liquid acetone from escaping and damaging the valves and other equipment

Warning Regulated Acetylene pressures must never be allowed to exceed 103 kPa (15 psig) or it may explode

112 Colour Coding of Cylinders

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 14 of 41

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Color-coding can be of great help but also a potential source of danger as there is no internationally recognized standard colour code

113 Storage Of Cylinders

1131

Cylinders should be stored in a safe dry well-ventilated place prepared and reserved for that purpose Flammable substances such as oil and volatile liquids or corrosive substances should not be stored in the same area Oxygen cylinders and flammable gas cylinders shall be stored separately at least 66 meters (20 feet) apart or separated by a fire proof 16 meters (5 feet) high partition All storage areas shall have ldquoNo Smoking Permittedrdquo signs prominently displayed All cylinders should be chained or otherwise secured in an upright position To prevent rusting cylinders stored in the open should be protected from ground contact extremes of weather or contact with water Valve caps shall be kept in place when cylinders are not in use Flammable substances shall not be stored within 50 feet of cylinder storage areas

1132

Cylinders shall not be stored at temperatures exceeding 54oC (130oF) Accordingly they should not be stored near sources of heat such as radiators furnaces or near highly flammable substances like gasoline Cylinders shall be stored out of the direct rays of the sun in protective enclosures or sun shelters

1133

Cylinder storage should be planned so that cylinders will be used in the order in which they are received from the supplier Empty and full cylinders must be stored separately with empty cylinders plainly marked as such to avoid confusion Empty cylinders should be segregated according to the type of gas they have held

1134

All cylinder storage rooms shall be ventilated sufficiently so that explosive concentrations of gas cannot accumulate Smoking or any other source of ignition shall be prohibited near storage areas and appropriately marked ldquoNo Smokingrdquo as in Section 1131 above All wiring shall be in conduit and electric switches shall be located outside the room All electrical installations shall meet the National Electrical Code (NFPA 70) for hazardous areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 15 of 41

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

114 Handling of Cylinders

Serious accidents may result from the misuse abuse or mishandling of cylinders

1141

Cylinders should never be lifted by their valves since the valves are not designed to take such stress When the cylinder is not in use the valve shall be protected with the valve cap

1142

All valves must be fully closed before a cylinder is moved Unless a trolley or special carrier is used regulators and hoses should be detached from the cylinders for moving

1143

If cylinders are to be lifted by a crane specially designed bottle holders with lifting eyes should be used Chain and wire rope slings can allow cylinders to slip Where a trolley is to be used for slinging its base should be strong enough to take the weight of the cylinders Do not lift a cylinder with an electromagnet

1144

Cylinders in transit on vehicles shall have valve caps in place and be firmly secured to prevent movement Cylinders shall be secured to avoid any violent contact Loading and unloading shall take place carefully Cylinders shall not be dropped thrown dragged used as rollers or as a support No damaged or defective cylinder shall be used

1145

When in doubt as to the proper handling of a compressed gas cylinder or its contents the supplier of the gas should be consulted Depleted cylinders shall be returned to the supplier with the valves closed and the valve protection caps in place Cylinders even those marked empty should be treated as a possible hazard and handled with great care as they still contain some gas

115 Inspecting Equipment

All equipment should be examined immediately before use and regularly maintained All welding operations shall be conducted in well-ventilated areas

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 16 of 41

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

1151

Only soapy water should be used to check for leaks Presence of a leak is often indicated by a hissing sound or unusual changes in the torch flame Cylinders and valves should be kept clean Valve sockets shall be kept free of grit dirt grease or oil JWSP-MAN-01 REV 0 Page 101 of 267 January 2006

1152

Hoses should be used for one type of gas only and color coded for identification They should be examined before use for any signs of splitting which might give rise to leakage All connections should be made by clips or crimps The hoses used for acetylene and for oxygen shall not be interchangeable

1153

Connections and check valves should be regularly examined Equipment should be fitted with the correct pressure regulators and a regular check should be made to ensure that the regulator is working properly The torch nozzle should be kept closed An acetylene cylinder valve wrench shall be available at all times for the cylinder in use

1154

Means of torch ignition should be readily available A friction lighter shall be used for this purpose

1155

Acetylene can form explosive compounds in contact with certain metals or alloys particularly unalloyed copper or silver Joint fittings or lines made of copper should not be used and acetylene should not be allowed to come into contact with copper pipe work or tubing Only approved materials shall be used for acetylene systems

1156

It is dangerous to let the torch flame come into contact with gas cylinders or for the lighted torch itself to be left unattended Torches shall never be sat down while lit It is equally dangerous to rest blowpipes even extinguished ones on old drums ldquoEmptyrdquo drums that have contained low flash point liquids are known to have become lethal bombs when a hot welding torch was laid down on them

1157

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 17 of 41

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Cylinders in use should be kept upright on a custom-built stand fitted with a bracket to accommodate the hoses and equipment or otherwise secured The metal cap should be kept in place to protect the valve when the cylinder is not connected for use

116 Faults

It is not uncommon for minor ldquoexplosionsrdquo to occur during welding or cutting Most are more frightening than harmful but some can lead to very dangerous conditions

There are four general groupings of these faults

1 Snap out can occur during use when

- Both regulators are set at an incorrect pressure

- Torch nozzle obstructed

- Nozzle held too close to the work Corrective action

- Completely shut both torch valves

- Check regulator setting

- Check cylinder pressures

- Check nozzles

- Re-light

- Ensure adequate gas flow

2 Backfire can occur on lighting up when

- Regulators not set to correct pressure

- Light applied before flow of gas mixture properly established Corrective action

- Close both torch valves oxygen first

- Check cylinder pressures

- Check and adjust regulator settings

- Cool torch and check nozzle orifice for obstruction

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 18 of 41

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

- Re-light

3 A flashback is very dangerous Gases being mixed in the hose(s) cause flashback Usually this mixing of gases occurs when the hoses have been disconnected from regulators or torches or when a new hose is being used for the first time Sometimes it is due to loose connections Usually one of the hoses will have burst and possibly ignited

Preventive action

- Use flashback flame arrestors for regulator and torch

- Ensure all connections are tight

- Ensure cylinder valves are open and torch valves closed

- Set regulators to the required pressures

- Purge each hose separately and consecutively by opening the torch valve and allowing gas to flow for sufficient time to ensure only pure gas remains in the hoses

- Close the valve for each gas as the purge is completed

- This purge should be carried out only in the open or in extremely well ventilated areas

Corrective action

- Close both torch valves

- Close both cylinder valves

- Extinguish hose if alight

- Repair equipment and hoses

117 Fuel Gas and Oxygen Manifolds

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in English and Arabic letters at least 1-inch high which shall be either painted on the manifold or on a sign permanently attached to it Fuel gas and oxygen manifolds shall be placed in safe well ventilated and accessible locations They shall not be located within enclosed spaces Manifold hose connections including both ends of the supply hose that lead to the manifold shall be such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header connections Adapters shall not be used to permit the interchange of hose Hose connections shall be kept free of grease and oil When not in use manifold and header hose connections shall

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 19 of 41

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

be capped Nothing shall be placed on top of a manifold when in use which will damage the manifold or interfere with the quick closing of the valves

12 Electric Arc Welding

Arc welding is a process for joining metals by heating with an electric arc For arc welding two welding leads the electrode lead and the work lead are required

121 Voltage

The voltage across the welding arc is normally within the range 20-40V The voltage supplied however needs to be somewhat higher so that means of stabilizing and regulating the arc current can be introduced into the circuit Using DC a 60-80V supply will usually suffice Using AC an 80-85V supply will suffice although some of the latest techniques need an open circuit voltage of up to 100V between electrode and work It should be remembered that a nominal 100V supply has in fact a peak voltage of 141V For these reasons DC should be used for welding operations in any situation where the effect of electric shock is likely to be extreme such as in damp and confined spaces (tanks boilers etc)

122 Welding Connections

In each welding circuit there are three main connections

1) The welding lead

2) The welding return

3) The welding ground

1221

The welding lead is the conductor carrying the welding current from the point of supply to the electrode holder

1222

The welding return is the conductor carrying the current back from the work to the point of supply Its conductivity should at least equal that of the welding lead The welding return should be used to ground the metal case of the welding machine This high current capacity is essential because all the current fed to the arc has to be conducted back to the supply point The current involved could be as high as 300 amperes on a hand welding operation

1223

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 20 of 41

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

A continuous welding ground is essential and indispensable for conductors since electric currents as low as 50 mill amperes can be fatal The ground should be of low impedance so that there can be no rise in the potential of the work and so that sufficient fault current passes quickly enough to cut off the supply if necessary It is recommended that a separate substantial conductor bond the welding ground to the ground of the main supply system The frames of all fixed arc welding and cutting machines shall be grounded either through a third wire in the cable containing the circuit conductor or through a separate wire which is grounded at the source of the current Welding grounds and returns should be securely attached to the work by cable lugs by clamps in the case of stranded conductors or by bolts for strip conductors Bolts are unsatisfactory for stranded conductors since the strands can loosen under the bolt head and become detached (see Manufacturers Grounding Specifications for Electrically Powered Equipment and Engine Powered Equipment)

1224

Welding cable insulation needs to be abrasion resistant to withstand normal treatment over rough ground and the wear inflicted by foot and vehicular traffic Where feasible cables should be additionally protected by stringing overhead or by using cable covers They should be regularly examined for cuts or abrasions to the insulation damaged cable shall not be used Holders should be unplugged when not in use If joints become necessary standard plug and socket couplings shall be used Splices are not allowed in welding cables

1225

Electrode holders shall be constructed to accommodate all sizes of electrodes and with an ejector for hot spent stubs

1226

A shield should be fitted between electrode holder and handle to prevent live elements from being touched The handle itself shall be made of non-flammable insulating material and be free from joints or holes

1227 Auxiliary Power Outlets

Most welding machines are furnished with an alternator which produces 3 KVA of 115 and 230 volts As a safety factor all power hand tools which are not double insulated should be grounded to the welder frame Ground Fault Interrupters are required where power output exceeds 5 KV Placards must be placed on the welding machine

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 21 of 41

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

13 Welding and Cutting Tanks Vessels and Drums

Careful tests should be made to establish that the tank vessel or drum is free from explosive flammable vapours or substances The responsible supervisor should make a check before permitting any work to begin It is essential that past contents of the tank vessel or drum be identified If there is any doubt or if the tank is known to have had any kind of flammable or explosive content it should be cleaned and purged thoroughly prior to welding or cutting Extreme care should be taken in considering methods of tank welding and cutting as these jobs are hazardous operations unless correct safety measures are taken Welding and cutting on drums is strictly controlled and in most cases prohibited

Note The use of oxygen for blowing out containers and small tanks is forbidden

14 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all times Airline respirators may be needed for men working inside such places No gas cylinders should ever be allowed into such an area The hoses and equipment used inside must be in excellent condition Where work in confined spaces has to take place over several days the hoses and equipment shall be taken outside overnight in case of any leakage that could occur resulting in a build-up of gas

15 Personnel Protection

151

Helmets welding hoods and goggles are necessary to protect eyes and face against heat and the effect of the intense light emitted by welding operations

152

Goggles are required to protect the eyes of the welder from pieces of flying slag chips during electric arc welding They should be fitted with opaque sidepieces These goggles should also be worn under the regular welding hoods

153

Electric welding operations must be effectively screened to prevent nearby personnel from being affected by harmful radiation Screens should be made from fire resistant materials or should be

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 22 of 41

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

suitably treated with a fire resistant compound Screens should be designed and placed so as not to restrict the flow of air for ventilation purposes

154

Gloves are necessary protection to the hands against heat sparks molten metal and radiation Leather suitably reinforced at points of maximum wear is the material most generally worn Gloves should be long enough to protect wrists and forearms When gloves are not long enough protective sleeves of similar materials should be worn Boots and leggings are essential to provide effective protection against heat flying sparks and falling metal Pant cuffs shall never be worn inside of the safety boot

SECTION 1D - PRESSURE TESTINGIt is essential that safe practices be observed during pressure testing due to the potential hazards associated with high-pressure liquids and gases

INSTRUCTIONS AND STANDARD

American Petroleum Institute Standards

API-STD-620-90

Design and Construction of Large Welded Low Pressure Storage Tanks Eighth Edition

American National Standards Institute

ANSI B 165-88

Steel Pipe Flanges and Flange Fittings

ANSI B 313-90

Chemical Plant and Petroleum Refinery Piping

ANSI B 314-89

Liquid Transportation Systems for Hydrocarbons Liquid Petroleum Gas Anhydrous Ammonia and Alcohols

ANSI B 318-89

Gas Transmission and Distribution Piping System American Society of Mechanical Engineers Standards

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 23 of 41

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Section VIII (ASME Boiler and Pressure Vessel Code)

11 Preparation

111 Safety Requirements for (Pressure Testing)

The person in charge of hydrostatic testing should have read and fully understand the safety requirements and procedures involved with pressure testing All persons who will work on the pressure test must be informed of the potential hazards and the necessary safety precautions A work permit shall be issued prior to commencement of hydrostatic test operations

112 Supports

Piping vessels supports and foundations designed for gas service shall not be overloaded by the extra weight of the test liquid Temporary supports and braces may be required

113 Vents and Drains

Vents of adequate capacity shall be installed at high points to vent air gas from the item while it is being filled with the test liquid Hazardous gases or vapours must be vented clear of any area where personnel are working or where there is any possible source of ignition Drains must be installed at a suitable location to allow removal of the test liquid

114 Valves

Where isolation valves are used to contain test pressures they must be of adequate rating for the pressure to be encountered If isolation valves are used in lieu of blinds provisions shall be made to ensure that no over-pressurizing can occur in equipment that is not being tested due to possible valve leak

115 Piping and Joints

Prior to testing investigations shall be carried out to verify whether or not temporary restraints are required to restrict the movement of piping and joints during testing when necessary adequate restraints shall be provided

116 Vacuums

On vessels or tanks which could collapse if subjected to a vacuum there must be sufficient vent relief capacity to assure that the vessel cannot be subjected to a vacuum by draining the test fluid or by sudden cooling

12 General Requirements

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 24 of 41

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

121

Do not approach system never previously tested corroded piping or vessels or vessels with welds never previously tested during the stepwise increase in pressure to the strength test pressure After the strength test pressure has been reached and held for a specified interval the equipment may be approached The actual pressure at which the system under test will be approached for close inspection shall be specified in the test procedure

122

Pressure relief valve(s) shall be used to prevent over pressuring of the equipment

123

Any ancillary equipment that is part of the system and not required to be included in the test must be isolated by valves (subject to part 114) or blind flanged and vented or disconnect

124

Only calibrated test gauges shall be used and they should be mounted in the upright position Pump discharge gauges must be visible to the pump operator for the duration of the test

125

The pressure rise during a pressure test should be gradual and under control to allow time for material to strain and time for personnel to check for leaks

13 Test Liquid

131

Water is normally the preferred test liquid Alternatives must be approved by a deviation from the standard or they may be used if they are specifically permitted by contract specifications and or manufactures specifications

132Pneumatic (gas) testing may be required for specified jobswork Pneumatic testing other than specified jobswork may be done only with the explicit permission of the Project Manager Testing with air or other gases under pressure can be hazardous due to the explosion potential

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 25 of 41

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Section 1E - Blasting amp Painting To define and promote safe working procedures for abrasive blasting as well as painting operations which must be adhered to by personnel and contractors

10 Introduction

11

Abrasive blasting involves the utilisation of hand-held or automatic equipment which directs a blast of abrasive material (wet or dry) against a surface in order to clean the surface remove burrs and excess surface material or develop a surface finish

12

Common abrasives vary from metal shot and clipped wire to non-metallic abrasives such as aluminium oxide garnet glass beads metallic slag plastic media silicon carbide crushed pips and most commonly mineral slag

13

The two types of abrasive air blast cleaning systems to be considered

A) Portable blast cleaning machines consisting of a source of compressed air in the 7 bar range a pressure vessel or container to contain the abrasive a metering device to control the air-to-abrasive ratio and flow a flexible hose to deliver the abrasive a hand-held nozzle to direct the abrasive onto the blasting surface and fitted with the approved safety devises

B) Manual units within blast cleaning rooms These units are similar to the portable units except that the operation is confined to a chamber especially designed for the purpose

List of Safety Equipment

1 Air fed Blast Helmet including spare visors for the helmet

2 Ear Muffs plugs

3 Operators Breathing Equipment for cleaner air

4 Blast apron (ankle length)

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 26 of 41

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

5 Complete blast suit

6 Leather gloves

7 Safety shoes

8 The pot operators should also be wearing appropriate safety clothing and dust masks

20 Health hazards

21

The principal hazards associated with abrasive blasting are the vast amount of airborne dust usually generated during operation The dust originates from broken-down abrasives as well as pulverised surface coating and abraded material from the object being blasted The health hazard is related to the concentration and particle size of the dust as well as its composition Remembering differing blasting media have differing compositions and therefore differing health risks As far as composition is concerned the greatest hazard lies with dusts containing silica (quartz)

22

The inhalation of this dust over an extended period causes the serious disabling lung disease known as silicosis The most common source of silica dust is the use of silica-containing materials such as silica sand as an abrasive Other forms of media can carry other types toxicants be aware of the risks and prepare accordingly

23

Dust originating from the component being blasted can also pose a health hazard Metal dusts such as lead cadmium and manganese are extremely toxic upon inhalation

24

Paint coatings may also contain lead or chromium pigments which may also present a health hazard if inhaled

25

A second health hazard connected with abrasive blasting is that of excessive noise Noise originates from the abrasive blast discharge nozzle as well as from the impact of the abrasive on the surface being cleaned Compressors may also contribute to high noise levels

30 Safety Measures

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 27 of 41

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

31

In a blast-cleaning chamber the ventilation and exhaust system as well as the filter system should be inspected regularly to ensure correct functioning

32

Blast operators and assistants must wear personal protective equipment whenever performing blasting work This equipment should consist of the following Heavy canvas or leather gloves gauntlets and leggings where appropriate heavy canvas or leather aprons safety shoes and suitable eye protection as well as ear muffs

33

For personal health reasons respiratory protective equipment should be assigned to individual workers for their exclusive use

34

Respirators should be checked routinely to ensure safe and effective operation

35

All manual abrasive blasting units should be equipped with positive abrasive shut off or dead manrsquos controls which cannot be activated by dropping the nozzle or hose

36

In order to reduce the possibility of static electricity discharges all hose lines should be manufactured from an approved rubber anti-static material Grounding wire shall be AWG-4 or larger

37

The air pressure should not exceed the manufactures specifications

38

Whenever possible blasting operations being carried out with a portable unit should be isolated from other personnel in the area This can be done by erecting suitable screens

39

Blast chambers shall be cleaned of dust and waste material daily to prevent dust build up Vacuum or wet methods of dust removal are preferred

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 28 of 41

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

310

Respirable air-fed hoods shall be worn by all personnel inside confined spaces whenever

A) Blast cleaning or spray coating is in progress

B) Solvent cleaning or brush painting is in progress in a confined space having a volume of less than 16 msup3

311

After blasting operations are completed all spent abrasive media must be captured and removed to the approved dumping site as soon as possible

40 Storage handling of Paint and abrasives

41

Paint and thinner shall be stored in well-ventilated area or shelter according with recommended storage temperatures Shelter storage temperature shall not exceed 35 degree centigrade unless stated otherwise in the paint manufacturer data sheet

42

Paints which have exceed the shelf life given in the data sheet shall be set aside and removed Expired shelf life paint shall not be used

43

Temporary storage of paint materials covered with canvas tarpaulins shall not exceed 14 days period

44

Paint container showing signs of leakage shall be discarded and not to be used for coating

45

All spray painting work shall be carried out with adequate ventilation or with appropriate

protection so as to remove and disperse solvent vapours and dust particles avoid fire and

explosion ensure safety of personnel and provide a safe working environment Fans supplying

fresh air shall be provided to all work areas where natural airflow is restricted

46

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 29 of 41

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Solvents and coatings shall not be applied to surfaces warmer than 80degC if practical alternatives exist

50 Airless spray coating

51

Airless spray guns shall never be pointed at anyone or at any part of the body

52

The trigger safety catch shall be engaged whenever the airless gun is left unattended

53

Airless spray equipment shall not be operated if any of the pressure system components is not in good condition

54

Solvents shall not be flushed into containers that are hotter than 50degC

Table 1 A - Ventilation Requirements for Confined Spaces

Volume of Confined Area Required Air Mover Capacity

msup3 BBL Ls cfm

16 100 472 1000

80 500 1180 2500

160 1000 2360 5000

800 5000 4720 10000

1600 10000 7080 15000

4000 25000 9440 20000

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 30 of 41

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Table 1B ndash PPE to be worn or used during Blasting and Coating

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

OSHA APPROVED Respirable Airfed Hood And Filter 1000129995 (21-444-934) 1000129991 (21-443-500)

Respirator Chemical Cartridge 1000128213 (27-370-800)

Dust Respirator 1000128165 (21-370-500)

Face Shield (1) 10000129345 (21-426-121)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

Blast cleaning operator other workmen

times times

times times times

Coating removal

times times times

Solvent cleaning

times times times

Coating Application

Brush Spray Brush Spray Brush Spray Brush Spray

O C O C O C O C O C O C O C O C

Epoxy amp Coal Tar epoxy times times times times times

Alkyd times times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 31 of 41

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times

Table 1B ndash PPE to be worn or used during Blasting and Coating (Contrsquod)

Key O = Outdoors C = Confined Spaces

Type of work to be Performed

Goggles Safety impact 1000129810 (21-434-249)

Gloves Leather 1000124493 ( 21-432-353)

Gloves Rubber 1000129636 (21-432-360 )

Hearing Protection 10000127803 (21-327-105) 10000127807 (21-327-272)

O C O C O C O C

Surface preparation

Wire brushing chipping amp Grinding

times times times times

times

times times

times

times

Blast cleaning operator other workmen

times

times

times

times

Coating removal

times

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 32 of 41

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

timesSolvent cleaning

times

Coating Application

Brush Spray

All

O C O C

Epoxy amp Coal Tar epoxy

times

times

times

times

Alkyd times times

Inorganic Zinc

times times

Chlorinated Rubber

times times

Bituminous times times times

polyurethane times times

SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor(If different from company Site HSE Officer)

1 Understand the requirements of the companys HSE policy2 Inspect the work site daily to report and correct unsafe methods and conditions3 Keep a permanent record of all injuries fires motor vehicle accidents (MVAs) property

damage and craneheavy equipment accidents that have occurred at the site4 Keep a record of every weekly safety meeting on site complete with subject discussed

and a list of attendees5 Set a personal example

12 Plant Equipment Manager1 Ensure that all equipment purchased or hired is safe is guarded and equipped with safety

devices and has been subjected to all necessary tests

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 33 of 41

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

2 Make certain that operators and attendants are employed only on equipment for which they have been thoroughly trained

3 Check that periodic tests inspections and maintenance are carried out when due4 Attend promptly to all equipment defects and advice site management of the need for

any dangerous equipment to be taken out of service until properly repaired

13 Site Engineer1 Organize sites so that work is carried out to the required standard with minimum risk to

men equipment and materials 2 Know the requirements of the companyrsquos HSE policy3 Be familiar with work permit procedures4 Give precise instructions on responsibilities for correct work methods5 Plan and provide for good housekeeping6 Coordinate with sub-contractors and other contractors on site to avoid any confusion

about areas of responsibility7 Position equipment effectively and ensure that electricity supply is installed used and

maintained correctly8 Check that equipment and tools (both power and hand tools) are maintained in good

operating condition9 Make sure that all men know how to obtain and administer first aid properly and

efficiently to all injured persons They should also know how to summon assistance in case of emergency and nominate others to act in your absence

10 Make sure that suitable personal protective equipment is available and that it is used11 Release supervisors and men when necessary for safety and fire training12 Cooperate with the safety engineer and the fire department by acting on their

recommendations13 Set a personal example

14 Foreman Supervisor1 Be familiar with those parts of the companyrsquos HSE policy applicable to the work on which

subordinate workers are engaged2 Incorporate safety procedures in routine tasks and see that they are obeyed3 Conduct weekly safety meetings with subordinates4 Conduct daily work site inspections to identify and correct any existing unsafe conditions

Document and coordinate the safety inspection activities and findings with the job site safety supervisor

5 Correct unsafe acts such as horseplay or the taking of unnecessary risks

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 34 of 41

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

6 Ensure that new employees are properly instructed in precautions to be taken before they are allowed to start work

7 Commend men who by action or initiative eliminate hazards8 Report accidents unsafe conditions and defects in equipment to immediate superiors9 Set a personal example

15 Worker1 Use the correct tools and equipment for the job Use protective clothing and equipment

provided2 Do nothing to endanger self or work mates3 Keep tools in good condition4 Refrain from horseplay and abuse of safety devices

equipment and welfare facilities4 Report any accidents near misses or hazardous conditions to immediate supervisor5 Read the Company safety rules and take note of special safety precautions in restricted

areas6 Obey all posted warning signs

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 35 of 41

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

INTERNAL MEMO

MARCON EMPLOYEESSubject REWARD FOR SAFETY COMPLIANCE AT Riyadh Refinery Work Site

In view to encourage our workers at site following strictly all safety requirement of PPE Body Harness and other site safety related requirement at site use of mobile and off coarse without any minor injury and attending daily tool box meeting at site Management has decided to reward with the following every month

Best employee for Safety compliance 1 x Samsung Smart Mobile phone

2nd employee for Safety compliance 1 x Wrist Watch

3rd employee for Safety compliance SR 200 ndash Mobile Phone recharge voucher

4th employee for Safety compliance SR 100 ndash Mobile Phone recharge voucher

5th employee for Safety compliance SR 50 ndash Mobile Phone recharge voucher

One employee consecutively rewarded for 3 months with Best OR 2nd employee for Safety compliance then he will be further rewarded with a cash price of SR 2000-

This reward will be applicable only for direct worker viz labor skilled worker technician foreman welder fabricator blaster painter mason etc

Award winner will be decided in coordination with Safety supervisor Safety officer Execution Engineers amp Project Manager

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik MohammedOperations Manager

CC Administration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 36 of 41

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

INTERNAL MEMO

TO MARCON EMPLOYEES

Subject SAFETY ISSUES

This is to bring to all of you who are working in this site Riyadh refinery should strictly follow and complies with the safety requirements

Keeping in mind to protect you in all aspect we are forcing you to strictly follow the safety requirements

Safety violators shall be punished as follow

1st violation Warning2nd violation 1 day salary deduction3rd violation 3 days salary deduction4th violation 5 days salary deduction5th violation Termination without any benefits and deportation

Reward One who fulfills and does fully follows daily all the requirements of the safety he shall be rewarded by the company by the end of this job

GOOD LUCK AND TAKE CARE OF YOURSELF AND OTHER AT WORK

Sheik Mohammed Date 00092015Operations Manager

CC Adminstration

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 37 of 41

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

INJURY REPORTING amp RECORDKEEPINGDOC No MRT-FRM-HSE-

001-124 Revision 00Issue Date 10 Nov

2014

Prepared ByHSE SUPERVISOR

Reviewed ByOPERATION MANAGER

Noted byGENERAL MANAGER

Project Riyadh Refinery

As of today (Hrs)Current date

(2015)

Man-hours Worked

First Aid Injuriesillness (FAI) Cases Nil Nil

Medical Treatment Cases (MTC) Nil Nil

Lost Time Injuryillness (LTI) Cases Nil Nil

On-Job Fatalities Nil Nil

Attachments are the details related to report under

Case study

Occupational Injury report

Incident report

Risk impact assessment

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 38 of 41

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

INCIDENT ACCIDENT REPORT

Form No MRT-HSF-008Revision 01Page 39 of 41

1 Place of Accident Incident 2 Day Date Time

3 Has the First Aid given to the injured person

Accident Incident Description

Select Cause of Accident Incident (where applicable)

- Behavior ( ) - Physical ( ) - Management Supervisor ( ) - Procedural

- Other (Health issue) please explain

No Name of VictimType First

Aid Taking care of in Not able to work for (days)

Near Misses

(Incident)

Minor (illness Injury)

Major Y N Hospital Time oftreatment

1234567

ESTIMATE LOSSNo Type of Loss Estimate No Type of Loss Estimate-WI1 82 93 104 115 12

Incident Accident Analysis

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 39 of 41

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT

CORRECTIVE AND PREVENTIVE ACTIONNo Cause Action PIC Due Date

Verify by Safety Officer

OTHER EXPLANATION

Reported by Acknowledged by

MR Concerned Department Owner Project ManagerDate Date

Doc No MRT-FRM-609-JSA-001-Rev 01 Page 40 of 41

• Table of Contents
• SECTION 1A - CONFINED SPACES
• SECTION 1B - PERSONAL PROTECTIVE EQUIPMENT
• SECTION 1C- WELDING CUTTING AND BRAZING
• SECTION 1D - PRESSURE TESTING
• Section 1E - Blasting amp Painting
• Table 1 A - Ventilation Requirements for Confined Spaces
• Table 1B ndash PPE to be worn or used during Blasting and Coating
• SECTION 1F ndash Responsibilities for Site Safety Officer Supervisor
• INJURY REPORTING amp RECORDKEEPING
• INCIDENT ACCIDENT REPORT