SAUDI ARAMCO CONSTRUCTION SAFETY

MANUAL
PREFACE
Dhahran, Saudi Arabia
February, 1993

The purpose of the Saudi Aramco Construction Safety Manual (CSM)

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

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

The construction industry functions in a dynamically changing work

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

Good loss prevention is an integral part of good project

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

A. G. AL-GHANIM,
Senior Vice President,
 Engineering and Project
Management

____________________________________

February 1993 - Construction Safety Manual - Table Of Contents Page ii

February 1993 - Construction Safety Manual: Table of Contents
Page i
I. Administration
........................................................................
1
1.0SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM
2
1.1 Loss Prevention Policy Implementation
2
1.1.1 Compliance With Construction Requirements
2
1.1.2 Operating Standards and Instructions
2
1.1.3 Personal Protection
2
1.1.4 Inspection

2
1.1.5 Education and Training
3
1.1.6 Motivation and Recognition
3
1.1.7 Job Placement
3
1.1.8 Response to Accidental Occurrences
3
1.1.9 Contractor Safety
3
1.1.10 Off-The-Job Safety
3
1.1.11 Traffic Safety
3
1.1.12 Accountability
4
1.1.13 Compliance Reviews
4
1.2 Saudi Aramco Loss Prevention Requirements For
Contractors 4
1.2.1 Non-Compliance
4
1.2.2 Assistance
...........................................................................
4
1.2.3 Standards and Instructions
5
1.3 Contractor's Loss Prevention Program
5
1.3.1 Written Program
5
1.3.2 Hazard Identification Plan
6

February 1993 - Table Of Contents Page ii

 1.3.3 Safety Supervisor
6
1.3.4 Safety Discussion
6

2.0SAUDI ARAMCO LOSS PREVENTION DEPARTMENT

SERVICES
7
2.1 Loss Prevention Program
7
2.2 Program Management Services
8
2.3 Program Maintenance Services
9

3.0ACCIDENT INVESTIGATION, ANALYSIS AND REPORTING

10
3.1 Reports Required by Saudi Aramco
10
3.2 Accident Investigation
11
3.2.1 Responsibilities for Investigation
11
3.2.1.1Supervisor/Safety Representative
11
3.2.1.2Project Manager
11
3.3 Cases to be Investigated
12
3.4 Accident Investigation Guidelines
12
3.5 Accident Analysis
12
3.5.1 Classification
12

4.0RESPONSIBILITIES FOR SAFETY

16
4.1 Contractor Senior Management
16
4.2 Design Engineer
.........................................................................
16
4.3 Contractor's Safety Officer
16
4.4 Construction Manager/Superintendent
17
4.5 Site Safety Supervisor
18
4.6 Equipment Manager/Supervisor
18
4.7 Engineer/Supervisor
18

February 1993 - Table Of Contents Page iii

 4.8 Foreman
18
4.9 Worker
19

5.0EMERGENCY PROCEDURES
20
5.1 Action to be Taken
20
5.2 Contact After Office Hours
20
5.3 Help in an Emergency
20

6.0SAFETY TRAINING
22
6.1 Safety Training for Supervisors
22
6.2 Safety Training for Workmen
22
6.2.1 Integrated Practices
22
6.2.2 Specialized Training
22
6.2.3 Use of Persuasion
23
6.2.4 Course Requirements
23
6.3 Scope of Training
24
6.3.1 Safety Training Topics For Supervisors
25
6.3.2 Induction Safety Topics For Workmen
27

7.0SITE PLANNING AND HOUSEKEEPING

28
7.1 Initial Planning
28
7.1.1 Hazard Identification Plan
28
7.1.2 Loss Prevention Program
29
7.1.3 Protection of Employees and Equipment
29
7.1.4 Transportation
29
7.1.5 Lifting Equipment
29
7.1.6 Demolition
...........................................................................
29

February 1993 - Table Of Contents Page iv

 7.1.7 Excavations
29
7.1.8 Scaffolding
29
7.2 Site Layout
30
7.2.1 Site Accommodation
30
7.2.2 Adequate Access Roads
30
7.2.3 Project Sign
30
7.2.4 Safe Means of Access and Egress
31
7.2.5 Parking Facilities
31
7.2.6 Drainage
...........................................................................
31
7.2.7 Vehicle / Heavy Equipment Paths On Site Vs
Pedestrian Paths
...........................................................................
31
7.2.8 Sand
...........................................................................
31
7.2.9 Fire Prevention
31
7.2.10 Site Illumination
31
7.3 Storage Areas
31
7.4 Welfare Facilities
32
7.5 Good Housekeeping
33
7.6 Construction Sites and Materials Storage Yards
33

8.0FIRST AID
36
8.1 Provision of First Aid Facilities
36
8.2 First Aid Attendants
37
8.3 First Aid Facilities At Work Site
38
8.4 Labor And Workmen Law
40

9.0PERSONAL PROTECTIVE EQUIPMENT

42

February 1993 - Table Of Contents Page v

 9.1 Head Protection
43
9.2 Eye and Face Protection
43
9.2.1 Eye Protection from Impact
44
9.2.2 Eye Protection from Radiant Energies
44
9.2.3 Face Protection
44
9.3 Hand Protection
44
9.4 Foot Protection
44
9.5 Hearing Protection
45
9.5.1 Ear Plugs
...........................................................................
45
9.5.2 Ear Muffs
...........................................................................
45
9.6 Fall Restraining/Arresting Devices
45

10.0 BREATHING APPARATUS

52
10.1 Selection of Equipment
52
10.1.1 Requirements For Use
53
10.1.2 Misuse
...........................................................................
53
10.1.3 Hazardous Substances
54
10.1.4 Contaminants
54
10.2 Respiratory Protective Devices
54
10.2.1 Air Purifying Respirators
54
10.2.1.1 Gas Masks
54
10.2.1.2 Chemical Cartridge Respirators
55
10.2.1.3 Particulate Filter Respirators (Dust
Respirators)
55
10.2.2 Supplied Air Respirators
55
10.2.2.1 Air Line Respirators
55

February 1993 - Table Of Contents Page vi

 10.2.2.2 Abrasive Blasting Respirators
56
10.2.2.3 Air Supplied Suits
56
10.2.3 Self Contained Breathing Apparatus (SCBA)
56
10.3 Training
57
10.4 Safety Precautions
57
10.4.1 Air Compressors
57

11.0 FIRE PREVENTION

60
11.1 Before the Job Starts
60
11.2 Layout
.........................................................................
61
11.3 Equipment Protection
61
11.4 Control of Ignition Sources
62
11.5 Flammable Liquids
62
11.5.1 Storage
...........................................................................
62
11.5.2 Handling of Flammable Liquids
63
11.5.3 Ventilation
...........................................................................
63
11.6 Combustible Materials
63
11.7 Housekeeping
63
11.8 Emergency Equipment
63
11.8.1 Water-Type Fire Extinguisher
64
11.8.2 Carbon Dioxide Type Extinguisher
64
11.8.3 Dry Chemical Type Extinguisher
64
11.8.4 Pressurized Water
64
11.9 Reporting a Fire
65
11.10 End-of-Shift Checks
65

February 1993 - Table Of Contents Page vii

 12.0 RADIO COMMUNICATIONS
67
12.1 Equipment
68
12.1.1 Remote Control Unit
68
12.2 Safe Operation
68
12.3 Radio Phrases
68
12.4 Phonetic Alphabet
69
12.5 International Communications Union Agreement
70
12.5.1 Monitoring of Circuits
71
12.5.2 Secrecy Act
71
12.5.3 Penalties
...........................................................................
71
12.6 Message Priorities for Company Operations
71
12.7 Distress Messages
73
12.7.1 MAYDAY
...........................................................................
73
12.7.2 Urgency Signal
74
12.7.3 Priority Traffic
75

13.0 TRANSPORTATION
76
13.1 Driver Requirements
76
13.2 Driver's Responsibilities
76
13.3 Motor Vehicle Regulations: Saudi Arab
Government and Saudi Aramco
.........................................................................
78
13.4 Vehicle Condition
78
13.5 Driver Training
80
13.6 Enforcement of Safe Driving Practices
80
13.7 Action Taken After a Saudi Aramco Motor Vehicle
Accident 81
13.7.1 Emergencies
81

February 1993 - Table Of Contents Page viii

 13.7.2 Remain at Scene
81
13.8 Passenger Seating and Seat Belts
82
13.9 Desert Driving
82
13.9.1 Stay With Vehicle
82
13.9.2 Sand Tires
...........................................................................
82
13.10 Vehicle Admittance to Restricted Areas
83
13.11 Operation of Motor Vehicles Within Saudi
Aramco Communities
83
13.11.1
...........................................................................
Seat Belts
...........................................................................
83
13.11.2 Traffic Regulations
83

14.0 AIRCRAFT OPERATION

84
14.1 General Operating Responsibilities
84
14.1.1 Captain/Pilot
84
14.1.2 Camp Supervisors
84
14.2 Passenger Briefing/Instructions, General (All
Aircraft Types)
85
14.3 Transportation of Dangerous Goods
86
14.4 Hours of Operation for Single-Engine Helicopters
86
14.5 General Precautions for Helicopters
86
14.5.1 Life Vests
...........................................................................
86

February 1993 - Table Of Contents Page ix

II. General And Civil
........................................................................
87
1.0 WORK PERMIT SYSTEM
88
1.1 Definitions
88
1.1.1 Restricted Areas
88
1.1.2 Issuer (Operation Supervisors)
89
1.1.3 Receiver (Authorized Craftsmen)
89
1.1.4 Work Permit
89
1.2 Issuance and Approval
89
1.2.1 Power Distribution Department Clearances
90
1.3 Precautions
90
1.3.1 Checklist
...........................................................................
90
1.3.2 Clear Area
...........................................................................
90
1.3.3 Work Stoppage
90
1.4 Handling of Issued Work Permit
90
1.5 Closing Out and Filing the Permit
91
1.6 Certification
91
1.7 12 Rules on Work Permit Procedure
91
1.8 Hold Tags and Multiple Lockouts
91

2.0 EXCAVATIONS, TRENCHING AND SHORING

96
2.1 Before Work Starts
99
2.2 Work Permit
99
2.2.1 Excavation near Saudi Telephone Cables
99
2.3 Underground Obstructions
100

February 1993 - Table Of Contents Page x

 2.4 General Precautions
100
2.4.1 Shoring Protective Systems
100
2.4.2 Personnel Protection
100
2.4.3 Inspection
...........................................................................
101
2.4.4 Clearance
...........................................................................
101
2.4.5 Mechanical Excavator
101
2.4.6 Walkways
...........................................................................
101
2.5 Access and Egress
101
2.6 Hazardous Atmospheres and Materials
101
2.6.1 Ventilation
101
2.6.1.1Hazardous Atmospheres
102
2.6.1.2Emergency Rescue Equipment
102
2.6.2 Exhaust Gases
103
2.6.3 Organic Lead
103
2.7 Edge Protection, Markers and Fixed Lighting
103
2.8 Roads, Streets, and Sidewalks
103
2.9 Backfilling
103
2.10 Borrow Pits
103

3.0 DEMOLITION
124
3.1 Before Work Starts
125
3.1.1 Responsible Supervisor
125
3.1.2 Original Drawings
125
3.1.3 Disconnections
125
3.1.4 Adjacent Structures and Public Areas
125

February 1993 - Table Of Contents Page xi

 3.1.5 Barricades/Signs
125
3.2 Method of Demolition
125
3.2.1 Demolition of Equipment Containing PCB:
Polychlorinated Biphenyl (ASKAREL)
126
3.2.2 Demolition Of Buildings With Asbestos /
Insulation Materials
...........................................................................
126
3.3 Stability During Demolition
126
3.4 Working Place Clearance
126
3.4.1 Access
...........................................................................
126
3.4.2 Glass Removal
126
3.5 Structural Steel Removal
127
3.6 Tanks, Vessels and Pipe Work (Explosion
Prevention) 127
3.6.1 Welding and Hot Cutting
127
3.6.2 Cold Cutting
127
3.6.3 Steaming and Ventilation
127
3.6.4 Residue Cleaning
127
3.7 Protective Clothing and Equipment
127
3.8 Mechanical Equipment Guards
128

4.0 ASBESTOS AND OTHER FIBERS

129
4.1 Types of Asbestos
129
4.2 Health Risks
129
4.3 Before Work Starts
130
4.3.1 Air Sampling
130
4.3.2 Job Details
130
4.3.3 Chest X-rays
130
4.4 Storage and Transportation
130

February 1993 - Table Of Contents Page xii

 4.5 Work Area
131
4.6 Handling and Use
131
4.6.1 Wetting/Ventilation
131
4.6.2 Cutting
...........................................................................
131
4.6.3 Protective Equipment
131
4.7 Protective Clothing
132
4.7.1 Types
...........................................................................
132
4.7.2 Contamination
132
4.7.3 Review
...........................................................................
132
4.8 Respiratory Equipment
132
4.8.1 Type
...........................................................................
132
4.8.2 Use
...........................................................................
132
4.8.3 Care
...........................................................................
133
4.9 Washing and Changing Facilities
133
4.10 Disposal of Waste Asbestos Materials/Clothing
133
4.11 Cleanliness of Work Areas and Equipment
133

5.0 WELDING, CUTTING, AND BRAZING

134
5.1 Gas Welding: Oxy-Acetylene Equipment and Use
134
5.1.1 Gases
...........................................................................
134
5.1.2 Color Coding of Cylinders
135
5.1.3 Storage Of Cylinders
135
5.1.4 Handling of Cylinders
136

February 1993 - Table Of Contents Page xiii

 5.1.5 Inspecting Equipment
137
5.1.6 Faults
...........................................................................
139
5.1.7 Fuel Gas and Oxygen Manifolds
140
5.2 Electric Arc Welding
140
5.2.1 Voltage
...........................................................................
140
5.2.2 Welding Connections
141
5.3 Protective Measures
142
5.4 Welding and Cutting: Tanks, Vessels and Drums
144
5.5 Confined Spaces
144
5.6 Personnel Protection
145
5.7 Health Hazards
145
5.7.1 Radiant Energy
145
5.7.2 Respiratory Effects
146

6.0 EXPLOSIVE MATERIALS

148

7.0 PILING OPERATIONS

149
7.1 Before Work Starts
149
7.1.1 Cranes
...........................................................................
150
7.1.2 Pile Gates
...........................................................................
150
7.1.3 Inspection
...........................................................................
150
7.1.4 Wedges
...........................................................................
150
7.1.5 Timber Block
150
7.1.6 Ground Support
151

February 1993 - Table Of Contents Page xiv

 7.2 Driving Piles
151
7.2.1 Pitching
...........................................................................
151
7.2.2 Driving
...........................................................................
151
7.3 Pile Extraction
151
7.4 General Precautions
152

8.0 ROADWORKS
153
8.1 General
153
8.2 Street and Road Construction, Excavations, and
Maintenance Traffic Controls
154

9.0 WORKING PLACES, LADDERS, AND SCAFFOLDING

155
9.1 Working Places, General
156
9.1.1 Falls
...........................................................................
156
9.1.2 Access and Egress
156
9.1.3 Lighting
...........................................................................
156
9.1.4 Prevention of Falls
156
9.1.5 Ramps
...........................................................................
156
9.1.6 Falling Material
157
9.1.7 Hot Surfaces
157
9.1.8 Slipping and Tripping
157
9.1.9 Roof Work
157
9.1.10 Insecure Structures
157
9.1.11 Work Over Water
158
9.2 Ladders and Stepladders
158
9.2.1 Selection

February 1993 - Table Of Contents Page xv

 ...........................................................................
158
9.2.2 Condition
...........................................................................
159
9.2.3 Position
...........................................................................
159
9.2.4 Use
...........................................................................
160
9.2.5 Stepladders
162
9.2.6 General
...........................................................................
162
9.3 Scaffolding Components
163
9.4 Requirements Common to All Scaffolding
168
9.4.1 Foundations
168
9.4.2 Posts
...........................................................................
168
9.4.3 Runners
...........................................................................
169
9.4.4 Bearers
...........................................................................
169
9.4.5 Board Bearers
169
9.4.6 Bracing
...........................................................................
170
9.4.7 Ties
...........................................................................
170
9.4.8 Platform Units
171
9.4.9 Guardrail Systems and Toeboards
172
9.4.10 Access
...........................................................................
172
9.4.11 Scaffold Ladders
172
9.4.11.1 Portable Straight and Extension
Ladders 173
9.4.11.2 Vertical Ladder
173

February 1993 - Table Of Contents Page xvi

 9.4.12 Workmanship
174
9.4.13 Inspections
174
9.5 Fabricated Tubular Frame and System
Scaffolding 174
9.6 Tube and Coupler Scaffolds
176
9.6.1 Independent Tied Scaffold
176
9.6.2 Light Duty Tube and Coupler Scaffolds
176
9.6.2.1Design, Loading and Dimensions
176
9.6.2.2Platform
177
9.6.2.3Limitations
177
9.6.3. Medium Duty Tube and Coupler Scaffold
177
9.6.3.1Design, Loading, and Dimensions
177
9.6.3.2Platform
177
9.6.3.3Limitations
178
9.6.3.4Bearers
178
9.6.4 Heavy Duty Tube and Coupler Scaffolds
178
9.6.4.1Design, Loading and Dimensions
178
9.6.4.2Platform
178
9.6.4.3Limitations
178
9.6.4.4Bearers
179
9.7 Free-Standing Tower Scaffolds
179
9.7.1 General Requirements
179
9.7.2 Design, Loading and Dimensions
179
9.7.3 Runners and Bearers
179
9.7.4 Bracing
...........................................................................
179
9.7.5 Ties
...........................................................................
179
9.7.6 Platform

February 1993 - Table Of Contents Page xvii

 ...........................................................................
180
9.7.7 Access
...........................................................................
180
9.7.8 Limitations
180
9.8 Mobile Tower Scaffolds
180
9.8.1 Foundations
180
9.8.2 Operation
...........................................................................
181
9.8.3 Limitations
181
9.9 Scaffolds for Tanks and Vessels
181
9.9.1 Bracket Scaffolds
181
9.10 Special Scaffolds
182
9.11 Scaffold Terminology
182

10.0 HAND TOOLS AND POWER TOOLS

193
10.1 Hand Tools, General
194
10.1.1 Quality
...........................................................................
194
10.1.2 Cleanliness
194
10.1.3 Repair and Storage
194
10.1.4 Selection
...........................................................................
194
10.1.5 Electrical Risks
194
10.2 Individual Hand Tools, Precautions
194
10.2.1 Screwdrivers
194
10.2.2 Hammer
...........................................................................
195
10.2.3 Chisels
...........................................................................
195
10.2.4 Picks and Shovels
195

February 1993 - Table Of Contents Page xviii

 10.2.5 Spanners and Wrenches
195
10.2.6 Pipe Wrenches
195
10.2.7 Pliers
...........................................................................
196
10.2.8 Jacks
...........................................................................
196
10.2.9 Hacksaws
...........................................................................
196
10.2.10
...........................................................................
Hand saws
...........................................................................
196
10.3 Power Tools, General
196
10.3.1 Quality
...........................................................................
196
10.3.2 Repair and Storage
197
10.4 Pneumatic Tools
197
10.4.1 General
...........................................................................
197
10.4.2 Individual Tools, Precautions
198
10.4.2.1 Jack Hammer and Concrete Breakers
198
10.4.2.2 Rock Drill
198
10.4.2.3 Grinding Machine
198
10.5 Cartridge Operated Tools
203
10.5.1 General
...........................................................................
203
10.5.2 Storage
...........................................................................
203
10.5.3 Selection and Training of Personnel
203
10.5.4 Personal Protective Equipment
204
10.5.5 Issue and Returns
204

February 1993 - Table Of Contents Page xix

 10.5.6 Work Permits
204
10.5.7 Use
...........................................................................
204
10.5.8 Maintenance and Repair
206
10.6 Electrically Operated Tools
207
10.6.1 General
...........................................................................
207
10.6.2 Maintenance and Storage
208
10.6.3 Personal Protective Equipment
208
10.6.4 Individual Tools, Precautions
209
10.6.4.1 Grinders
209
10.6.4.2 Drills
209
10.6.4.3 Saws
209
10.6.4.4 Radial Saws
210

11.0 PAINTS AND COATINGS

220
11.1 Flammability Hazards of Coating Materials
220
11.1.1 Flammable Materials
220
11.1.2 Flash Point (Definition)
220
11.1.3 Flammable (Explosive) Limits (Definition)
220
11.1.4 Fire Precautions
221
11.2 Health Hazards Associated With Paints
221
11.2.1 Toxic Materials
221
11.2.2 Dermatitic Materials
222
11.2.3 Prevention of Health Hazards
222
11.3 Ventilation in Confined Spaces
222
11.4 Surface Preparation
223
11.4.1 Abrasive Blast Cleaning
224

February 1993 - Table Of Contents Page xx

 11.4.2 Hydroblast and Steam Cleaning
224
11.4.3 Hand and Power Tool Cleaning
224
11.4.4 Chemical Cleaning
225
11.4.5 General Safety in Surface Preparation
225
11.5 Personal Protective Equipment
226
11.6 Paint Application
228
11.6.1 Paint Materials
228
11.6.2 General Safety In Paint Application
228
11.7 Scaffolding and Ladders
229
11.8 Tarring Operations
229
11.9 General Safety for Paints and Coatings
229

12.0 CONCRETE, CONCRETE FORMS, AND SHORING

232
12.1 General
.........................................................................
232
12.2 Reinforcing Steel
232
12.3 Bulk Concrete Handling
232
12.4 Concrete Placement
232
12.4.1 Concrete Mixers
232
12.4.2 Guardrails
...........................................................................
232
12.4.3 Bull Floats
...........................................................................
232
12.4.4 Powered Concrete Trowels
233
12.4.5 Concrete Buggies
233
12.4.6 Pumpcrete Systems
233
12.4.7 Concrete Buckets
233
12.4.8 Discharging on Slope
233

February 1993 - Table Of Contents Page xxi

 12.4.9 Back-Up Man, Truck Spotter
233
12.4.10 Pneumatic Hose
233
12.5 Vertical Shoring
233
12.5.1 General Requirements
233
12.5.2 Tubular Welded Frame Shoring
234
12.6 Forms and Shoring
234
12.6.1 General Provisions
234
12.6.2 Vertical Slip Forms
235
12.6.3 Tube and Coupler Shoring
235
12.6.4 Single Post Shores
236

February 1993 - Table Of Contents Page xxii

III. Mechanical Equipment And Materials
........................................................................
237
1.0 CRANES AND LIFTING EQUIPMENT
238
1.1 Competent Person
239
1.2 Saudi Aramco Crane Operations (General
Requirements)
239
1.3 Saudi Aramco Crane Operator Qualifications
240
1.4 Special Crane Operating Procedures
240
1.5 Effect of Wind Speeds on Crane Operations
240
1.6 Overhead Power Lines
240

2.0 SLINGS AND LIFTING GEAR (RIGGING)

245
2.1. Safe Working Load (SWL)
245
2.2. Chain Slings
246
2.2.1 Grades
...........................................................................
246
2.2.2 Repairs
...........................................................................
246
2.3 Wire Rope Slings
246
2.4 Synthetic Webbing Slings
247
2.4.1 Removal from Service
247
2.4.2 Repaired Slings
247
2.5 Synthetic and Natural Fiber Rope Slings
248
2.6 Care of Slings
249
2.7 Hooks
249
2.8 Spreader Bars
250
2.9 Eyebolts And Safety Hoist Rings
250

February 1993 - Table Of Contents Page xxiii

 2.10 Shackles
251
2.11 Rigger
.........................................................................
251

3.0 MECHANICAL EQUIPMENT

257
3.1 Operators
258
3.1.1 Qualifications
258
3.1.2 Licensing Requirements
258
3.2 Machinery Guards
259
3.2.1 Multi-Piece Tire Rims and Locking Rings
259
3.3 General Requirements
259
3.4 Compressors
260
3.5 Concrete Mixers and Batching Plants
261
3.6 Dumpers and Dump Trucks
262
3.7 Excavators
263
3.8 Fork Lift Trucks
264
3.9 Generators
265
3.10 Graders, Dozers, Scrapers, Loaders And
Miniloaders 266
3.11 Woodworking Machinery
266

4.0 MATERIALS HANDLING

268
4.1 Planning
268
4.2 Machine Transport
269
4.2.1 Dumpers
...........................................................................
269
4.2.2 Tractors and Trailers
270
4.2.3 Conveyor Belts and Monorails
270
4.2.4 Concrete Pumps
270

February 1993 - Table Of Contents Page xxiv

 4.3 Site Stores
270
4.4 Manual Handling
271

February 1993 - Table Of Contents Page xxv

IV. Electrical And Radiation
........................................................................
275
1.0 ELECTRICITY
276
1.1 Voltage
277
1.2 Temporary Installations
277
1.3 Hand Tools and Lighting
278
1.4 Work on Live Equipment
279
1.5 Overhead and Underground Cables
280
1.6 Overhead Power Transmission and Distribution
281
1.6.1 Initial Inspections, Tests, or Determinations
281
1.6.2 De-energizing Lines and Equipment
282
1.6.3 Emergency Procedures and First Aid
282
1.6.4 Night Work
282
1.6.5 Work Near/Over Water
282
1.6.6 Hydraulic Fluids
283
1.6.7 Live-Line Tools (Hot Sticks)
283
1.6.8 Material Handling
283
1.6.8.1Unloading
283
1.6.8.2Pole Hauling
283
1.6.8.3Storage
283
1.6.8.4Framing
283
1.6.8.5Attaching the Load
284
1.6.9 Grounding for Protection of Workers
284
1.6.9.1Isolation and Voltage Testing
284
1.6.9.2Applying and Removing Grounds
284

February 1993 - Table Of Contents Page xxvi

 1.6.9.3Grounding Distance
284
1.6.9.4Removal of Grounds for Testing
Purposes 284
1.6.9.5Grounding Electrode
284
1.6.9.6Grounding Cables And Clamps
285
1.6.10 Overhead Lines
285
1.6.10.1 Metal Tower Construction
285
1.6.10.2 Stringing/Removing De-energized
Conductors
287
1.6.10.3 Stringing Adjacent to Energized
Lines 288
1.6.11 Underground Lines
289
1.6.11.1 Work in Manholes
290
1.6.11.2 Trenching and Excavating
290
1.6.12 Construction in Energized Substations
291
1.6.12.1 Barricades and Barriers
291
1.6.12.2 Control Panels
291
1.6.12.3 Mechanized Equipment
291
1.6.12.4 Substation Fences
291
1.7 Electric Shock
292

2.0 IONIZING RADIATION

295
2.1 Methods of Protection Against Radiation
295
2.1.1 Distance
...........................................................................
295
2.1.2 Time
...........................................................................
295
2.1.3 Shielding
...........................................................................
296
2.2 Classification of Personnel and Exposure Limits
296
2.2.1 Radiation Workers
296

February 1993 - Table Of Contents Page xxvii

 2.2.2 Non-Radiation Workers
296
2.2.3 Exposure Limits
296
2.3 Responsibilities for Safe Handling
297
2.3.1 Contractor
...........................................................................
297
2.3.2 Competent Person
297
2.3.3. Radiographer
297
2.4 Shipping and Transportation
298
2.5 Storage Areas
298

February 1993 - Table Of Contents Page xxviii

V. Chemicals And Operations
........................................................................
300
1.0 LIQUEFIED PETROLEUM GASES
301
1.1 General
301
1.2 Storage
302
1.3 Handling of Cylinders
302
1.4 Leakage
303
1.5 Transportation
304
1.6 Operation
304
1.7 Action in Case of Fire
305
1.8 Bulk Installations
306
1.9 First Aid
306

2.0 PLANT OPERATIONS

307
2.1 Additional Information On Saudi Aramco
Instructions and Standards
307
2.1.1 General Instruction Manual
308
2.1.2 Producing Instruction Manual
308
2.1.3 Refinery Instruction Manual
308
2.1.4 Saudi Aramco Engineering Standards
308
2.2 Work Permit System
308
2.3 Operation of Plant Equipment
308
2.4 Shutdown and Maintenance in Plant Operations
309
2.5 Commissioning
309
2.6 Emergency Procedures: Saudi Aramco Disaster
Plan 309
2.6.1 Gas Release Emergency Procedures
310

February 1993 - Table Of Contents Page xxix

 3.0 PRESSURE TESTING
311
3.1 Preparation
312
3.1.1 SAES-A-004 (Pressure Testing)
312
3.1.2 Supports
...........................................................................
312
3.1.3 Vents and Drains
313
3.1.4 Valves
...........................................................................
313
3.1.5 Pipings And Joints
313
3.1.6 Vacuums
...........................................................................
313
3.2 General Requirements
313
3.3 Test Liquid
314

4.0 CHEMICALS
316
4.1 Hazard Identification System
317
4.2 Health Hazards
318
4.2.1 Inhalation Pathway Hazard
318
4.2.2 Skin Hazards
319
4.2.3 Hazards of Swallowing Chemicals
319
4.3 Emergency Treatment
319
4.3.1 Artificial Respiration
319
4.3.2 First Aid
...........................................................................
319
4.3.3 Showers and Eyewash Fountains
319
4.4 Fire Hazards
321
4.5 Reactivity Hazards
321
4.6 Transportation, Storage and Disposal
321
4.6.1 Transportation
321

February 1993 - Table Of Contents Page xxx

 4.6.2 Storage
...........................................................................
322
4.6.3 Containers
...........................................................................
322
4.6.4 Disposal
...........................................................................
322
4.7 Work on Equipment Which Has Contained
Tetraethyl Lead (Organic Lead Compounds)
324
4.7.1 Introduction
324
4.7.2 Precautions
325

February 1993 - Table Of Contents Page xxxi

VI. Marine
........................................................................
329
1.0 COFFERDAMS
330
1.1 Design
330
1.2 Before Work Starts
330
1.3 Construction
330
1.4 Potential Hazards
331
1.4.1 Structural Collapse
331
1.4.2 Overhead Loads
331
1.4.3 Dislodgment of Struts and Wales
331
1.5 Inspection
331
1.6 Leaks
332

2.0 MARINE OPERATIONS

333
2.1 Other Publications
333
2.2 General
334
2.3 Behavior on Floating Craft
334
2.4 Preparation for Transportation by Sea
334
2.5 Tide and Sea Effects
335
2.6 Care of Tools and Equipment
335
2.7 Housekeeping
335

3.0 DIVING OPERATIONS

337
3.1 Employment of Qualified Divers
337
3.2 Diving Equipment
338
3.2.1 Compressors
338

February 1993 - Table Of Contents Page xxxii

 3.2.2 Reserve Air Supply
339
3.2.3 Bail-Out Equipment
339
3.2.4 Maintenance
339
3.3 Safeguards
340
3.4 Physical Fitness
344
3.5 Medical Diving Emergencies: Procedures and
Responsibilities
345
3.5.1 Sports Divers
345
3.5.2 Commercial Divers
345
3.5.3 Coordinator, Diving Emergencies
345
3.5.4 Diving Medical Team
345
3.5.5 Marine Department
346
3.6 Personnel Transfer at Sea
346

February 1993 - Table Of Contents Page xxxiii

Appendix A
........................................................................
349
INDEX TO APPENDIX A
350

A.1
PROJECT MANAGEMENT AND CONTRACTOR'S SAFETY
COMPETITION SITE REGISTRATION FORM
351

A.2
CONTRACTOR SAFETY COMPETITION, RULES OF
COMPETITION
352

A.3
Saudi Aramco Safety, Health and Environmental
Requirements
357
1. Compliance With Safety Rules - Schedule 'D'
357
2. Deviations From Safety Rules
357
3. Failure To Comply
357
4. Saudi Aramco Assistance
357
5. Loss Prevention Program
358
6. Work Permits
358
7. Welding And Cutting Equipment
358
8. Personal Protective Equipment
358
9. Tools And Portable Power Tools
358
10. Cartridge Operated Tools
359
11. Ladders
359
12. Scaffolding
359
13. Electrical Installations And Equipment
359
14. Cranes And Rigging Equipment
359
15. Mechanical Equipment
359

February 1993 - Table Of Contents Page xxxiv

 16. Saudi Aramco Plant Operations
360
17. Transportation
360
18. Injury And Damage Reporting
360
19. Excavations
361
20. Work Over Or Adjacent To Water
361
21. Fire Prevention
361
22. Formwork
361
23. Ionizing Radiation
361
24. First-Aid Facilities
361
25. Handling, Transportation And Disposal Of
Hazardous Materials And Waste
362
26. Explosives
363
27. Sandblasting
363

A.4
HAZARD IDENTIFICATION PLAN (HIP)
364
HAZARD IDENTIFICATION PLAN:
365
I. Conduct Hazards Identification Review.
365
II. List Potential Hazards
365
III. Hazard Classification
365
IV. Corrective Action
366

February 1993 - Table Of Contents Page xxxv

Appendix B: Emergency/Disaster Planning And
Response
........................................................................
368
B.1
SEARCH AND RESCUE PROCEDURES
369

B.2
EMERGENCY/DISASTER PLANNING AND RESPONSE
370
B.2.1 General Provisions
371
B.2.2 Definitions
371
B.2.3 Plan Development Action Items
377

February 1993 - Table Of Contents Page xxxvi

Appendix C: Fire Safety Checklist For Evaluating
Construction Materials Store Yard
........................................................................
397
C.1
Fire Safety Checklist For Evaluating Construction
Materials Store Yard
398

February 1993 - Table Of Contents Page xxxvii

Appendix D: Saudi Aramco Crane Safety
Handbook
........................................................................
402
D.1
Crane Safety Handbook
403

February 1993 - Table Of Contents Page xxxviii

Appendix E: Suggestion Form
........................................................................
404

February 1993 - Table Of Contents Page xxxix

Appendix F: Distribution Form
........................................................................
406

February 1993 - Table Of Contents Page xl

Appendix G: Sanitary Code
........................................................................
408
Implementing The Saudi Aramco Sanitary Code - GI 151.006
409

February 1993 - Table Of Contents Page xli

Appendix H: General Instructions Master Index
........................................................................
410
General Instructions (GI) Master Index
411

February 1993 - Table Of Contents Page xlii

Appendix I: List Of Figures
........................................................................
415
List Of Figures
416

February 1993 - Table Of Contents Page xliii

Appendix J: List Of Tables
........................................................................
419
List Of Tables
420

February 1993 - Table Of Contents Page xliv

Appendix K: Forms
........................................................................
421
Preliminary Accident Report
423

Contractor Monthly Safety Report

424

Injury Summary
425

(Page ___of___)
425

Lift Plan For Cranes

426

Wire Rope Sling Inspection Log

427

Cartridge/Tool Issuance Control

428

Emergency Reporting Instructions

429

Project Management And Contractor's Safety Competition

Site Registration Form
430

February 1993 - Table Of Contents Page xlv

I. Administration

February 1993 - Construction Safety Manual: I. Administration

Page 1
1.0 SAUDI ARAMCO LOSS PREVENTION POLICY AND
PROGRAM
Saudi Aramco is committed to prevention of accidents to minimize loss of life or
bodily injury to its employees and damage to its physical assets.

In fulfilling this commitment, which is as essential and equally important as

production objectives, Saudi Aramco will provide and maintain a safe and healthful
work environment and protect the public against foreseeable hazards resulting
from operations.

Loss in production and property resulting from accidental occurrences can be

minimized through good management. Loss prevention is one aspect of this loss
control philosophy and is the direct responsibility of line management.

All management functions, including business line and associated management,

will comply with Saudi Arab Government and Company loss prevention
requirements applicable to the design, operation, maintenance and construction of
facilities and/or equipment. When conformity with any of these requirements is
not practicable or cost effective, an amendment to such a requirement will be
considered. Reviews for compliance with this policy will be performed on a
selective basis.

1.1 Loss Prevention Policy Implementation

1.1.1 Compliance With Construction Requirements

The application of the best petroleum industry loss control

practices minimizes risk to personnel and property. The design,
construction, modification, operation and maintenance of
facilities and equipment and construction as practiced by Saudi
Aramco and/or contractors, will meet Saudi Arab Government
and Saudi Aramco safety requirements as covered in this manual
and in relevant General Instructions, including the Company's
Engineering Standards. When conformity with any of these
requirements is impractical or not cost effective, a waiver will be
sought from the Chief Engineer.

1.1.2 Operating Standards and Instructions

Risks that cannot be eliminated through design are controlled by

operating standards and instructions. Compliance with safety
standards and instructions will be consistently enforced for both
Saudi Aramco operations personnel and contractors alike.

1.1.3 Personal Protection

Personal protective equipment, periodic environmental

monitoring and bio-surveillance will be used to help to protect all
employees against exposure to safety and health hazards (e.g.,
radiation, H2S, etc.) which cannot be eliminated.

February 1993 - Construction Safety Manual: Saudi Aramco Loss Prevention Policy And Program Page 2
 1.1.4 Inspection

Inspections to detect and correct unsafe practices and conditions

will be conducted periodically by Saudi Aramco and/or
contractor.

1.1.5 Education and Training

All employees shall be provided with ongoing safety education

and training as well as helping to develop those skills that are
required to perform, supervise and manage assigned tasks
without mishap.

1.1.6 Motivation and Recognition

Good communications, a viable suggestion system and the

recognition of good safety performance, encourages employee
participation in loss prevention programs.

1.1.7 Job Placement

Employees must only be assigned tasks that are consistent with

their physical capacities and job skills; this enable employees to
work without endangering themselves or others.

1.1.8 Response to Accidental Occurrences

Site specific effective emergency response plans must be

established as per the guidelines of Appendix B.2 of this manual.
These should include measures to contain or control an
emergency or disaster when an accident occurs to minimize the
loss of resources, a reporting and investigation system to
determine the cause of the accident, and the adoption of
corrective actions to avoid a recurrence.

1.1.9 Contractor Safety

Saudi Aramco proponent departments will monitor all

construction activity to ensure that services are performed in
conformity with Saudi Aramco loss prevention policies, principles
and practices and do not imperil any person or property.
Proponents will register each contractor employing 50 or more
persons in the Saudi Aramco Contractor Safety Competition.
(See Appendix A - Figures A.1, A.2 and A.3.)

1.1.10 Off-The-Job Safety

Off-the-job safety training (e.g. seat belt use) shall be vigorously

practiced to provide the means for all employees to protect
themselves and their families from harm during off-duty hours.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 3
 1.1.11 Traffic Safety

Operators of Company vehicles must receive defensive driving

training and driver evaluations and be in possession of a current
Saudi Arab government driver's license. A vehicle operator will
be held accountable for the vehicle assigned to him and he must
ensure that it is always operated in a safe and lawful manner.

1.1.12 Accountability

All employees shall be held accountable for personal and

functional safety performance. An important factor in an
employee's overall job performance evaluation will be how well
the employee meets his safety responsibilities.

1.1.13 Compliance Reviews

On a selective basis, compliance reviews will be conducted by

teams that include people with related expertise to determine
compliance with this policy. In order to ensure the credibility and
effectiveness of the review, the team members must be
detached from the operation being reviewed.

1.2 Saudi Aramco Loss Prevention Requirements For

Contractors

Saudi Aramco Loss Prevention requirements for contractors are

contained in Schedule 'D' of contracts (See Appendix A - Figure A.4). The
safe practices specified in Schedule 'D' shall be followed by all
contractors during the performance of all work under each contract with
Saudi Aramco.

The requirements in Schedule 'D' are the minimum acceptable to Saudi

Aramco. Any deviation from the requirements of Schedule 'D' must be
signed in writing by the Company representative. The contractor shall
also take any additional measures which the Company representative
may determine to be reasonable and necessary to protect against the
injury (or death) of any person, or damage (or loss) of any property
during the contractor's performance of the work under the contract.

1.2.1 Non-Compliance

The Company representative will notify the contractor, in writing,

of any violation of the requirements of Schedule 'D' and provide
corrective action to rectify the situation. After receipt of such
notice, the contractor shall immediately take corrective action.
Such notices when delivered to the contractor's representative at
the site of the work shall be deemed sufficient notice to the
contractor under Schedule 'D'. If the contractor fails to take
corrective action promptly, the company representative may
issue an order stopping all or part of the work until satisfactory
corrective action has been taken. The contractor will not be

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 4
 eligible to use any part of the lost time incurred as a result of
such stop orders as the subject of a claim for extension of time,
additional costs or damages. Compliance with the provisions of
Schedule 'D' by subcontractors shall be the responsibility of the
contractor.

1.2.2 Assistance

The contractor may request advice on establishing feasible and

effective safety practices for the job. The company
representative will assist the contractor's representative by
providing guidance on good safety practices, pointing out unsafe
conditions, and applying his experience and judgment in helping
to improve the contractor's overall job safety.

1.2.3 Standards and Instructions

All work and equipment must conform to Saudi Aramco

Standards and General Instructions. Where no standard or
instruction is available to cover a particular item, the contractor
shall request that Saudi Aramco specify the standard of work or
equipment required. The term, "Approved Standards" in
Schedule 'D' refers to standards which are approved by Saudi
Aramco.

1.3 Contractor's Loss Prevention Program

The contractor shall develop and implement a loss prevention program

that will conform with Saudi Aramco loss prevention policies and
procedures.

1.3.1 Written Program

Prior to the commencement of contractual activity, the

contractor shall submit a written job-specific loss prevention
program to the Saudi Aramco company representative. The
latter is required to forward a copy of the program to the Loss
Prevention Department. The Contractor's written loss prevention
program shall address the following:

1. Title page (B.I./J.O.)

2. Project title and brief scope of work
3. Organization chart
4. Vicinity map and key plan
5. Hazard identification plan
6. Traffic plan
7. Safety polity and assignment of responsibilities
· Prime and sub contractors
8. Desert driving
· Search and rescue procedures
9. Safety inspections
10. Safety reports and records

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 5
 11. Contractor camp sanitation and safety
12. Work permit
13. Welding and cutting equipment
14. Personal protective equipment
15. Tools and portable power tools
16. Ladders
17. Cartridge operated tools
18. Electrical installation and equipment
19. Scaffolding
20. Cranes and rigging equipment
21. Mechanical equipment
22. Transportation
23. Saudi Aramco plant operations
24. Injury and damage reporting
25. Excavation
26. Fire prevention
27. Form work
28. First-aid facilities
· Medical evacuation procedures
29. Dust control
30. Job site inspections
31. General safety rules
32. Emergency evacuation procedures
33. Hazardous material and waste management
34. Security procedures
35. Ionizing radiation
36. Demobilization plan
37. Work over or adjacent to water
38. Explosives
39. Abrasive blasting & painting/coating
40. Lock out and tag system

1.3.2 Hazard Identification Plan

As part of the Contractor Loss Prevention Program, the contractor

shall develop a detailed Hazard Identification Plan based on the
initial hazard identification data supplied by Saudi Aramco
Project Management Team.

Prior to the start of construction, the contractor shall conduct a

hazard identification tour with the Company representative and
the Saudi Aramco Loss Prevention representative. Once this has
been completed, the contractor will prepare and submit a Hazard
Identification Plan. (See Appendix A - Figures A.3 and A.4.)

1.3.3 Safety Supervisor

The contractor shall designate one or more full-time safety

supervisor(s) to coordinate and monitor the loss prevention
program. The names and addresses of the Saudi Aramco
approved safety supervisors shall be included with the written
program.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 6
 1.3.4 Safety Discussion

The contractor shall ensure that every craft and crew supervisor
holds a weekly ten-minute safety meeting with his men to
discuss hazards on the job, and review and update procedures to
prevent accidents. These weekly meetings shall be documented
and such documentation shall be maintained and made
available for review at the Contractor's on-site office.

February 1993 - 1.0 Saudi Aramco Loss Prevention Policy And Program Page 7
2.0 SAUDI ARAMCO LOSS PREVENTION DEPARTMENT
SERVICES
A full complement of loss prevention services is provided by the area Loss
Prevention divisions.

The area divisions are in turn provided support from the central Planning and
Technical Services Division consisting of Technical Services Unit, Support Services
Unit and a Planning and Program Group.

2.1 Loss Prevention Program

Loss Prevention superintendents ensure that a range of loss prevention

engineering services are provided to organizations within their assigned
areas through such activities as:

2.1.1

Directing the review of new plant design in the assigned area of

operation to ensure conformity of facilities to loss prevention
engineering standards.

2.1.2

Providing input to the Board of Engineers in the development of

Saudi Aramco Engineering Standards.

2.1.3

Managing major safety reviews and incident investigations with

Saudi Arab Government officials, US. Companies, and local area
management.

2.1.4

Administering safety-related training programs for local area

operations management and personnel in an effort to enhance
the safety awareness of operations personnel and proper
acceptance of responsibilities.

2.1.5

Serving on special committees and task forces such as the

Radiation Protection Committee, and providing personnel to
develop or assist in the development of General Instructions,
position papers and standards.

February 1993 - Construction Safety Manual: Saudi Aramco Loss Prevention Department Services Page 8
 2.1.6

Directing in-depth program reviews of area operations involving

procedures and facilities with follow-up on implementation of
recommendations resulting from these reviews.

2.1.7

Interfacing with Government Affairs to provide input on safety

related issues to non-Saudi Aramco projects and providing
monitoring of these projects to assure conformity.

2.2 Program Management Services

Superintendents and their subordinates provide department heads with

program management services such as:

2.2.1

Assisting with the development of formal loss prevention

programs; ensuring consistency with Company and business line
policies, principles and practices; and providing consultative
services in their implementation.

2.2.2

Monitoring and evaluating loss prevention systems through the

Compliance Review Program.

2.2.3

Providing project review, waiver and other technical consulting

services; recommending revisions to Saudi Aramco Engineering
Standards; and developing new hazard control standards as
required.

2.2.4

Analyzing, interpreting and reporting accident statistical data.

2.2.5

Initiating and administering safety management training.

2.2.6

Coordinating response to government concerns about fire and

safety issues.

2.2.7

Serving on special accident investigation committees.

February 1993 - 2.0 Saudi Aramco Loss Prevention Department Services Page 9
2.3 Program Maintenance Services

Superintendents and their subordinates provide program maintenance

services such as:

2.3.1

Providing technical interpretation of standards, procedures,

principles and practices; and consulting services in their
application from a loss prevention standpoint.

2.3.2

Conducting loss prevention policy, program and procedural

surveys and inspections.

2.3.3

Identifying and assessing processes, operations and other risks

(or hazards) and recommending solutions.

2.3.4

Initiating and administering supervisory and highly specialized

safety training beyond the capability of operating management
or training specialists.

2.3.5

Administering work permit and certain other safe work

procedures.

2.3.6

Acting as Saudi Aramco's representative to the Saudi Arab

Government on local safety issues.

2.3.7

Advising on proper selection and use of personal protective

equipment and evaluating its effectiveness.

2.3.8

Monitoring and providing input on other activities as required to

ensure proper response to accidental occurrences, including the
development of containment and mitigation methods for liquid
chemical spills or vapor releases, conducting accident
investigations and recommending corrective measures.

February 1993 - 2.0 Saudi Aramco Loss Prevention Department Services Page 10
3.0 ACCIDENT INVESTIGATION, ANALYSIS AND
REPORTING
Much is learned through experience. A thorough investigation and analysis of an
accident can help to prevent future accidents. To learn by experience, however,
means that a system for the retrieval of information must be set up and statistical
records must be kept of injury, death and property damage. With such a system
operational, information can be collated and analyzed to show accident patterns.
The contractor can then emphasize those areas in which safety education and
training is needed most.

The contractor is responsible for reporting accidents to Saudi Aramco and in some
cases to the Saudi Arab Government as required. This section covers these
reporting requirements and the principles behind accident investigation and
analysis.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.001 Notification Requirements for Incidents (Including Fires)

GI 6.003 Guide for Committees Investigating Major Incidents or Engineering

Reviews of Other Incidents

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 7.026 Lifting/Elevating and Mobile Equipment Accident Reporting

Procedures

3.1 Reports Required by Saudi Aramco

Reports are required by Saudi Aramco as per Schedule 'D' of the

contract.

Contractor shall ensure that an immediate report is made to the

Company Representative in the case of all:

· Fatal injuries
· Injuries requiring medical attention which result in lost time
· Damage over SR 10,000 to contractor's plant or equipment
· Damage, in any amount, to Saudi Aramco's equipment or property
· Fires
· Damage and near misses to cranes and heavy equipment (GI 7.026)

For accidents involving Contractor employee fatalities, serious injury to

two or more Contractor employees, or damage to Saudi Aramco
equipment or property, a preliminary written report shall be submitted
within 24 hours followed by a detailed written report submitted within
three days to the Company Representative. In addition, Saudi Aramco
may convene an engineering review or investigation committee in

February 1993 - Construction Safety Manual: Accident Investigation, Analysis And Reporting Page 11
 accordance with the requirements of GI 6.001 and GI 6.003 (see Figure
I.1).

Contractor shall maintain, in a format approved by the Company

Representative, a current record showing all:

· Work injuries
· Fires
· Incidents of property damage over SR 10,000
· Motor vehicle accident
· Incidents involving damage to Saudi Aramco equipment and property
· Damage and near misses to cranes and heavy equipment (GI 7.026)

The record shall be available for inspection at all times and shall be
submitted to Saudi Aramco on request. (See Figure I.2.)

A final written report shall be prepared and submitted to the Company as

per the provisions of GI 6.003. In the case of serious accidents,
however, a detailed account of the circumstances, witnesses' statements
and descriptive photographs are required.

In addition to the reports required above, the contractor must keep a

record of all injuries and damages on a form approved by the Company
(Figure I.2). A copy of this record shall be sent to the proponent
department and to the contractor's project management. Monthly
summary reports are required in addition to the individual reports.

3.2 Accident Investigation

The point of an accident investigation is to prevent recurrence of similar

accidents; to determine facts rather than to find faults.

The main reasons for conducting an accident investigation are:

1. To find the causes so that similar accidents may be prevented;

2. To determine the point at which "unplanned" events took over from
the "planned" sequence of events;
3. To recommend what corrective action should be taken.

3.2.1 Responsibilities for Investigation

3.2.1.1 Supervisor/Safety Representative

The supervisor and/or safety representative shall carry

out an immediate investigation of any accident which
occurs within his area of responsibility. The preliminary
accident report must be completed and submitted
within 24 hours to the Saudi Aramco Company
representative with a copy to the Loss Prevention
Department. A final report on the incident shall be
submitted within three days detailing any additional
information and corrective action needed.

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 12

 3.2.1.2 Project Manager

The project manager shall review all accident reports to

ensure that all the necessary corrective action has
been taken and that he has addressed any items that
may require action on his part.

3.3 Cases to be Investigated

Incidents that result in property damage or serious injuries to personnel

and hospitalization of two or more employees must be fully investigated
and reported. Unless the real cause is known, the hazard cannot be
controlled in the future. The near-miss incident is equally important from
the point of view of prevention and should also be thoroughly
investigated.

3.4 Accident Investigation Guidelines

The scene of an accident must be left undisturbed until Government

Affairs, Industrial Security, the Loss Prevention Department and the
safety supervisor have conducted their investigation. In some cases the
accident site must be rendered safe so as not to contribute to further
accidents. However precautions shall be taken to keep the accident
scene intact as much as is possible, to assist local police in their
investigation. The investigation should include, but not be limited to the
following:

1. Questioning the man in charge and finding out what was planned.
2. Finding out the injured man's job or the normal configuration and
function of the damaged equipment or plant.
3. Questioning the injured man as soon as possible.
4. Questioning the witnesses separately as to what they actually saw,
not what they think happened.
5. Studying the equipment or plant layout and noting any signs of
misuse.
6. Finding the explanation of any irregularities.
7. From the information obtained, establishing the reason why the
"unplanned" events took over from those that were "planned".
8. Recommending items of corrective action and methods of
implementing them to prevent the recurrence of the incident.
9. Making a scaled drawing of the accident scene and supplement that
with supporting photographs.

3.5 Accident Analysis

3.5.1 Classification

Contractors can use nine main classifications to analyze

industrial accidents. Every contractor should go through the
following classifications and their breakdowns to determine
which of these (if any) apply to the incidents in which they were
involved. These records help to illustrate accident trends. In

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 13

 turn, this helps the Loss Prevention Department (Saudi Aramco)
evaluate their safety program and modify or upgrade it as
needed. This information is supplemental to the findings and
reporting requirements of the preceding "Accident Investigation"
sections.

The nine classifications with their individual breakdowns are:

1. Falls (Of Persons from Heights) 5. Equipment

To the ground or another level Moving Parts
From scaffolding Equipment in motion
From ladders Hot surfaces
Into holes, trenches, etc.
Into water

1a. Falls (Of Persons on the Level) 6. Hand Tools

To the ground Cartridge hammers
Against objects Power tools
Non-power tools

2. Handling Objects 7. Transportation

From lifting Road
From pulling or pushing Site
Handling materials
Electric shock

3. Striking Against Objects 8. Lifting Appliances

Protruding nails Cranes
Scaffold tubes and fittings Hoists and winches
Stepping or kneeling on objects Pull-lifts, pulleys, wheels, etc.
Piling frames
A-frames
Excavations

4. Struck by Objects 9. Hazardous Atmospheres

Falling objects Hydrogen Sulfide
Foreign bodies in eyes Others
Flying objects

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 14

FIGURE I.1: PRELIMINARY ACCIDENT REPORT

Detailed Report Required Within 3 Days Control No_________________

Accident Location: Date Of Accident: Time Of Accident:

Company: Personnel Injured: Badge Number:

Type Of Injuries: Property Damage And Estimated Cost

Damage:

Description Of Accident:

Witness Statement(s)

What Caused The Accident:

What Corrective Action Has Been Taken

Signed:_______________________________________________________________Badge
No:________________________

Date Of Report:________________________________________________

Name (Printed):_____________________________________________________________________

Company:___________________________________________________ Job
Title:_________________________________

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 15

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 16
FIGURE I.2: CONTRACTOR MONTHLY SAFETY REPORT

PROJECT TITLE:___________________________________ LOCATION:_________________________________

CONTRACTOR:_______________________________________________________________________________________

BUDGET ITEM No:._______________________________________ CONTRACT No.:________________JOB No:_______

1. Work Injuries:

2. Fires:

3. Incidents Or Property Damage (Over SR 10,000):

4. Motor Vehicle Accidents:

5. Incidents Involving Damage To Saudi Aramco Equipment:

6. Crane, Heavy Equipment & Manlift Accidents:

7. Safety Meeting:

(A) Topics Discussed:

1.
2.
3.
4.
5.
(B) Attendance:

(C) Instructor(s):

Prepared By:_____________________________ Contractor Safety

Officer:_____________________________________

Signed By:____________________________________ Saudi Aramco

Representative:____________________________

Date:___________________________

February 1993 - 3.0 Accident Investigation, Analysis And Reporting Page 17

4.0 RESPONSIBILITIES FOR SAFETY
The Saudi Aramco proponent must ensure the company's safety and accident
prevention policies are clearly understood by all employees and contractor
personnel. The duties and responsibilities of employees, supervisors, and
management must be stated in writing by the company's management. All
employees should satisfactorily discharge the responsibilities of their job, and be
aware that their safety record will be taken into account during performance
appraisals.

The main responsibilities of various members of a construction team are cited in

the following:

4.1 Contractor Senior Management

1. Initiate the company's policy for the control of injury, damage and
fire.
2. Administer the policy himself or appoint a senior member of staff to
do so.
3. Know the requirements of Schedule 'D' and the relevant parts of
Saudi Arab Government Workmen's Regulations, and ensure they
are observed by his company.
4. Ensure that all supervisors are qualified and that they receive
adequate and appropriate training.
5. Make sure that in tendering, at planning stages and throughout the
contract, allowance is made for suitable and sufficient equipment to
enable the jobs to be done with minimum risk.
6. Coordinate safety activities between Saudi Aramco, subcontractors
and any other individual contractors who may be working on the
same site.
7. Institute proper system for investigation, reporting and estimating
the cost of injury, property damage and fire loss. Initiate analysis to
discover accident trends and promote action to prevent recurrence.
8. Reprimand any supervisor for failing to discharge satisfactorily the
responsibility allocated to him.
9. Set a personal example.
10. Ensure that a formal Hazard Identification Plan is prepared in order
to identify and correct hazards which may be encountered during
construction. (See Appendix A.4.)

4.2 Design Engineer

Design for safety, taking into consideration those risks that might arise
during construction or in the operation of plant or equipment. Follow
established process hazard analysis techniques to evaluate and correct
hazards during the design process.

4.3 Contractor's Safety Officer

1. Advise management on the following:

February 1993 - Construction Safety Manual: Responsibilities For Safety Page 18

 · Ways to prevent injury to personnel, damage to plant and/or
equipment and fires.
· Ways to improve existing work methods.
· Legal and contractual requirements affecting safety, health
and welfare.
· Provision and use of protective clothing and equipment.
· Potential hazards on site before work starts and on the
safety organization and fire precautions required.
· Changes in safety requirements.

2. Carry out site surveys to see that only safe work methods are in
operation, that health and safety requirements are being observed,
and welfare and first aid facilities are adequate and properly
maintained.
3. Determine the cause of any accident (or dangerous occurrence), and
recommend means of preventing recurrence of such an incident.
4. Supervise the recording and analysis of information on injuries,
damage and production loss. Assess accident trends and review
overall safety performance.
5. Assist with training employees at all levels.
6. Take part in discussions on injury, damage and loss control.
7. Keep up-to-date with recommended codes of practice and safety
literature. Circulate information applicable to each level of
employees.
8. Foster within the company an understanding that injury prevention
and damage control are an integral part of business and operational
efficiency.
9. Attend job progress meetings where safety is an item on the
agenda. Report on job safety performance.

4.4 Construction Manager/Superintendent

1. Understand the company's safety policy and the responsibility

allocated to each grade of supervision.
2. Know the requirements of Schedule 'D' and relevant Saudi Arab
Government Workmen's Regulations, and ensure that they are
observed.
3. Ensure that tenders adequately allow for sound working methods
and reasonable welfare facilities.
4. Determine the following at the planning stage:

· The most appropriate order and method of performing the

job.
· Allocation of responsibilities for Saudi Aramco, sub-
contractors, and other contractors.
· Storage areas, access, etc.
· Any hazards identified under the hazard identification
procedure described in Appendix A.4.
· Facilities for welfare, first aid and sanitation.
· Work permit procedures and requirements.
· Basic precautions for dealing with fire hazards.

February 1993 - 4.0 Responsibilities For Safety Page 19

 5. Provide written instructions to establish work methods, explain the
sequence of operations, outline potential hazards at each stage, and
indicate precautions to be adopted.
6. Check over work methods and precautions with supervision before
work starts.
7. Create safety awareness by promoting safety meetings,
presentations, open forum discussions and by implementing safety
training.
8. Set a personal example on site by wearing appropriate protective
clothing and equipment at all times.
9. Ensure that all accidents are reported to Saudi Aramco in
accordance with Section 3.

4.5 Site Safety Supervisor

(If different from contractor's safety officer)

1. Understand the requirements of Schedule 'D' and the company's

loss prevention policy.
2. Inspect the work site daily to report and correct unsafe methods and
conditions.
3. Keep a permanent record of all injuries, fires, motor vehicle
accidents (MVAs), property damage and crane/heavy equipment
accidents which have occurred at the site.
4. Keep a record of every weekly safety meeting on site complete with
subject discussed and a list of attendees.
5. Set a personal example.

4.6 Equipment Manager/Supervisor

1. Ensure that all equipment purchased or hired is safe, is guarded and

equipped with safety devices and has been subjected to all
necessary tests.
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 due.
4. Attend promptly to all equipment defects and advise site
management of the need for any dangerous equipment to be taken
out of service until properly repaired.

4.7 Engineer/Supervisor

1. 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 Schedule 'D'.
3. Be familiar with work permit procedures.
4. Give precise instructions on responsibilities for correct work
methods.
5. Plan and provide for good housekeeping.
6. Coordinate with sub-contractors and other contractors on site to
avoid any confusion about areas of responsibility.

February 1993 - 4.0 Responsibilities For Safety Page 20

 7 Position equipment effectively and ensure that electricity supply is
installed, used and maintained correctly.
8. Check that equipment and tools (both power and hand tools) are
maintained in good operating condition.
9. 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.
11. Make sure that suitable personal protective equipment is available
and that it is used.
12. Release supervisors and men when necessary for safety and fire
training.
13. Cooperate with the safety engineer and the fire department, by
acting on their recommendations.
14. Set a personal example.

4.8 Foreman

1. Be familiar with those parts of Schedule 'D' applicable to the work on

which subordinate workers are engaged.
2. Incorporate safety procedures in routine tasks and see that they are
obeyed.
3. Conduct weekly safety meetings with subordinates.
4. 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.
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 hazards.
8. Report accidents, unsafe conditions and defects in equipment to
immediate superiors.
9. Set a personal example.

4.9 Worker

1. Use the correct tools and equipment for the job. Use protective
clothing and equipment provided.
2. Do nothing to endanger self or work mates.
3. Keep tools in good condition.
4. Refrain from horseplay and abuse of safety devices, equipment and
welfare facilities.
5. Report any accidents, near misses or hazardous conditions to
immediate supervisor.
6. Read the Company safety rules and take note of special safety
precautions in restricted areas.
7. Obey all posted warning signs.

February 1993 - 4.0 Responsibilities For Safety Page 21

5.0 EMERGENCY PROCEDURES
Saudi Aramco departments and organizations have established disaster and
emergency response plans that are documented in general instructions (GIs),
department operating instruction manuals (OIMs), terminal instruction manuals
(TIMs), and refinery instruction manuals (RIMs), etc. All managers and supervisors
are expected to become familiar with the emergency procedures of the plants and
areas in which any of their staff are working. Construction site-specific written
emergency procedures shall be prepared by the Contractor and submitted as part
of the Contractor's loss prevention program plan. Details of the written procedures
may be obtained from the Saudi Aramco representative, operating supervisor, or
loss prevention engineer.

General guidelines for preparing emergency response plans can be found in the
following Saudi Aramco Loss Prevention Department publication:

Guidelines For Preparing Emergency Response Plans, October 1989

5.1 Action to be Taken

In an emergency, or on hearing the "Stop Work Alarm", every supervisor

shall ensure the following:

1. All work is stopped at once.

2. All equipment is shut down.
3. All men are evacuated to a pre-determined assembly point.
4. A roll call is taken and every man is accounted for.
5. No one is permitted to return to work until notification has been
received from operations or from the company representative that it
is safe to do so.

Refer to the specific procedures established in each Company operating

area.

5.2 Contact After Office Hours

The contractor's supervisor shall give his home address and telephone
number (and that of his replacement) to the company representative so
that he may be contacted after hours in case of emergency involving the
contractor's job or equipment. These telephone numbers are to be kept
current and posted at the job-site.

5.3 Help in an Emergency

5.3.1

In the event of an emergency situation (serious personal injury,

fire, critical damage to operating equipment, etc.) help may be
obtained by contacting the nearest Saudi Aramco Main Gate or
Security Control Center. This may be done:

February 1993 - Construction Safety - Emergency Procedures

Page 22
 1. By telephone: Dial the emergency telephone number
110.
2. By radio: Radio an operations group that has a telephone
in the Saudi Aramco system and ask them to dial 110 when
the Main Gate or Security Control Center cannot be
contacted directly.
3. By messenger: Send a messenger to the nearest
telephone, radio, or Saudi Aramco Main Gate or Security
Control Center.

5.3.2

When transmitting a message by telephone, radio, or

messenger, ensure that you clearly identify yourself by giving:

· Your exact location

· Nature of emergency
· Service required and repeat the message
· Your name
· Your badge number

Stay on the telephone until you are told to hang up. If possible,
post a lookout to direct the ambulance, fire truck or helicopter to
the right location.

February 1993 - 5.0 Emergency Procedures Page 23

6.0 SAFETY TRAINING
Good safety training is important to employees who are learning a new trade but it
is also necessary to keep supervisors and skilled operators up-to-date with current
safety technology and practices. Safe working practices are learned when
employees understand how an accident was caused. Measures can then be taken
to prevent a recurrence. People who are trained to do their jobs correctly can also
be expected to do them safely.

INSTRUCTIONS AND STANDARDS

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements - Loss

Prevention Program

6.1 Safety Training for Supervisors

6.1.1

The immediate job of preventing accidents falls upon the

supervisor not because it has been arbitrarily assigned to him,
but because accident prevention and production control are
closely associated supervisory functions.

The most direct way to develop the desired attitudes and to

impart the necessary information about safety to supervisors is
to give them safety training.

6.1.2

The course for supervisors should include legal requirements,

company and administrative policies and safety aspects of the
work likely to be undertaken by the supervisors. An outline of
such a course is given in 6.3.1 of this section.

6.2 Safety Training for Workmen

Accident prevention training for workmen should incorporate the items

listed in 6.3.2.

6.2.1 Integrated Practices

Safe working practices must be integrated into training for

specific skills.

It is expected that those who have attended recognized training

establishments will have received the necessary safety
instructions.

February 1993 - Construction Safety Manual - Safety Training

Page 24
 6.2.2 Specialized Training

Before their training is complete, new employees and new

entrants to industry are more susceptible to accidents.
Contractor's must provide safety orientation and training for new
employees.

Induction training should teach new workers to identify common

on-site hazards and how to guard against them. It should also
cover the main requirements of the company's accident
prevention policy and instruct newcomers specifically in those
areas which affect them personally (e.g., if it is company policy
that safety helmets and protective footwear should always be
worn, then this should be made clear and they should be told
how and where to obtain them).

Suitable induction courses together with job training containing

an integrated safety content will go a long way towards
achieving safe working conditions. Site supervision, however,
must ensure that correct job methods are being utilized and
workmen are periodically reminded to be aware of hazards in the
work place.

6.2.3 Use of Persuasion

The training providing skill and information should be

supplemented by the techniques of persuasion. Persuasion has
an important function and should not be overlooked in any
comprehensive program. It is commonly applied by the use of
posters which graphically indicate bad habits, pin-point the
advantages of a safe working environment and give detailed
information, advice, or instruction on special safety points to
remember.

Posters can be useful provided that:

· They are designed with due regard for the industry and its
type of operation.
· They are displayed where workmen spend some time when
not working and specific posters are displayed where most
appropriate (e.g., ladder hazards in ladder storeroom).
· They are mounted on properly designed and maintained
bulletin boards.
· They are changed at frequent intervals.
· Only a few posters are displayed simultaneously.

Posters can stimulate thought on accident prevention, but they

are no substitute for organized training. The most effective
posters are those that help to reinforce safety training.

February 1993 - 6.0 Safety Training Page 25

 6.2.4 Course Requirements

An induction safety course for workmen should be aimed at

specific hazards which they could encounter at a specific job site.
A suggested outline of such a course is given in 6.3.2.

6.3 Scope of Training

Safety training needs to be ongoing if it is to accomplish optimum

results. The program material and presentation should cover the safety
subject and be interesting enough to hold the trainee's attention. A
limited training effort, such as an occasional safety meeting, may prompt
supervisors to do a better job for a short time, but interest starts to lag
unless an effective safety training program is in place.

Good job safety instruction not only produces more skilled workers, but
also impresses upon them the high value that the employer places on
job safety. Frequent follow-ups and attention by the supervisor to correct
work practices also help to create understanding and to eliminate
resentment, which is a source of some undesirable work attitudes. (See
6.3.1.)

February 1993 - 6.0 Safety Training Page 26

 6.3.1 Safety Training Topics For Supervisors

1. The Law and Safety 2. Policy and Administration

Statutory requirement Effect of incentive on accident
Appropriate regulations prevention
Duties of employer and employee Human relations
Schedule 'D' (Contractual Safety Consultation
Requirements)
Safety Officer: duties, aims, objectives

3. Safety and the Supervisor 4. Principles of Accident Prevention

Safety and efficient production go Attitudes of management, supervision
together and operations
Accidents affect morale and public Methods of achieving safe operations
relations
Accident and injury causes

5. Site Inspection 6. Human Behavior

The role of management Motivating agencies
Hazard Identification Procedure Individual behavior
Records results Environmental effects
Follow-up procedures Techniques of persuasion
Feedback

7. Site Tidiness 8. Health

Site organization Medical examination
Relationship of site housekeeping to Hazard to health on site
accident occurrence
Site access Sanitation and welfare
Equipment storage Protective clothing
Material stacking First Aid/CPR
Materials handling

9. Personal Protective Equipment 10. Electricity

Eye, face, hands, feet and legs Appreciation of electrical hazards
Respiratory protective equipment Power tools
Protection against ionizing radiation Arc welding
Low voltage system
Lighting and power system on sites
Grounding/Ground fault circuit
interrupters (GFCIs)

11. Oxygen and Acetylene 12. Equipment

Equipment
Cylinder storage and maintenance Accidents related to moving parts of
machinery
Condition and maintenance of valves, Appreciation of principles of guarding
regulators, and gauges

February 1993 - 6.0 Safety Training Page 27

Condition and maintenance of hoses Importance of regular maintenance
and fittings
Pressures

13. Transportation 14. Excavations

Transport to and from site Method of shoring
Hazard connected with site transport Precautions while shoring
Competent drivers Precautions at edge of excavations
Dumpers Removal of shoring
Tipping trucks Sheet steel piling
Movement near excavations

15. Working Places, Ladders, and 16. Cranes and other Lifting
Scaffolding Machines
Hazards connected with the use of Licensing, certification and training
ladders required for operation of cranes
Maintenance and inspection Slinging methods
Type of scaffold Signaling
Overloading Access to crane(s)
Work on roofs Maintenance and examination
Fragile material Ground conditions
Openings in walls and floors Hazards and accident prevention
methods connected with the use of
different types of cranes/heavy
equipment
Use of safety belts and nets Crane Lift Plan for all lifts

17. Lifting Tackle 18. Fire Prevention and Control

Slings - single and multi-legged Principle causes determining fire
Safe working loads (SWLs) Understanding fire chemistry
Safety hooks and eyebolts Fire fighting equipment
Cause of failure Fire fighting training
Maintenance and examination

19. Communications
Effective methods of communication (particular interest to non-English speaking
workers)
Method and preparation of reports
Safety committees
Safety meeting

February 1993 - 6.0 Safety Training Page 28

 6.3.2 Induction Safety Topics For Workmen

1. Hazard Identification Procedure

Hazards on site:
· Machinery
· Transport
· Flammables on site (hydrocarbon)
· Fire
· Falls
· Electricity
· Site housekeeping
· Handling materials

2. Precautions Against the Above Hazards

· Simple precautions that can be taken by workmen

on site.

3. Personal Protective Equipment

· What is available
· How to obtain it
· Correct use and care

4. Health

· Site welfare facilities

· Potential health hazards
· First Aid/CPR

5. Duties of the Company

· Brief outline of the responsibilities of the Company

by law
· Details of Company's accident prevention policy
· Saudi Aramco Safety and Loss Prevention
Requirements For Contractors (Schedule 'D')
· Saudi Arab Labor Law

6. Employee's Duties

· Brief outline of responsibilities of employee under

law
· Explanation of how new employees fit into the
Company's plan for accident prevention.

February 1993 - 6.0 Safety Training Page 29

7.0 SITE PLANNING AND HOUSEKEEPING
This section outlines the procedure to be followed prior to and during a contract. It
cannot claim to cover every type of contract that is likely to occur, but it does
provide a detailed logical process to serve as a guide in deciding upon a plan of
action.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Standards:

GI 1021.000 Street And Road Closure And Excavations, Reinstatement And Traffic
Controls

SAES-P-123 Lighting; Illumination Requirements

SAES-B-007C Portable, Mobile and Auxiliary Fire-Fighting Equipment

Appendix C: Typical Construction Materials Store Yard.

Fire Safety Checklist for Evaluating Construction Materials Store Yard

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements (See

Appendix A)

National Fire Protection Association:

NFPA 80-A Protection of Buildings from Exterior Fire Exposures

NFPA 231 - Appendix 'C'

Protection of Outdoor Storage

7.1 Initial Planning

Prior to the start of any contract, an analysis is made by the contractor to

ensure that construction will be conducted in a safe manner. Similarly,
accident prevention is analyzed, both at the planning stage and
throughout the contract, so that the contractor will be able to eliminate
or reduce accidents. Accident prevention is a real factor in the economic
success of all contracts.

Among other factors that must be considered at the initial planning

stage are: results of a Hazard Identification Plan, loss prevention
program, protection of employees and equipment, transportation, lifting
equipment, excavation, scaffolding and work in restricted areas requiring
work permits.

February 1993 - Construction Safety Manual: Site Planning And Housekeeping Page 30
 7.1.1 Hazard Identification Plan

The contractor shall conduct a Hazard Identification tour with the

Company and Saudi Aramco Loss Prevention representatives to
identify potential hazards prior to construction start-up.

7.1.2 Loss Prevention Program

A loss prevention program required in Schedule 'D' for specific

job-related activities part of proposed construction work will be
developed and coordinated by the contractor's safety supervisor.
Part of this program will be a ten-minute safety discussion with
the workmen, at least once a week, on the hazards at the site
and the procedures to be followed to prevent personal injury and
minimize property damage.

7.1.3 Protection of Employees and Equipment

Schedule 'D' details the requirements to be followed by the

contractor to reduce losses. It places the responsibility for the
protection of men and equipment on the contractor and outlines
general minimum acceptable standards.

7.1.4 Transportation

The contractor must provide transportation to and from the site

for his employees.

Saudi Aramco requires that employees must be transported only

in the passenger compartment of vehicles. (See Section I.13.)
The provision of buses for larger sites will have to be considered.
Inspection and maintenance of vehicles and the selection and
training of drivers are other major considerations.

7.1.5 Lifting Equipment

Cranes, hoists and lifting equipment should be considered well

ahead of actual requirements both from the point of view of
economical use and the safety of personnel and equipment. Lift
plans shall be submitted as required. (See Section III.1 and III.2.)

7.1.6 Demolition

Some contracts in existing plant areas may require demolition

before new work can begin. Only minor demolition should be
done by construction personnel. Specialist contractors should be
employed for the demolition of larger structures. (See Section
II.3.)

February 1993 - 7.0 Site Planning And Housekeeping Page 31

 7.1.7 Excavations

Timber for shoring, steel sheet piles, etc. should be present on

site prior to starting excavation work. All excavation work will be
closely supervised by experienced staff. (See Section II.2.)

7.1.8 Scaffolding
For all work carried out above ground level where no permanent
work place is available, temporary work places in the form of
scaffolding must be provided. An adequate supply of scaffold
material must be on site. There must be sufficient experienced
men capable of erecting and dismantling the scaffolding
properly. Ladders, built to an acceptable standard, must be
supplied and readily available for access to elevated work areas.
(See Section II.9.)

7.2 Site Layout

The site layout must be planned before any work is started. This will
assist in making the job easier and more efficient, thus increasing
productivity and profit.

Items to be considered under site layout include the following:

7.2.1 Site Accommodation

This includes shacks, storage huts, compounds, racking areas,

lock-up boxes, office buildings, etc.

7.2.2 Adequate Access Roads

To be kept clear and unobstructed at all times.

7.2.3 Project Sign

Erect project sign at the main entrance to the construction site

and other sites, i.e., office, laydown yard, fabrication yard, etc.,
as designated by the Company representative.

The sign shall be a minimum of four feet in height, and eight feet
in width. The printing on the sign shall be black and white and
shall be in both Arabic and English. The Arabic text will be
above, or to the right of the English text.

The sign shall list:

· PROJECT MANAGEMENT ORGANIZATION

· PROJECT TITLE
· BUDGET ITEM NUMBER (BI NO.)
· PRIME CONTRACTOR NAME, ADDRESS, AND TELEPHONE
NUMBER

February 1993 - 7.0 Site Planning And Housekeeping Page 32

 · HOUR EMERGENCY PHONE NUMBERS FOR COMPANY
REPRESENTATIVE AND CONTRACTOR

The sign shall be erected within two weeks after the contractor
has started work on site. Contractor shall also erect and
maintain sufficient signs on or near the site to direct delivery
vehicles and visitors to the work site.

Example of Job Site Sign:

SAUDI ARAMCO/CENTRAL AREA PROJECTS

SAUDI ARAMCO BUILT GOVERNMENT SCHOOLS
BOYS SECONDARY - DAMMAM BI (2510) (ERC. 1990)
CONTRACTOR:
NAME
PO. BOX
LOCATION
TELEPHONE NUMBER
SAUDI ARAMCO REPRESENTATIVE
TEL. - OFFICE/TEL. - HOME

7.2.4 Safe Means of Access and Egress

To be provided on site wherever employees are likely to go; these

must be kept clear and unobstructed at all times.

7.2.5 Parking Facilities

To be provided in clearly defined areas on site.

7.2.6 Drainage

The site should have good drainage and be graded in such a way
that water does not pool up during construction.

7.2.7 Vehicle / Heavy Equipment Paths On Site Vs Pedestrian

Paths

Pathways for workmen must be clearly marked and distinct from

vehicular travel routes on site.

7.2.8 Sand

In sand dune areas that might lie adjacent to or around a

construction site, consideration should be given to the
movement or build up of sand.

7.2.9 Fire Prevention

Suitable fire extinguishers must be readily available on site. The

area around fire extinguishers or hydrants must be kept clear so
that they are readily accessible in case of emergency. They must

February 1993 - 7.0 Site Planning And Housekeeping Page 33

 be regularly inspected and maintained. Site personnel must be
trained in the use of fire fighting equipment. (See Section I.11).

7.2.10 Site Illumination

Adequate lighting must be provided in all areas of the job site in

accordance with SAES-P-123.

The National Electric Code and National Fire Protection

Association standards should be consulted for specific areas.
Grounding requirements will be per NFPA. In hazardous areas
(e.g., tank farms and indoor fuel areas), NFPA 30, 37, 58 and 70
will be enforced.

7.3 Storage Areas

Note: See Appendix C. Fire Protection Checklist for Evaluating

Construction Materials Store Yard; and Figure III.13 (Typical Construction
Materials Store Yard).

7.3.1

Storage areas must be adequate for all material and equipment

to be stored.

7.3.2

They should not be within 15 meters (50 feet) of permanent or

temporary structures.

7.3.3

Storage areas should be clearly marked.

7.3.4

They should have directional signs to facilitate speedy delivery.

7.4 Welfare Facilities

Adequate welfare facilities must be provided. The following are

minimum requirements:

7.4.1

Canteen or eating area adequate for total work force must be

provided. This area shall be clean of refuse and meet Saudi
Aramco Sanitary Code requirements.

7.4.2

Rest area must be provided.

February 1993 - 7.0 Site Planning And Housekeeping Page 34

 7.4.3

Adequate toilet and washing facilities must be provided. Toilets

shall be provided in places where they may be easily accessible
at the rate of one toilet for every fifteen workmen or less. These
shall be maintained in a sanitary condition.

7.4.4

An adequate supply of drinking water must be available.

Common drinking cups or dips are prohibited.

7.4.5

First aid facilities must be supplied and arrangements made for

medical care and for emergency situations.

7.4.6

Where necessary, safe smoking areas must be provided, with the

concurrence of the responsible area Loss Prevention office.

7.5 Good Housekeeping

The required standard of housekeeping must be established on site and

all personnel informed of this standard. Trash, debris and refuse should
be collected daily. All employees shall clean their respective work areas
daily before quitting.

Covered containers, drums, etc., should be provided at various, clearly

marked locations throughout the work site. The containers should be
emptied daily at approved rubbish dumps.

7.6 Construction Sites and Materials Storage Yards

(See Appendix C)

7.6.1

The contractor's engineer shall establish the perimeter of the

site by agreement with the proponent department. He may
consult the Loss Prevention Department for assistance.

7.6.2

The perimeter fence for construction sites and materials storage

yards shall be properly grounded and of sound construction and
design appropriate for the intended protection of the area. The
Saudi Aramco Industrial Security organization should be
consulted for details.

February 1993 - 7.0 Site Planning And Housekeeping Page 35

 7.6.3

The fence shall be frequently inspected by a representative of

the contractor's engineer.

7.6.4

Any access paths through the proposed site shall be rerouted

outside the perimeter. Loss Prevention Department is to be
consulted on any such rerouting.

7.6.5

Where a fence crosses existing roads, red and white, blue and
white, or black and reflective yellow (or white) flags shall be
fastened to the fence. If access is blocked, a dead-end sign will
be erected on the approach to the fence with the distance of the
obstruction marked below the sign. However, if there is a
temporary by-pass, a "DIVERSION AHEAD" sign shall be erected
on the approach to the fence and diversion arrows showing the
route shall be displayed on the fence in black and yellow (or
white) reflective material.

7.6.6

A suitable number of soundly constructed access gates shall be

provided. The number of access gates will be kept to a minimum
on main thoroughfares (See NFPA 231 Appendix 'C'). A
minimum of two fifteen-foot wide gates are required.

7.6.7

Standard Saudi Arab Government stop signs will be fixed to the

inside of the vehicle access gates.

7.6.8

Temporary signs should be erected to route traffic in the safest

manner to, from, and within the site. Temporary signs shall not
be placed on public highways and roads (reference Saudi Arab
Government traffic regulations).

7.6.9

While not in use all power driven construction equipment must

have the ignition locked and key removed. If there is no lock for
the cab and access can be readily made into the engine
compartment, then the machine must be made immobile by
disconnecting the battery or by any other means especially if the
equipment is left outside the perimeter. This must be carried out
before leaving the equipment unattended.

February 1993 - 7.0 Site Planning And Housekeeping Page 36

 7.6.10

Crane booms, bulldozer blades, and front end loader buckets on

all construction equipment should be lowered when the
equipment is left overnight. For a crane boom where this is not
possible, the boom will be locked off in such a manner that it
cannot be dropped or blown over by the wind.

7.6.11

Job site electrical power must be de-energized at night unless

required for specific lighting facilities or used by a night
watchman.

7.6.12

The project will provide its own barricades. Barricades will only
be supplied by the area Industrial Security Departments on a
short term emergency basis.

7.6.13

Any excavation or obstruction of any kind likely to create a

hazard to vehicular traffic at night will be adequately lit and a
sign posted. (See GI 1021.000.)

7.6.14

If large pools of water are formed which cannot be adequately

drained, these shall be separately fenced or barricaded if they
constitute a safety hazard.

February 1993 - 7.0 Site Planning And Housekeeping Page 37

 7.6.15

There shall be no indiscriminate dumping of excavation spoil or

building materials. Fire hydrants, manholes and electrical
conduits will be kept clear at all times. The contractor's engineer
shall designate sites for dumping.

7.6.16

All manhole covers will be replaced or the manhole properly

barricaded.

7.6.17

Guy ropes will be clearly marked day and night as will any rope
used as a barricade.

7.6.18

Refuse must be disposed of at a job site approved for such

purposes and the contractor must have permission to use the
site. Approved disposal sites can be those of Saudi Aramco or
local municipalities. It is forbidden for contractors to dump
refuse in any unauthorized area.

7.6.19

Clock stations can be requested from Industrial Security provided

sufficient notice is given to ensure their availability.

7.6.20

The Saudi Aramco Project Representative shall notify the Loss

Prevention Department representative and also the area
Industrial Security Department about the time and place for the
pre-construction meeting and also the first weekly site meeting
which these departments should plan to attend.

7.6.21

It is the responsibility of the Company representative to initiate

road closure requirements on work activity to ensure that all
construction/maintenance adheres to the conditions of GI
1021.000 (See Appendix D) and that a notice of intent is placed
in the company "Highlights and Notices" publication before work
start-up.

February 1993 - 7.0 Site Planning And Housekeeping Page 38

8.0 FIRST AID
First aid is the immediate help that is provided at the site to an injured or seriously
ill person before professional medical help can be obtained.

It is the responsibility of all contractors to ensure that proper first aid is available
to their employees on all job sites.

Provisions shall be made prior to start-up of the project for prompt medical
attention in case of medical emergencies.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1321.015 Request for Air Medical Evacuation

GI 150.002 First Aid / CPR Training and First Aid Kits - Remote Areas

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Injury and Damage Reporting

First Aid Facilities

8.1 Provision of First Aid Facilities

Every contractor shall provide first aid facilities on all sites for his
employees. The first aid facility shall be kept in a sanitary condition at
all times. Minimum requirements shall include the following: a
telephone; desk; hot and cold water; wash basin; examining table; air
conditioning; adequate lighting; and dust tight medical supply cabinet.

8.1.1

First aid supplies shall be kept readily available in a cabinet

designated for those supplies only. (See 8.3 for a recommended
list of cabinet contents.)

8.1.2

This cabinet shall be placed under the charge of a first aid

attendant, who shall ensure the cabinet is well stocked at all
times.

8.1.3

A suitable type of stretcher must be available on all sites.

February 1993 - Construction Safety Manual - First Aid Page 39

 8.1.4

Contractors shall post notices indicating the following:

1. The name of the person who is in charge of the first aid

cabinet.
2. The hospital to which any injured person who requires
hospital treatment is to be sent.
3. The telephone number of the doctor or first aid attendant
employed by the contractor.
4. The emergency telephone number to be called for
assistance.

8.1.5

Contractors on pipeline and power line work or who are working

in remote areas shall ensure that one vehicle is equipped with a
well-stocked first aid kit for each crew, and that at least one man
in every crew is trained in first aid. The vehicle shall be marked
to indicate that it carries a first aid kit. (See GI 150.002. First
Aid Training and First Aid Kits - Remote Areas.)

8.1.6

A site register shall be maintained by all contractors listing all

injuries treated. (See Figure I.3 Example.)

8.2 First Aid Attendants

8.2.1

When more than 50 persons are employed within a radius of 15

kilometers, first aid facilities run by a nurse familiar with first aid
cardiopulmonary resuscitation (CPR) requirements and
exclusively assigned to medical duties.

8.2.2

Those persons in charge of first aid supplies on smaller sites with

less than 50 workers should be trained in first aid procedures.

8.2.3

The contractor shall provide, or make arrangements to provide, a

dedicated emergency vehicle (ambulance), properly supplied
and marked, to transport injured personnel to the nearest
designated health care facility.

Each ambulance shall be equipped, as a minimum, with the

following supplies:

· Stretcher and blankets

February 1993 - 8.0 First Aid Page 40

 · Portable oxygen
· Splints for bone fractures
· Bandages/rubber tourniquet
· Sterile wash water

8.2.4 Medical Evacuation Capabilities

Saudi Aramco has the ability to provide air medical evacuations

(Medevac) for both onshore and offshore medical emergencies
with helicopters or fixed wing aircraft. The procedures to initiate
a Medevac are covered in GI 1321.015 and shall be
incorporated in the Contractor's Loss Prevention Program plan.

8.3 First Aid Facilities At Work Site

(Originally Published in Umm al-Qura, No. 2534 July 26, 1974)
Decision No. 404 Based on Articles 245 of Labor Law

Article I

An employer who employs less than fifty workmen shall provide at the
work site a first aid cabinet containing bandages, medicines, and
disinfectants as follows:

1. A sufficient number of not less than 12 sterile, small-size

finger dressings.
2. A sufficient number of not less than 6 sterile medium-size
hand dressings.
3. A sufficient number of not less than 6 sterile large-size
hand dressings.
4. A sufficient supply of absorbent cotton wool for packing and
firming up splints. Such supply shall not be less than 200
grams of cotton wool in small 25-gram packages and two
500-gram packages.
5. A sufficient number of not less than 12 gauze bandages 7
cm. in width.
6. A sufficient number of not less than 12 gauze bandages 11
cm. in width.
7. Not less than 4 yards of adhesive tape in rolls, 1 cm. in
width.
8. Not less than 100 grams of Mercurochrome in aqueous
solution.
9. Two 10-gram shakers of sulfa powder for sterilization of
wounds.
10. 100 grams of aromatic ammonia solution in a glass bottle
with a glass stopper.
11. A medium-sized Thomas' thigh splint, a wooden posterior
leg splint, a wooden elbow splint, a wooden Carr splint for
the forearm, a wooden palm splint, and other types of
ready-to-use splints.
12. A minimum of 6 triangle bandages.
13. A minimum of safety pins.

February 1993 - 8.0 First Aid Page 41

 14. Ointment for burns containing a disinfectant and an
analgesic.
15. A minimum of ten 70 x 70 bandages for burns.
16. A pair of scissors with blunt ends.
17. A sufficient number of stretchers for moving injured
persons.

If work is carried out in scattered locations which are more than 300
meters apart, a separate cabinet shall be provided for every group
consisting of more than ten workmen.

Article II

The employer shall assign one or more persons to be responsible for

administering first aid to the injured at all times during working hours,
provided that the person-in-charge shall be one of the establishment's
employees who will either be trained in first-aid procedures in
accordance with a program to be agreed upon with the Saudi Red
Crescent Society, or who holds a certificate from a hospital attesting that
he has practiced first-aid and is qualified to administer it.

Article III

An employer who employs 50 or more laborers shall provide at the work

site a first aid room which meets the following standards:

(a) It shall meet all sanitary specifications.

(b) It shall be conveniently located and readily accessible to
injured persons and stretcher-bearers.
(c) Where quick means of transporting for the injured are not
available, the said room shall not be more than 300 meters
from the farthest work site.
(d) An adequate number of stretchers shall be available for
moving the injured to the first aid room.
(e) First aid materials and supplies shall be no less than those
specified under Article I, provided that they are in
proportion to the number of workmen.
(f) A licensed nurse shall be on duty at all times during
working hours under the supervision of a physician.

Article IV

Supplies of any item in the first aid cabinets and rooms shall be
replenished whenever they fall below the levels specified herein.

Article V

The first aid cabinet shall be of hard wood or sheet metal, measuring 85
cm. in length, 45 cm. in width, and 30 cm. in depth. They shall be
painted white and shall be provided with one lock and more than one
key. The cabinets shall bear the Red Crescent insignia and the words
"First Aid Cabinet". All first aid cabinets shall be conveniently located in
clean place above floor level and shall always be ready for use and

February 1993 - 8.0 First Aid Page 42

 easily accessible at all times. Signs shall be posted in conspicuous
places at the various work sites to indicate the location of the cabinet
and the name of the workmen in charge of first aid.

Article VI

An employer who employs less than fifty workmen shall assign an

appropriate number of his workmen to receive first aid training in
accordance with Article II.

Article VII

The Director General of the Department of Labor Inspection shall be

charged with implementing this decision. He is authorized to increase
the contents of the first aid cabinets or rooms in those industries and
trades requiring such an increase, to stipulate special first aid
procedures to implement the above articles, to determine the placing (if
he deems it necessary) of first aid cabinets for any group comprising less
than ten workmen, and to fix the number of stretchers and the number
of workmen to be trained.

February 1993 - 8.0 First Aid Page 43

8.4 Labor And Workmen Law

Saudi Labor And Workmen Law

Chapter 7
Protection An Social Services
Labor And Workmen Law
Articles 134-6

Article 134

The employer shall provide first-aid services for the workmen in

accordance with the standards to be determined by the Minister of Labor
in collaboration with the Minister of Health. If the number of his
workmen in a single location or town, or within a radius of fifteen
kilometers, exceeds fifty, he shall employ a nurse who shall be familiar
with first-aid services and shall be exclusively assigned to rendering such
services; the employer shall assign a physician to examine and treat the
workmen at the place to be provided by the employer for this purpose,
and the employer shall provide them with the medicines necessary for
their treatment. The aforementioned services shall be free of charge
whether during work hours or otherwise. If in the cases mentioned
above, the number of workmen exceeds a hundred, the employer shall,
in addition, provide them with all other means of treatment in cases
requiring treatment by specialists, or performance of surgical other
operations. In case operations are performed, as well as in cases of
incurable diseases, the expenses shall be taken from the Social
Insurance Funds. The costs of treatment, medicines and hospitalizations
in government or charitable hospitals, as well as the party who will
assume such costs, shall be determined pursuant to the decision to be
made by the Minister of Labor in agreement with the Minister of Health,
or to the rules laid down in the Social Insurance Law.

However, if the number of workmen is less than fifty, the employer must
provide the workmen with a medical aid cabinet which shall be
maintained in a good condition and shall contain the bandages,
medicines, and antiseptics to be determined by the Minister of Labor in
agreement with the Minister of Health, in order to provide the workmen
with first aid.

Article 135

Every employer who employs more than fifty workmen shall inform the
appropriate Labor Office of the name of the physician who he has
selected to treat his workmen. In case he employs more than an
hundred workmen, he shall inform the Office of the names of the
physicians and specialists whom he has selected to treat his workmen,
and of the names of the hospitals which he has designated for that
purpose. In both cases, he must notify the appropriate Labor Office of
the minimum number of days fixed for the examination of workmen,
provided that this minimum shall not be less than three times a week.

Article 136

February 1993 - 8.0 First Aid Page 44

 Every employer shall prepare for each workman a medical file showing
the result of the medical examination performed on the workman upon
his employment, a description of the cases of his illness, the stages of
his treatment, and the periods of his absence from work, provided that
mention shall be made in the file of the kinds of ordinary and
occupational diseases and labor injuries.

February 1993 - 8.0 First Aid Page 45

FIGURE I.3: INJURY SUMMARY

Injury Summary (Page ___of___)

Project:__________________________________Project No.:________________________Month & Year:____________________
Contractor:__________________________________File No.:_________________________

Injur Name Of Badge Craft Date Of Carry Days Nature Of Injury And Brief Description Of Accident State
y No. Injured Numb Acciden Over Lost Part Of Body Affected What, Where, How, Why
er t Yes/No This
Mont
h

Total Lost Time Total Total Man-hours Worked

Injuries This Month: Days This Month:
Lost:

Report Prepared By:________________________________

Signature:_________________________________
Title And Telephone:__________________________________________________________________

February 1993 - First Aid Page 46

9.0 PERSONAL PROTECTIVE EQUIPMENT
When a hazardous situation is recognized, steps should be taken to eliminate the
hazard by engineering controls. Should it prove impractical to eliminate the
hazard, 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 and Saudi Aramco. (See Table I.1.)

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.020 Personal Flotation Devices For Work Over, On Or Near Water

GI 7.027 Personnel Work Platform Operations

GI 8.002 Prescription Safety Glasses

GI 8.003 Breathing Apparatus

GI 8.005 Protective (Safety) Footwear

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-H-102 Safety Requirements For Painting

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements

OSHA:

Code Of Federal Regulations 1910, 1915 and 1926

ASTM D120.E1-87

Standard Specifications For Rubber Insulating Gloves

ANSI Z 41-83 Personnel Protection - Protective Footwear

ANSI Z 87.1-89 Practice for Occupational and Educational Eye and Face
Protection

ANSI Z 89.1-86 Personnel Protection - Protective Headgear For Industrial

Workers - Requirements

February 1993 - Construction Safety Manual - Personal Protective Equipment Page 47

9.1 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 chin strap.

9.1.1

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.

9.1.2

The suspension cradle gives a helmet its impact distribution

qualities. It is therefore essential that it be properly adjusted to
the wearer's 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.

9.1.3

Ancillary equipment such as ear muffs, welders 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.

9.1.4

Safety hats or helmets shall not be painted.

9.1.5

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.

9.1.6

A safety helmet should be worn by all persons at all times when

on a construction job site; in an operating plant area; or
whenever there are overhead hazards. Metal hard hats do not
afford proper impact or electrical protection and, therefore, are
prohibited from all Saudi Aramco work areas.

9.2 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,

February 1993 - 9.0 Personal Protective Equipment Page 48

 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. (See Figures I.9 and I.9A.) The
wearing of contact lenses is not recommended in areas where eye
protection is required.

9.2.1 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.
5. Chemical goggles.

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

9.2.3 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.

9.3 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. (See Figure I.5.). 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.

February 1993 - 9.0 Personal Protective Equipment Page 49

9.4 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 are sturdy work shoes with leather uppers
and/or leather composition with steel toe caps. Soles and heels are
"non"-slip type. Fashion type safety "toe" shoes with canvas, nylon
and/or other soft composition uppers or soles are not considered safety
shoes and are not approved by Saudi Aramco.

9.5 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 (dBA) and measured
by a sound level meter. Medical authorities state that continual
exposure to noise levels above 90 dBA for an eight hour day, five day
work week may endanger a person's hearing. The safe period of
exposure to a noise level is inversely proportional to the level of the
noise. (See reference SAES-A-105, 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.

Exposure to impulsive or impact noise shall not exceed the requirements

of SAES-A-105, Noise.

Whenever it is infeasible to reduce the noise levels or duration of

exposure to within the limits of SAES-A-105, hearing protection devices
shall be provided and used. There are two types of hearing protection
available, 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.

9.5.1 Ear Plugs

Ear plugs 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.

9.5.2 Ear Muffs

Ear muffs cover the external ear to provide an acoustic barrier.

The effectiveness of ear muffs varies considerably due to
differences in manufacturer, size, shape, seal material, shell

February 1993 - 9.0 Personal Protective Equipment Page 50

 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.

9.6 Fall Restraining/Arresting 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
ground work, where fall restraining and arresting protection 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. (See Figure
I.6.)

9.6.1

Full body harnesses are required when working in areas with no

guard rails at heights above 1.82 meters (6 feet) or for potential
falls of six feet or greater. Exceptions shall require the review
and concurrence of the Loss Prevention Department.

9.6.2

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.

9.6.3

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 anchorage.

9.6.4

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.

9.6.5

Fall protection devices shall be capable of supporting a minimum

dead weight of 2450 kilograms (5400 pounds). (Refer to OSHA
29 CFR 1910.66, Appendix C - 1991.)

February 1993 - 9.0 Personal Protective Equipment Page 51

 The maximum length of standard lanyards shall be limited to
provide for a fall of no greater than 1.82 meters (6 feet) except in
the case of mechanical fall arresting devices which have been
reviewed and received concurrence by the Loss Prevention
Department. The lanyard shall have a minimum breaking
strength of 2,450 kilograms (5,400 pounds).

All fall arresting/restraining devices and hardware shall be

manufactured to ANSI or equivalent standards and fully
described in the Hazard Identification Plan (HIP), including type,
model and manufacturer.

9.6.6

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 2,450 kilograms (5,400 pounds).

February 1993 - 9.0 Personal Protective Equipment Page 52

TABLE I.1: BASIC PERSONAL PROTECTIVE EQUIPMENT

The table below is a list of basic personal protective equipment. Many job
classifications may require additional personal protective equipment depending on
the work location, type of job, local hazards, conditions, etc. The Loss Prevention
or Industrial Hygiene office in your area should be contacted for further details.

Typical Job Classifications Basic Personal Protective

Equipment To
Be Worn (see key below)
Abrasive blast cleaner See Section II.11, Table II.7
Boiler maker 1, 8, 9, 10D, 15B
Carpenter 1, 8, 9, 10C, 15A
Electrician 1, 2, 8, 9, 10B, 15A, or B
Iron worker - structural 1, 8, 9, 10D, 12/13, & 14 A/B, 15A
Lineman 1, 8, 9, 10C, 12/13 & 14 A/B, 15A
Mason 1, 8, 9, 10C/A, 15A
Material Control Man 1, 8, 9, 10C, 15A
Mechanic/Machinist 1, 8, 9, 10C/A, 15A
Painter See Section II.11, Table II.7
Pipe fitter 1, 8, 9, 10 C/D, 15A
Plumber 1, 8, 9, 10C, 15A
Rigger 1, 8, 9, 10C, 15A
Roof worker 1, 8, 9, 10C, 12/13 & 14 A/B, 15A
Scaffold erector 1, 8, 9, 10C, 13 & 14 A/B, 15A
Sheet metal worker 1, 8, 9, 10 C/D, 15A
Welder 1A &B, 4, 8, 9, 10D,/E, 15B

Key To Personal Protective Equipment

1. Safety glasses with side shields (1A=Clear, 1B=Shaded)

2. Face shield
3. Goggles, safety impact (3A=Clear, 3B=Shaded)
4. Welding hood and skull guard (Lens shaded to suit work)
5. Respirable air fed hood with filter
6. Respirator, chemical cartridge
7. Respirator dust
8. Safety hat helmet
9. Safety foot wear (9A=shoes, 9B=boots)
10. Gloves. (10A= Rubber coated, 10B= Rubber molded, 10C = General purpose, 10D= Leather,
10E=Heat resistant)
11. Ear protection (11A=Ear plugs, 11B=Ear muffs)
12. Standard safety belt
13. Full body harness
14. Lanyard 1.82m (6FD). (14A=Standard, 14B=Shock Absorbing)
15. One piece coverall (15A=Standard, 15B=Fire Resistant)

Notes: All personal protective equipment shall meet ANSI/OSHA or their

equivalent requirements. Any worker 1.82 m above ground without the protection
of a guard rail 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

February 1993 - 9.0 Personal Protective Equipment Page 53

supplied to the worker through the use of an air fed hood or self contained
breathing apparatus.

February 1993 - 9.0 Personal Protective Equipment Page 54

FIGURE I.4: PROTECTIVE GOGGLES, SPECTACLES, FACE SHIELDS AND HELMETS

A. Typical safety glasses/side shields B. Safety glasses/side shields (others)

C. Face shields

D. Weld goggles (cup) E. Weld goggles (chip) F. Weld goggles (soft)

G. Typical safety goggles H. Safety goggles (others) I.

Welding helmet
TYPICAL EYE PROTECTION APPLICATIONS

Operation Hazards Protection

Acetylene-welding, Sparks, molten metal, D, E, F
cutting burning harmful rays, flying
particles
Electric arc welding Sparks, molten metal, I
intense rays, flying
particles
Chemical handling Splash, acid burns, fumes G, H (Severe +C)
Chipping Flying particles A, B, C, E, F, G
Furnace operations Glare, heat, molten metal D, E, F
Grinding (light) Flying particles A, B, C, G
Grinding (heavy) Flying particles C, D, E, G
Laboratory Chemical splash, glass G, H (A or B +C)
breakage
Machining Flying particles A, B, C, G
Molten metals Heat, glare, sparks, D, E (A or B tinted + C)
splash
Spot welding Flying particles, sparks A, B, C, G

February 1993 - 9.0 Personal Protective Equipment Page 55

FIGURE I.4A: PROTECTION AGAINST RADIANT ENERGY

Protection against radiant energy requires the selection and use of the
proper shades of welding filter lens or plate.

The table below shall be used as a guide for the selection of the proper
shade numbers of filter lenses or plates used in welding. Shades more
dense than those listed may be used to suit the individual's needs.

FILTER LENS SHADE NUMBERS FOR PROTECTION AGAINST RADIANT ENERGY

Welding Operation Comfort Shade number

Shielded metal-arc welding 1/16-, 10

3/32-, 1/8-, 5/32-inch diameter
electrodes
Gas-tungsten arc welding and gas- 11
metal arc welding (nonferrous) 1/16-,
3/32-, 1/8-, 5/32-inch diameter
electrodes
Gas-tungsten arc welding and gas- 12
metal arc welding (ferrous) 1/16-, 3/32-,
1/8-, 5/32-inch diameter electrodes
Shielded metal-arc welding 3/16-, 12
7/32-, 1/4-inch diameter electrodes
Shielded metal-arc welding 5/16-, 3/8- 14
inch diameter electrodes
Atomic hydrogen welding 10-14
Carbon-arc welding 14
Soldering 2
Torch brazing 3 or 4
Light oxy fuel gas cutting, up to 1 inch 3 or 4
Medium oxy fuel gas cutting, 1 inch to 4 or 5
6 inches
Heavy oxy fuel gas cutting, over 6 5 or 6
inches
Gas welding (light), up to 1/8-inch 4 or 5
Gas welding (medium), 1/8-inch to 1/2 5 or 6
inch
Gas welding (heavy), over 1/2-inch 6 or 8
Air-carbon arc cutting 12

February 1993 - 9.0 Personal Protective Equipment Page 56

FIGURE I.5: SPECIALIZED HAND PROTECTORS

Heat Resistant Gloves

These gloves are made from materials that provide insulation to hot or cold objects. The purpose of this
material is to give the user enough time to perform his task or to stop handling the object before his hand
is injured.

Rubber Molded Gloves Rubber Coated Gloves

These gloves are made from materials that Similar to the rubber molded glove in
performance. These
are resistant to penetration by many chemicals. gloves also have an inner lining that
improves wear ability.

(A & B) Leather Gloves

These gloves are used to protect the wearer

from abrasions. They also provide some
resistance to hot/cold surfaces, but minimal
protection from most chemicals.

(C) Welding Glove

Generally made from leather, these gloves

provide the user with protection from hot
sparks/slag during welding. They also provide
some heat resistance.

February 1993 - 9.0 Personal Protective Equipment Page 57

A B C

February 1993 - 9.0 Personal Protective Equipment Page 58

FIGURE I.6: TYPICAL SELF-POWERED PLATFORM FOR BUILDING MAINTENANCE

February 1993 - 9.0 Personal Protective Equipment Page 59

10.0 BREATHING APPARATUS
Where industrial processes create hazardous atmospheric contaminants, the first
consideration should always be the application of engineering measures to control
the contaminants. In those cases where engineering control measures are not
possible, affected personnel must be supplied with personal respiratory protective
equipment.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Air Supplied Breathing Apparatus

TM-3 Technical Memorandum And Attachment - Oil By-Products Protection

Program (Saudi Aramco Medical Services Organization, Dhahran,
Saudi Arabia)

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Personal Protective Equipment

American National Standards:

ANSI Z88.2. - 1980

Practices for Respiratory Protection

US. Bureau of Mines:

Respiratory Protection (See 30 CFR Part II)

10.1 Selection of Equipment

A wide variety of respiratory protective equipment is available. As each

type is suitable for certain applications, it is necessary to develop an
orderly method for determining the appropriate device to be employed.

Persons should not be assigned tasks requiring the use of respirators

unless it has been predetermined by medical examination that the
worker is physically able to perform the work and use the breathing
apparatus properly.

Each user must receive instructions on the proper use and limitations of
the device, as well as demonstrations and practice in how to fit and wear
it. Personnel shall not be placed in a hazardous environment for which
the respirator is not designed, such as a location where there is a lack of
sufficient oxygen.

February 1993 - Construction Safety Manual - Breathing Apparatus Page 60

 Consider the following factors when selecting a suitable respiratory
protective device:

1 The nature of the hazardous operation or process.

2 The type of air contaminant, including its physical properties,
chemical properties, physiological effects on the body, and its
concentration.
3 The period of time for which respiratory protection must be
provided.
4 The location of the hazard with respect to a source of
uncontaminated respirable air.
5 The state of health of the personnel or users involved.
6 The functional and physical characteristics of the respiratory
protective devices.
7 The use of approved respirators only.

The contractor must know the specific hazards for which a given type of
respiratory equipment is approved. He should not permit respiratory
equipment to be used for protection against hazards for which it was not
designed.

10.1.1 Requirements For Use

As with all personal protective equipment, respirators only work

if you use them correctly. For face mask respirators, always
make sure that the mask fits properly, that there is a tight seal
and no air leakage. Proper fit is important to prevent
contaminants from leaking in. Beards, dentures and facial bone
structure can affect the fit of the respirator. Be sure to wear the
right respirator for the hazard. Always keep the respirator clean
and well-maintained. Never alter or modify the respiratory
equipment. Finally, follow manufacturer's specifications for
proper cartridge use and established safety procedures. Do not
hesitate to consult your supervisor if there are any questions
concerning your personal respiratory protection.

10.1.2 Misuse

Workers sometimes consider respiratory equipment a nuisance,

not realizing that failure to wear it may endanger their lives.
This attitude can be changed by education and training.
However, as the risk of injury or death is very real when safety
precautions are ignored, any worker refusing to wear the
necessary respiratory equipment will not be allowed to work
without it.

Common misuses of respiratory protection equipment include:

a. Using air-purifying (chemical cartridge type) respirators

when toxic levels are above the respirator-rated capacity.
b. Using air-purifying (chemical cartridge type) respirators in
oxygen deficient atmospheres.

February 1993 - 10.0 Breathing Apparatus Page 61

 c. Using incorrect cartridges or filters for the type contaminant
and the concentration encountered.
d. Using defective or improperly inspected equipment.
e. Using equipment without having received adequate on
training on it.

10.1.3 Hazardous Substances

Protection is required against those hazardous substances which

can be inhaled into the respiratory system, ingested via the
digestive tract and absorbed into the skin causing systemic
injury to the human body. Hazardous substances which can
enter the body through the respiratory system, the digestive
tract and the skin include, but are not limited to, the following:

· Asbestos
· Creosol (cresylic acid)
· Hydrogen cyanide (hydrocyanic acid)
· Tetraethyl lead and its compounds
· Mercury and its compounds
· Nitroglycerine
· Organic phosphate insecticides
· Solvents

10.1.4 Contaminants

Air supplied to respiratory equipment must be free from

contaminants. (See GI 8.003.) Respirable air shall be controlled
to the following conditions at all times:

1 Oxygen, not less than 19-23% vol.

2 Carbon monoxide, not more than 10 parts per million (ppm)
3 Carbon dioxide, not more than 0.10% vol.
4 Oil mist, not more than 5 mg/m 3 @ NTP
5 Water vapor, not more than 0.76 mg/l
6 Particulates, none

The above standards are based on Compressed Air Gas

Association (Table No. 1) and referred to as Grade 'D' breathing
air. Respirable air quality must meet this standard, at a
minimum.

The air delivered to the user must be less than 100 oF (38oC) and
supplied at 6 standard cubic feet per minute (6 SCFM). Air
cooling devices (e.g. vortex tubes) may be necessary.

10.2 Respiratory Protective Devices

Respiratory protective devices can be classified as follows:

1 Air purifying respirators

February 1993 - 10.0 Breathing Apparatus Page 62

 2 Supplied air respirators
3 Self-contained breathing devices

10.2.1 Air Purifying Respirators

10.2.1.1 Gas Masks

The gas mask type of respirator consists of a face piece

and filter. No one chemical agent has been found that
will remove all gaseous contaminants, so the canister
must be carefully chosen to fit the specific need. A
canister designed for a specific gas will give longer
protection than a canister designed for a multitude of
gases and vapors. Canister gas masks with full face
pieces are effective against higher concentrations of
contaminants. However, they do not provide
protection against oxygen deficiency.

10.2.1.2 Chemical Cartridge Respirators

Chemical cartridge respirators consist of a face piece
(usually half mask) connected directly to one or two
small containers of filters/chemicals. The chemicals
used are similar to those found in gas mask canisters,
but cartridge respirators are for use only in
atmospheres not immediately dangerous to life or
health. An area where the chemical cartridge
respirator works very well is in spray painting. It is
critical that the cartridge be matched to the specific
application.

10.2.1.3 Particulate Filter Respirators (Dust Respirators)

A particulate filter respirator protects against the

inhalation of nonvolatile particles. The major items to
be considered are:

1 The resistance to breathing offered by the filtering

element;
2 the adaptation of the face piece to faces of various
sizes and shapes;
3 the fineness of the particles to be filtered out, and
their toxicity.

10.2.2 Supplied Air Respirators

A supplied air respirator permits the user to breathe respirable

air while working in a hazardous atmosphere. Important
advantages are simplicity of design, usage under diverse
conditions, and good protection (when properly selected,
adequately supplied with respirable air, and used for the
purposes for which they were designed and approved).

February 1993 - 10.0 Breathing Apparatus Page 63

 10.2.2.1 Air Line Respirators

The air line respirator (see Figure I.8) is suitable for

respiratory protection in atmospheres not immediately
hazardous to life. Equipping the respirator with a small
cylinder of compressed air to provide an emergency air
supply qualifies the respirator for use in immediately
hazardous atmospheres. It is particularly suited to
some types of jobs because it is light and may be worn
for long periods of time without appreciable discomfort.
For example, it is often used for spray painting,
insecticide spraying, welding, metalizing and
prolonged production work in hazardous areas.

There are two basic types of air line respirators:

1 the continuous flow,

2 the pressure demand flow.

The continuous flow respirator may be assembled to a

half mask, full face piece, or hood, whereas the
demand flow type must always be used with a tight-
fitting face piece.

1 In the continuous air line respirator, a set amount of

air is continuously fed to the face piece. The
amount is regulated by an air control valve of
special inlet design which is not susceptible to
accidental changes of the setting even when jarred.
A slight positive pressure on the inside of the mask
is always maintained to prevent inward leakage of
the contaminated outside atmospheric air.

2 The pressure demand flow air line respirators are

normally used when air must be conserved, as may
be the case when the supply is from a cylinder of
compressed air. They contain a regulator at the
lower end of the breathing tube. This permits air to
flow under slight preset positive pressure to the
face piece only when the wearer breathes.

10.2.2.2 Abrasive Blasting Respirators

Abrasive blasting respirators are used to protect

personnel engaged in sand or other abrasive blasting
operations.

The requirements for this type of respirator are the

same as those for an air line respirator of the
continuous flow type with the addition that mechanical
protection from abrasive particles is needed for the
head and neck.

February 1993 - 10.0 Breathing Apparatus Page 64

 10.2.2.3 Air Supplied Suits

The most extreme condition requiring respiratory

equipment is rescue or emergency repair work done in
atmospheres which are extremely corrosive to the skin
and mucus membranes, in addition to being acutely
poisonous and immediately hazardous to life.

For these conditions, full suits of impervious clothing

with respirable air supplies are available. This
equipment must be used only by well-trained and
qualified personnel. Consideration must be given for
the clearance of safety equipment through manholes
and other accessways. (See Figure I.9.)

10.2.3 Self Contained Breathing Apparatus (SCBA)

When entry into a hazardous atmosphere is necessary, self

contained breathing apparatus shall be used. This equipment
typically consists of a high pressure cylinder of air, a cylinder
valve, a regulator, a face piece and tube with an exhalation
valve. The need to have the mask properly fitted before use is
important. A person who wears glasses or who has a beard
cannot wear this type of breathing apparatus as a proper seal
cannot be obtained between the mask and face.

SCBAs must be used in lieu of airline respirators when the

distance from the source of fresh air supplied via the air line
hose is greater than 91 meters (300 ft) per ANSI Z88.2-1980.
However, an exception from this requirement is made in an
emergency situation where use of such equipment is necessary
to escape from a hazardous condition.

February 1993 - 10.0 Breathing Apparatus Page 65

10.3 Training

In many cases, respirators are used in emergency situations where there

is heightened physical demands on the body, due to stress and
excitement. Under such conditions, it is essential that the potential
users have been thoroughly trained and are medically fit (per TM - 3 or
equivalent) to cope with the increased level of physical activity and
stress. The local Loss Prevention Division and the Industrial Hygiene Unit
will assist contractors in the selection and use of respiratory protective
equipment.

10.4 Safety Precautions

When air supplied respirators are used, the following safety precautions
are required:

1 Breathing air compressors shall have:

· Pressure Relief Valve
· High temperature alarm
· Periodic carbon monoxide (CO) testing to ensure it meets the
CGA Grade 'D' limit
· Breathing air tested to meet requirements. (See section 10.1.4.)
2 Proper training of employees in the use of this equipment.
3 Fit testing of mask/hood prior to each use.
4 Employees determined by a medical evaluation to be physically fit
to use equipment.
5 Proper cleaning and inspection program for equipment.
6 Written standard operating procedures for using the equipment.
7 A rescue man with a self-contained breathing apparatus (SCAB) is
required when equipment is used in immediately dangerous to life
and health (IDLH) atmospheres.
8 Life lines shall always be attached to the safety belt worn by
employees using a respirator.

10.4.1 Air Compressors

· Air compressors shall operate at 245 oF and 150 psig

maximum. (See manufacturers' specifications.)
· Intake air filters to compressors and outlet filters to
operator mask/hood are required.
· Air supplied respirator's maximum intake temperature and
pressure are 140 oF (60oC) and 125 psig respectively. Filter
outlet temperature to operator's mask/hood is 100 oF
maximum. The air .supply rate is 6 CFM for hoods without
vortex tube and 25 CFM for hoods with vortex tube.

February 1993 - 10.0 Breathing Apparatus Page 66

FIGURE I.7: RESPIRATORY PROTECTION

Self Contained Breathing Apparatus Airline Respirator

(SCBA)

Chemical Cartridge
Respirator

Airline Hood With A Full Face Piece Gas Mask Used

In HC
Atmospheres

February 1993 - 10.0 Breathing Apparatus Page 67

FIGURE I.8: CLEARANCE CONSIDERATIONS FOR SAFETY EQUIPMENT

Deck-mounted hatch dimension.

As angle X increases, depth of
hatch must increase

February 1993 - 10.0 Breathing Apparatus Page 68

11.0 FIRE PREVENTION
This section covers measures to prevent fires and protect against all their possible
harmful effects, in order to avoid injury to personnel and loss of time and
materials.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.711 Fire and Safety Watch

GI 1781.001-1 Inspection/Maintenance - Fire Protection Equipment

GI 1787.000-1 Fire Reports

Abqaiq Plants Operations Instruction Manual:

No. 2.102 Fire Fighting Dispatching Procedure

Refinery Instruction Manual:

No. 1.806 Fire Watch

Saudi Aramco Engineering Standards:

SAES-B-7A Fire Water System and Design

SAES-B-7C Portable, Mobile, and Auxiliary Fire Fighting Equipment

Saudi Aramco Sanitary Code

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements - Fire

Extinguishers

National Safety Council Accident Prevention Manual for Industrial Operations

NFPA:
National Fire Codes
NFPA 231-Appendix C, Protection of Outdoor Storage.
"Fire Safety Checklist for Evaluating Construction Materials Store
Yard"

11.1 Before the Job Starts

Construction within a petroleum industry complex requires careful
planning since plants and support facilities being constructed are
frequently next to those already in operation. An accident at a

February 1993 - Construction Safety Manual - Fire Prevention

Page 69
 construction site can have serious effects on a nearby oil or gas facility
and vice-versa, because of a large amount of fuel present at both
locations. The factors which must be considered before the job starts
include site preparation, work permit schedules, types of work permits
required and type/quantity of equipment required on-site.

As part of this process, the contractor must take into account the
potential hazards that can be encountered on site; protection of
machinery and equipment; control of ignition sources; storage of
flammable and combustible materials; housekeeping; staff training; and
end-of-shift checks. These subjects are addressed in the Hazards
Identification Procedure prior to construction start-up in Appendix A of
this manual. This section focuses on means of avoiding and controlling
fires.

11.2 Layout

Good layout helps ensure the project can be carried out efficiently.
Overall requirements for site planning are in Section 7. (See Appendix C
attachment). The following principles of project layout and organization
can help minimize fire risks:

11.2.1

Avoid congestion around machinery and equipment where there

is a high level of activity and traffic.

11.2.2

Operations having a high fire risk, such as welding and spray

painting, should be isolated from flammable and explosive
materials or specially protected.

11.2.3

Be sure to provide adequate emergency access and egress.

11.2.4

Storage of flammable and explosive materials in the plant site

should be restricted to minimum quantities necessary for an
uninterrupted cycle of operations; use a larger, secondary
storage site outside the plant area where possible.

11.3 Equipment Protection

Some items of plant equipment need special handling and care after
they arrive on site and until they are commissioned. Examples are
computer (and other electronic instrumentation and control gear) and
large pumps and compressors. Such equipment should be covered and
protected against possible damage that could result from its exposure to
normal construction activity, dust, paint spray, etc. Consideration should

February 1993 - 11.0 Fire Prevention Page 70

 also be given to protecting it against fire, which could be caused by
storing it near combustible material and against water or other fire
fighting agents that might be used to put out a fire.

11.4 Control of Ignition Sources

Compliance with work permit procedures and conditions protects against

possible ignition of oil or gas from process operations. The contractor
must also take steps to prevent ignition of construction materials,
lubricants, and fuels used in the job itself.

11.4.1

Electrical equipment should be checked regularly for defects.

11.4.2

Smoking is permitted only in designated areas.

11.4.3

Welding equipment, asphalt kettles, heating appliances and

other open flames or hot surfaces should be segregated from
combustible materials.

11.4.4

Beware of indirect sources of ignition: hot welding slag dropped

from a height for example, or sparks from a fire under an asphalt
kettle are familiar examples of this.

11.4.5

Open fires and/or open burning of materials are strictly

prohibited. Authorization must be obtained from Saudi Aramco
Fire Protection Department.

11.4.6

Proper bonding and grounding techniques shall be used for any

operation where static electricity could become an ignition
source.

11.5 Flammable Liquids

Flammable liquids are those that can produce a flammable mixture in air
at ambient temperature. In Saudi Aramco, this is defined as a fluid
(liquid or gas) having a flash point of 55 oC (130oF) or lower. Care in
handling flammable fluids is of prime importance.

February 1993 - 11.0 Fire Prevention Page 71

 11.5.1 Storage

All flammable liquids must be kept in securely capped metal

containers or steel drums on which the contents are clearly
marked. Gasoline, acetone, spirits and other volatile liquids with
flash points below 32oC (90oF) should be kept in strong metal
lockers located in well-ventilated, non-combustible huts or sheds.
Drums containing flammable fluids shall be provided with proper
bung vents. Flammable storage areas must be securely locked
(or fenced), posted with a warning sign "Danger: Flammable
Area" and must be located at least 15 meters (50 feet) away
from the nearest building or storage area for combustibles. No
other materials should be stored with flammable liquids.

Flammable gases in cylinders (acetylene, propane, etc.) shall be

segregated from other materials, preferably under an open, well-
ventilated sun shade. Oxidizing gases (oxygen, chlorine, nitrous
oxide, etc.) shall be stored separately.

11.5.2 Handling of Flammable Liquids

(Reference NFPA 30)

In handling, the following precautions should be observed:

1 Transportation must always be in (closed) metal containers.

(Plastic containers are prohibited.)
2 Transfer operations should be carried out with funnels and
there should be no open flames within 15 meters (50 feet)
of the operation unless conditions warrant greater
clearance.
3 Containers are to be grounded and bonded during transfer
operations.
4 Screw tops and stoppers should be replaced immediately.
5 Any metal container holding flammable liquid must be a FM
(or UL) approved type of safety container.

11.5.3 Ventilation

Gasoline and diesel powered equipment should only be used in

well-ventilated areas. Exhaust pipes should be kept away from
combustible materials. Engines must be stopped before
refueling takes place.

11.6 Combustible Materials

Although the main material used in the construction of plants for the
petroleum industry is non-combustible steel or concrete, on a
construction site many materials are potential fuel for a fire: packing
material, scaffold planks, form lumber, electrical insulation, tires and
other rubber goods, lubricating oil and grease, and diesel fuel, in
addition to the flammable liquids (fuels, paints, solvents) mentioned

February 1993 - 11.0 Fire Prevention Page 72

 above. Therefore, daily site clean up of combustible materials is
required to reduce fire hazards.

11.7 Housekeeping

Rubbish, accumulated at a job site, provides a good starting point for a

fire. Waste should be removed at regular intervals and always at the end
of a working day. Metal bins with close-fitting lids should be provided for
oily rags, wood shavings, and other highly combustible wastes. Use non-
combustible absorbents to remove spills or leaks of oil. Contents of ash
trays should not be mixed with other waste. Good housekeeping on the
site can eliminate many of the situations where a fire can start.

11.8 Emergency Equipment

The Fire Protection Department area offices can assist in training Saudi
Aramco employees in the proper use of fire fighting equipment. (See GI
1781.001. Inspection and Maintenance of Fire Protection Equipment.)

Each contractor has a contractual obligation to provide and maintain

adequate, easily accessible fire extinguishers on the job site (Schedule
'D'). The contractor should consult with the local Fire Protection Unit for
advice on selection of such equipment. There are three types of fire
extinguishers normally found on construction sites: water, carbon
dioxide and dry chemical types. Contractor personnel should be aware
of the fire fighting equipment available on site and be familiar with its
use.

11.8.1 Water-Type Fire Extinguisher

Water extinguishers should be available around sites where there

will be Class "A" material, such as wood, paper, waste material,
or packing crates. The typical portable water extinguisher comes
in a 9.5 liters (2-1/2 gallon) size. On construction sites within
Saudi Aramco facilities a pressurized system of fire water
hydrants and hoses will normally be available, so this type of
extinguisher will have limited use.

11.8.2 Carbon Dioxide Type Extinguisher

The carbon dioxide (CO2) type extinguisher is normally used for

controlling electrical fires. These fires take place in motors,
switch-gear, and so forth and are usually very easily controlled
by de-energizing the circuits that supply the power. The
advantage of using CO2 in this particular instance is that it
leaves no residue in the mechanisms of the electrical equipment
and, therefore, does not further contribute to the damage.

February 1993 - 11.0 Fire Prevention Page 73

 11.8.2.1 CAUTION

A CO2 extinguisher should never be used in enclosed

areas where people are present, because the gas
displaces oxygen from the immediate environment.
When the oxygen level in the environment is reduced
sufficiently to put out a fire, the oxygen level is also
incapable of supporting human life.

11.8.3 Dry Chemical Type Extinguisher

A dry chemical type extinguisher is normally used in controlling

Class "B" fires in flammable liquids. A dry chemical extinguisher
normally comes in portable 9 kilograms (20 pounds) and 13.6
kilograms (30 pounds) sizes. A larger wheeled extinguisher of 68
kilograms (150 pounds) and above is available, but is usually
found only within petroleum operating areas. Some dry chemical
extinguishers today have a powder which is good in controlling
Class "A", "B", and "C" fires. This multipurpose ABC powder
gives this particular fire extinguisher a good chance of
controlling any type of fire involving a wood, a petroleum liquid,
or electrical equipment.

11.8.4 Pressurized Water

Where a pressurized water system is available on site, the

contractor is responsible for supplying hoses and nozzles. Since
most fires at construction sites involve Class "A" materials, they
can be fought with water. Charged water hoses, ready for use,
are a necessity. If there is no permanent system installed at a
particular location, a water tanker and portable water
extinguishers will have to be supplied in order to take care of any
Class "A" fires.

11.9 Reporting a Fire

Every fire, including those extinguished by contractor personnel, should

be reported to the Saudi Aramco representative. The Fire Protection Unit
will inspect the area, to offer suggestions for preventing a recurrence,
and to ensure the contractor has re-established his fire fighting
capability by recharging extinguishers or replacing equipment.

The emergency telephone number used for reporting a fire or any

emergency that requires Saudi Aramco assistance is 110. The contractor
must ensure that this number is posted at all telephones and that
instructions are placed indicating how to report the emergency correctly.

February 1993 - 11.0 Fire Prevention Page 74

11.10 End-of-Shift Checks

A routine inspection shall be made at the end of the working day to see
that everything is left in a safe condition. The following itemized
checklist shall be followed:

· Clean-up and removal of rubbish and waste materials.

· Switch off electrical equipment at the mains. Separate
circuits should be provided for security lights and other
equipment that has to be left turned on.
· Cover valuable equipment to protect it against dirt and
against the effects of water that might be used in an
emergency.
· Make a special check of smoking areas, hot equipment,
welding areas, etc. to be sure there is no possibility of
delayed ignition resulting in a fire.
· Return flammable liquids and gas cylinders to designated
storage areas.

February 1993 - 11.0 Fire Prevention Page 75

FIGURE I.9: K NOW YOUR FIRE EXTINGUISHER
Dry Chemical
Water Type Carbon Dioxide Sodium or Multi-Purpose
C02 Potassium ABC
Bicarbonate

Stored Pressure Stored Pressure

Cartridge Cartridge
Operated Operated
CLASS A FIRES - Yes No No Yes
Ordinary Combustibles
Wood, paper, trash

CLASS B FIRES - No Yes Yes Yes

Flammable Liquids and Gases
Gasoline, oil, paints, grease, etc.

CLASS C FIRES - No Yes Yes Yes

Energized electrical equipment

Pull pin, unclip Pull pin, unclip Unclip hose to Unclip hose to
METHOD OF OPERATION nozzle, squeeze discharge horn, break seal and break seal and
handle and direct squeeze handle strike actuator; strike actuator;
at base of fire and blanket fire squeeze nozzle squeeze nozzle
with CO2 and direct at base and direct at base
of flames, of flames,
sweeping from sweeping from
side to side. side to side.
RANGE 30'-40' 3'-8' 5'-20' 5'20'

STOCK NUMBER 21-104-550 21-102-223 21-102-820 21-102-775

Maintenance:

February 1993 - Fire Prevention Page 76

Maintenance should comprise of a monthly check by proponent organization - Check extinguisher is in correct location,
access is unobstructed and extinguisher is clearly visible. Check contents gauges, where fitted, indicate extinguisher
is serviceable. Check for signs of leakage, corrosion, or physical damage. Check seals are unbroken and up to date
inspection tag is fitted. If in doubt, contact your local fire control unit.

November 1992 Construction Safety Manual - 11.0 Fire Prevention Page 77

12.0 RADIO COMMUNICATIONS
In a widespread area such as that covered by Saudi Aramco operations, it is not
cost effective to lay down telephone lines and establish subsidiary installations for
communication. It is more feasible to develop a radio communications network
instead. The continuous development of the Saudi Aramco radio communications
system has enabled us to convey messages to the most remote corner of the
Company's operational area.

This section is mainly concerned with the two-way radio network which is installed
in vehicles, offices, outlying plants and allied facilities. This network is extensively
used by many employees in their day-to-day business. Standard procedures must
be followed in these radio operations.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 70.500 Disaster Contingency Plan - Dhahran Area

GI 80.500 Disaster Control - Refinery and Terminal - Ras Tanura

GI 1600.003 Destruction Of Obsolete/Damaged, Unneeded Communication

Equipment

GI 1601.002 Radio Asset Control And Accountability Program (RACAP)

GI 1602.001 Residential Telephone Service

GI 1602.002 Business Telephone Service Inside Aramco Communities And

Facilities

GI 1602.003 Business Telephone Service Outside Aramco Communities And

Facilities

GI 1603.001 Data Circuits, Message Switch And Facsimile Terminals

See also OIMs, RIMs, and TIMs.

No. 525.001 Disaster Control Plan - Plants and Pipelines Department - Abqaiq
Producing and Udhailiyah Producing Divisions (also in Saudi Aramco
GI Manual)

No. 85.001 Disaster Control Plan - Safaniya (also in Saudi Aramco GI Manual)

No. 554.001 Disaster Control Plan - Udhailiyah Area

No. 554.002 Disaster Control Plan - Qurayyah Seawater Treatment Plant

February 1993 - Construction Safety Manual: Radio Communications Page 78

Radio Telephone Procedure Guide:

Communications Department - Dhahran

12.1 Equipment

There are a minimum of three types of radio sets used in the Saudi
Aramco network today: the mobile radio set, the stationary radio set
with remote control, and the portable hand radio set.

12.1.1 Remote Control Unit

The remote control units located in offices are used to control

radio equipment at some other location. The unit controls used
by operating personnel are the volume control, hand set switch,
and the frequency switch. All other controls must be set by
technical personnel.

12.2 Safe Operation

Adjustment of equipment must always be carried out by authorized

personnel. Unauthorized tampering with equipment can result in electric
shock or equipment malfunction leading to circuit interference.

Under certain circumstances, radio waves can cause ignition of electric

blasting caps. Radio equipment must be shut down within 91 meters
(100 yards) of any blasting operations or where electric detonators are
used or stored.

Water Damaged Equipment:

Vehicle drivers and maintenance personnel are requested to exercise

great caution when washing vehicles containing radio equipment.

12.3 Radio Phrases

AFFIRMATIVE: This means Yes

BREAK: The work BREAK means the message will continue, but due to
the length of the message the operator will break the circuit to allow the
reception of EMERGENCY messages.

CORRECTION: This means that An error has been made; the correct
message is ...

DISASTER: When used on Company communications systems, DISASTER

warns all operators that a sudden misfortune has occurred, causing
either loss of life, property, fire, or a combination of the three. All
operators must stop transmitting unless involved in the disaster and
should standby unless told to transmit by Disaster Control or the Disaster
Control Post.

February 1993 - 12.0 Radio Communications Page 79

 DISASTER DRILL: This is an exercise for training personnel to handle
disaster situations.

HOW DO YOU READ?: This means that the operator is trying to

determine if the message is being received well.

MAYDAY: This is an international radio distress signal which is primarily

intended for ships and aircraft requiring assistance to save human lives
or property.

NEGATIVE: This means No.

OUT: An operator using the word OUT at the end of a transmission

indicates that he is finished with the communications circuit and any
other station may begin its call.

OVER: This means that the transmission of a message has ended, but
one station is waiting for the other to transmit.

OVER AND OUT: Do not use this phrase.

PRIORITY TRAFFIC: This is a message having preferential rating over the

routine. The expression "I have priority traffic" means the operator has
listened to the messages being transmitted and has determined that his
message is of greater urgency.

READ BACK: This means that the operator wants to make sure that his
message has been correctly understood.

RESUME TRAFFIC: All stations are free to transmit routine messages.

ROGER: This means that the operator has received and understood the
message and accepts responsibility to carry out any instructions therein.

SAY AGAIN: Do not use the word "repeat". If a message is to be

repeated, the operator shall instruct the station to "say again your
message".

SAY EVERY WORD TWICE: This phrase is used when the operator is
having trouble understanding, and wants each word said twice.

SPEAK SLOWLY: This phrase is used mostly in cases where technical

difficulties are causing the circuit to cut in and out.

STANDBY: Any or all operators told to STANDBY shall cease further use of
the communications circuit until further notice.

TRAFFIC: The information or signals transmitted over a communications

systems.

URGENT TRAFFIC: A message requiring the attention of all operators.

VERIFY: Check with originator and make certain the message is correct.

February 1993 - 12.0 Radio Communications Page 80

12.4 Phonetic Alphabet

In a radio message, some letters of the alphabet are likely to be

confused with others: as "B" with "P" and "D" with "T". A standardized
international phonetic alphabet for radio operators is in use to clear up
such ambiguities. Whenever a word is not properly understood by the
receiver, it is advantageous to utilize the Phonetic Alphabet. For
example, an operator intends to make clear "ABQAIQ". He will spell it
out like this: "A" as in "ALPHA"; "B" as in "BRAVO"; "Q" as in "QUEBEC";
"I" as in "INDIA"; and, so on. Use the phonetic alphabet which is listed
which follows:
PHONETIC ALPHABET

Letter Word Pronunciation

A ALPHA AL fah
B BRAVO BRAH vo
C CHARLIE CHAR lee
D DELTA DELL ta
E ECHO ECK oh
F FOX-TROT FOKS trot
G GOLF GOLF
H HOTEL hoh TELL
I INDIA IN dee ah
J JULIET JEW lee ETT
K KILO KEY loh
L LIMA LEE mah
M MIKE MIKE
N NOVEMBER No VEM ber
O OSCAR OSS car
P PAPA Pah PAH
Q QUEBEC keh BECH
R ROMEO ROW me oh
S SIERRA See AIR rah
T TANGO TANG go
U UNIFORM YOU nee form
V VICTOR VIC tor
W WHISKEY WISS key
X X-RAY ECKS ray
Y YANKEE YANG key
Z ZULU ZOO loo

February 1993 - 12.0 Radio Communications Page 81

12.5 International Communications Union Agreement

All Company communications systems and networks come under the

regulations of the International Communications Union Agreement. The
Saudi Arab government is a signatory of the Communications Agreement
and a member of the International Telecommunications Union (ITU).
Regulations which shall be binding on all members include the operating
of telegraph, telephone and radio. Any violation or infringement of any
communication system or network shall be reported to the violator's
administration by the control organization, stations, or inspectors
detecting them.

All stations must be established and operated in such a manner as not to

result in harmful interference to associated members or members of
recognized private operating organizations.

NOTE: All stations are forbidden to carry out the following: unnecessary
transmissions; the transmissions of superfluous signals; or false (or
deceptive) distress, safety, or identification signals.

Use of profane or obscene language is a violation of the International

Agreement.

Tampering with equipment is highly dangerous because of the high

voltage involved. Adjustments to equipment are only to be made by
competent and authorized personnel. Tampering can also cause off
frequency operation and other technical problems which are violations of
the ITU Agreement.

12.5.1 Monitoring of Circuits

Most voice transmissions are transmitted by radio waves and can

easily be monitored by outside agencies. It is forbidden to
disclose or divulge any information intercepted over the
Company communications systems.

12.5.2 Secrecy Act

All member nations of the ITU bind themselves to the Secrecy

Act which states: "They will take the necessary measures to
prohibit and prevent:

* The unauthorized interception of radio communications

not intended for public use.

* The divulgence of the contents, simple disclosure of the

existence, publication, or any use whatever, without
authorization, of information of any nature obtained by the
interception of radio or telephone communications."

Supervisors should be especially alert for violations of this kind

and use maximum disciplinary action toward violators.

February 1993 - 12.0 Radio Communications Page 82

 12.5.3 Penalties

All persons operating the communications systems will be held

responsible for any improper operation and will be held subject
to disciplinary action.

12.6 Message Priorities for Company Operations

1 MAYDAY

2 PAN/DISASTER

3 DISASTER DRILL

4 SAFETY SIGNAL (Number 3 Priority - International Frequencies)

5 PRIORITY TRAFFIC

6 ROUTINE

12.6.1 MAYDAY

(Broadcast to all stations)

When MAYDAY is spoken three times and followed by the words:

"this is (the call station, station identification, or other
identification of the mobile station)", indicates that a ship,
aircraft, or other vehicle is threatened by grave and imminent
danger and requires immediate assistance to save human life or
property.

The message has absolute priority over all other messages.

When the message is heard, all stations shall stop transmitting
and listen to the message. The nature of distress may be such
that the operator may not be able to complete the message or
repeat.

International Search and Rescue Monitor Stations shall 'fix' the

bearings of the signal and alert ships and aircraft in the area to
assist with the rescue.

All persons operating radio equipment must be thoroughly

acquainted with this type of priority message.

12.6.2 URGENCY SIGNAL

(International PAN; Company DISASTER)

This message is usually directed to a particular station.

PAN/DISASTER, when spoken three times and followed by the
words: "This is (the call sign or station identification)", indicates

February 1993 - 12.0 Radio Communications Page 83

 that the station has a critical emergency concerning injury, oil
operations or other extreme operating situation.

Messages of this nature carry priority over all messages except

MAYDAY. Company operators use the word DISASTER. Within
Company operations DISASTER has the same priority as the word
PAN for those operating on international circuits or frequencies.

12.6.3 DISASTER DRILL

At various times the Company conducts training exercises which

are associated with familiarization and indoctrination programs.
At the beginning of such a drill, radio stations will announce "A
DISASTER DRILL is being conducted", followed by the name of
the area. When a DISASTER DRILL is in progress, all stations
whether mobile or fixed must standby, except those having
MAYDAY, URGENCY, or DISASTER messages. The difference
between DISASTER and DISASTER DRILL must be thoroughly
understood.

12.6.4 SAFETY SIGNAL

No. 3 Priority - International Frequencies

This need only be understood by those operating on

international circuits or frequencies. The French pronunciation of
SECURITE will be spoken three times and followed by the station
identification. The SAFETY SIGNAL is used

when a station is going to broadcast a message concerning the

safety of navigation or giving important meteorological warnings.

12.6.5 PRIORITY TRAFFIC

Repairs to facilities involved in disasters should be classified as

PRIORITY TRAFFIC.

12.6.6 ROUTINE

All messages except those classified above should be ROUTINE.

12.7 Distress Messages

(Forms and Examples)

12.7.1 MAYDAY

1 Distress Signal

The distress signal is MAYDAY, MAYDAY, MAYDAY

followed by the name of station or station call letters
repeated three times.

February 1993 - 12.0 Radio Communications Page 84

 Give location, first.

Give the nature of the distress, second.

Give the kind of assistance required.

Complete message with any other information which

can be of assistance to rescue operations.

2 Stations Receiving Message

From the location given, the receiving stations can

determine if they are in the immediate vicinity. All
stations shall cease transmission. The station in the
immediate vicinity shall acknowledge receipt by
transmitting the following message: "(Give name of
station in distress; repeat three times) - This is the
(name of station), Roger, your Mayday Message."

This station assumes the full responsibility of a control

station for all further radio transmissions and all other
stations remain off the air unless directed to transmit
by the control station.

By virtue of acknowledging the MAYDAY message, the

receiving station assumes control and becomes fully
responsible. It may use any means at its disposal to
carry out the rescue operation.

3 End of Mayday Distress

When the distress traffic has ceased or when silence is

no longer necessary on a circuit or frequency which
has been used for distress traffic, the control station
shall transmit the following message:

"To all stations, to all stations, to all stations - This is

(control station identification, repeated three times)
distress traffic has ended with (station in distress
identification). All stations resume normal traffic."

The message should be repeated at intervals in order

to assure that all stations standing by receive the
message.

IMPORTANT: The transmission of MAYDAY messages for

the purpose of training is not permitted under any
circumstances.

February 1993 - 12.0 Radio Communications Page 85

 12.7.2 Urgency Signal

This signal indicates that the calling station has a very urgent
message to transmit concerning the safety of a person, ship, or
aircraft.

1 Signal

Radio operators, operating on international circuits or

frequencies, shall be alert for the urgency signal which
is PAN, repeated three times followed by the station
call letter or identification. The Company equivalent to
urgency signal is DISASTER.

2 Response

All stations shall cease transmitting and listen to the

message that follows. If the stations receiving the
message can be of any assistance, they shall
acknowledge and render all assistance possible;
otherwise, they shall cease transmission until the
urgency traffic has been cleared.

3 Procedures

All persons operating Company communications

equipment shall be familiar with the word DISASTER.
When it is heard, they shall cease transmitting until the
DISASTER is over. The procedures are outlined in the
General Instruction Manual, under Disaster Procedure,
Abqaiq, Dhahran, Ras Tanura.

4 Return to Normal

When the disaster has ended, the responsible parties

outlined in the General Instruction shall clear the radio
circuits for normal traffic.

12.7.3 Priority Traffic

Repairs to facilities involved in disasters would be classified as

priority traffic and the priority would depend on the situation.

February 1993 - 12.0 Radio Communications Page 86

13.0 TRANSPORTATION
This section outlines the procedures and responsibilities for preventing motor
vehicle accidents in Saudi Aramco's jurisdiction. In addition, it sets the standards
for driver performance, responsibility, and vehicle maintenance expected of all
contractor, service organization and Saudi Aramco drivers. All drivers are
expected to drive in a defensive manner and maintain control of their vehicles at
all times.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1183.215 Transporting Explosives in Company Owned/Leased/Rented Motor

Transport Vehicles

GI 150.002 First Aid / CPR Training and First Aid Kits - Remote Areas

GI 6.025 Control of Remote Area Travel and Search/Rescue Procedures

GI 6.029 Reporting and Recording Of Motor Vehicle Accidents

GI 6.030 Traffic and Vehicle Safety

GI 1321.015 Request for Air Medical Evacuation

Driving in Saudi Arabia: A Saudi Aramco guide to safer driving and desert travel.

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Transportation.

13.1 Driver Requirements

All contractors must employ only qualified personnel as drivers of motor

vehicles. It is the responsibility of the driver's supervisor, foreman, or
superintendent to verify the driver's credentials prior to his employment.
It is Saudi Arab Government law and a Company rule, that each person
driving a motor vehicle must possess and have on his person a valid
Saudi Arab Government driver's license.

13.2 Driver's Responsibilities

13.2.1

It is the responsibility of the driver to ensure that his vehicle is

safe to operate.

February 1993 - Construction Safety Manual: Transportation

Page 87
 13.2.2

It is the responsibility of each driver to take his vehicle to the

proper facility for servicing and repairs when they are required or
scheduled.

13.2.3

The driver of the vehicle is fully responsible and accountable for

the mechanical and physical condition of the vehicle. He must
report any damage, beyond normal wear and tear, immediately.

13.2.4

The driver is responsible for transporting materials properly and

ensuring that a load does not exceed the manufacturer's design
load capacity. All loads must be properly secured and tied down.
Materials should not extend over the sides of the truck. Loads
extending beyond the front or rear shall be marked with a red
flag. Also such loads must be equipped with visible brake and
tail lights at their rear end points.

13.2.5

Tires which have breaks in the casing, or with exposed fabric,

shall not be used.

13.2.6

Sand tires present a hazard if used on vehicles which are

operated at excessive speed especially when they are not
properly inflated. It is the driver's responsibility to ensure that
Saudi Aramco Transportation Department tire inflation standards
are maintained. Proper inflation pressures are posted at the
Department's tire shops.

13.2.7

Drivers shall not transport unauthorized persons in Company

vehicles. The driver's supervisor shall authorize all passengers
in the vehicle.

13.2.8

The driver and all passengers of a Company vehicle shall wear

seat belts at all times while the vehicle is in motion.

13.2.9

Drivers have full authority to refuse to transport any passenger

who refuses to use seat belts. Conversely, passengers may
refuse to ride with a driver who refuses to wear his seat belt.

February 1993 - 13.0 Transportation Page 88

 13.2.10

Passengers shall not be transported in the rear of pickups or on

truck beds.

13.2.11

Drivers should not transport more passengers than the number

of seat belts provided in the vehicle.

13.2.12

All drivers shall be familiar with what the Company considers

unsafe driving practices and avoid them at all times.

The driver must not exceed the posted speed limit. This is the
maximum speed allowed in a certain area.. Every driver is
expected to reduce his vehicle's speed under hazardous weather
or road conditions. (See GI 6.030.)

13.3 Motor Vehicle Regulations: Saudi Arab Government

and Saudi Aramco

Each driver shall become familiar with, and abide by, the Saudi Arab
Government Traffic Regulations. An English translation of these
regulations is available from the Loss Prevention Department.

13.3.1

Where there is no sign post indicating the maximum speed limit,

no vehicle may be driven at a speed greater than the following:

1. 100 kilometers per hour for light motor vehicles outside

city limits. (See GI 6.030.)

2. 70 km/hr for vehicles with sand tires.

To drive safely, speed must be reduced below the allowable

speed limit at night, or during fog, rain or sand storm.

13.3.2

Drivers shall comply with all Saudi Arab Government and Saudi
Aramco traffic signs.

13.3.3

All vehicles shall be parked correctly and/or in designated

parking areas. Parked vehicles shall not obstruct other
vehicles, roadways, accessways or fire hydrants.

February 1993 - 13.0 Transportation Page 89

13.4 Vehicle Condition

It is the responsibility of the driver to ensure his vehicle is safe to

operate. It is the responsibility of the driver to bring the vehicle in for
scheduled maintenance. The driver is responsible for inspecting a
vehicle before operating it to determine if the following items have been
provided and are in satisfactory condition:

Vehicle Inspection Checklist:

1. The vehicle number, company name, current inspection stickers and

license plate (front and back) must be in place.

2. Seat belts are mandatory for all vehicle occupants.

3. Two reflective warning triangles should be in each vehicle.

4. Windows and windshield must be clean and free of cracks or

damage. The glass must be in good condition. The windows must
open and close properly.

5. All lights (high and low beam headlights, tail lights, dash lights, stop
lights, turn signal lights, and the rear license plate light) must be in
working order. When fog lights (front & rear) and clearance lights
have been provided, they must be also be in good working order.

6. All brakes (foot and hand brakes) must be in good working order.
Check the foot and hand brake mechanism for correct operation.

7. The automatic transmission must be in good operating condition

and should shift into the parking position correctly.

8. Springs and shock absorbers must be in good condition with no

alignment or control problems.

9. There should be no excessive movement of the steering wheel and

no signs of damage. Steering knobs and loose coverings are
prohibited.

10. Tires should have no breaks in the tire casing or exposed fabric and
must be inflated to correct air pressure as specified by the
Transportation Department.

If the treads show any signs of wear like bare patches, this could
indicate defective steering, springs and/or shock absorbers.

11. Check the wheels for rim damage. Make sure the wheels are not
buckled or out of alignment and wheel lug nuts are in place and
secure on the rim.

12. If the vehicle is fitted with a trailer, the coupling must be intact and
working correctly. The trailer should have safety coupling chains,
rear brake lights, turn signals, tail lights and rear license plate lights.

February 1993 - 13.0 Transportation Page 90

 13. Make sure that the inside and outside rear view mirrors are clean,
adjusted, secured and undamaged.

14. Check that the windshield wiper blades are in good condition, and
operate properly. Inspect the rear window wiper, if fitted.

The windshield washer should work properly and there should be

water in the washer container.

15. The speedometer should be in good working order.

16. Test the exhaust system by starting up the engine of the vehicle,
listening for sounds and spotting any leaks associated with it. Check
to see if the tail pipe extends at least three inches from the body of
the vehicle. The tail pipe emissions should be released from a point
where they do not directly come into contact with the driver of the
vehicle or its occupants, thereby causing any adverse health affects
to any of them.

17. A properly inflated spare tire with a jack and tire wrench must be
provided. The tire wrench should be the correct size to fit the wheel
nuts of the vehicle.

18. Check the following fluids for leaks and proper levels, especially in
hot weather.

· Radiator coolant
· Oil
· Brake fluid
· Transmission oil (checked with engine running)
· Distilled water for the battery

NOTE: The driver should check the radiator coolant level only when the
engine is cool. Fluid should be added to the level mark on the
overflow expansion tank only if provided.

19. The vehicle's horn must be operational.

20. Note all damage on the vehicle, process the proper reports and have
the damage repaired. You could be charged with a hit and run
accident unless you have a police vehicle release for major damage,
and back up reports for minor parking lot "dings and scratches".

Each driver must conduct a vehicle inspection whenever taking

charge of a vehicle and periodically thereafter (at least once a
month) to ensure that all systems are operating properly and there
is no damage.

Passengers will be carried only in the passenger compartment of a

vehicle. All vehicle occupants must wear seat belts. Drivers shall
insist that all passengers wear seat belts before starting the vehicle.
Drivers can receive a moving violation for not adhering to this
regulation.

February 1993 - 13.0 Transportation Page 91

 Loose materials are to be kept out of the driving compartment. Do
not place materials (hard hats, etc.) on rear window shelf.

13.5 Driver Training

The Company conducts driver training courses for Saudi Aramco

employees. Details about the courses are available from the On-the-Job
Training Unit.

13.6 Enforcement of Safe Driving Practices

The Industrial Security Organization issues "Unsafe Driving Practice

Warning" notices.

13.6.1

Saudi Aramco drivers who commit traffic offenses are given

penalty points. Repeat offenders may receive disciplinary action.
(See GI 6.030.)

13.6.2

Contractors driving on Saudi Aramco facilities or in the

communities are required to abide by all Saudi Aramco and
Saudi Arab Government traffic regulations. Offenders will be
referred to proponent organizations for appropriate action,
including counseling and revocation of driving privileges within
Saudi Aramco. For repeat offenders, contract may be reviewed
for cancellation.

February 1993 - 13.0 Transportation Page 92

13.7 Action Taken After a Saudi Aramco Motor Vehicle
Accident

All motor vehicle accidents (MVAs) shall be reported to the closest main
gate or security control center. This must be done by telephone, radio,
or by sending a message with a passing driver. Other procedures in GI
6.029 must then be followed.

The Main Gate/Security Control Center telephone numbers are:

Dhahran: 874-
2055
Ras Tanura: 673-
5231
Abqaiq: 572-
5291
Udhailiyah: 577-
8114
Yanbu: 321-
4284
Mubarraz: 577-
2344
Abu Ali: 678-
2228
Berri: 678-
7226

Other procedures as detailed in GI 6.029 must then be followed.

13.7.1 Emergencies

In the event of serious injury, fire or hazardous road block caused

by an accident on Saudi Aramco facilities, the emergency
telephone number 110 should be used. For emergencies
occurring off Saudi Aramco facilities, a Main Gate/Security
Control Center telephone number can be used (see above). This
will allow both the Main Gate/Security Control Center and Medical
Controller to be informed and they will ensure that the proper
unit will respond to assist. When reporting any accident, make
sure the message is understood before hanging up.

13.7.2 Remain at Scene

A driver shall not leave the scene of an accident or move his

vehicle after an accident unless he needs to take an injured
person to a hospital. This is a Saudi Arab Government law and
the Traffic Department investigating officer is the only one
delegated the authority to release vehicles involved. The Saudi
Aramco Government Affairs Representative will advise you of this
release. If a damaged vehicle is blocking traffic or is stopped on
the highway, reflective triangles must be used to warn
approaching traffic of the vehicle's presence.

February 1993 - 13.0 Transportation Page 93

13.8 Passenger Seating and Seat Belts

Passengers shall be transported only in passenger compartments of cars,

trucks and buses. The number of passengers being transported in the
passenger compartment of a vehicle must not exceed the
manufacturer's specifications.

Seat belts shall be worn by the driver and passengers in all vehicles
except buses with more than 14 seats, where seat belts are only required
for drivers.

13.9 Desert Driving

All persons who drive in the desert should study "Driving In Saudi
Arabia," the Saudi Aramco guide on safe driving tips and desert travel. It
is recommended that the driver have a copy with him in the vehicle.
Copies may be obtained from any Loss Prevention area office.

In particular, any person who drives in the desert shall ensure that:

1. His immediate supervisor knows his destination and route.

2. His vehicle is in good condition with adequate fuel, oil, and water.
3. His vehicle has tools, equipment, and spares for emergency use.
4. He has sufficient food and drinking water to sustain him until rescue,
should he be stranded.
5. He is familiar with survival and rescue techniques and procedures.
6. Driver shall pass the off-the-road vehicle test conducted by Saudi
Aramco Driver Training Unit before being permitted the use of 4-
wheel drive vehicles.

13.9.1 Stay With Vehicle

A person lost or stranded in the desert must stay with the vehicle
as it provides shelter and to make it easier for searchers to
locate him.

13.9.2 Sand Tires

Sand tires are hazardous to use when they are not properly
inflated, when they are driven at high speeds or when the roads
are wet. It is the driver's responsibility to ensure the following
requirements are met for sand tires:

VEHICLE TYPE TIRE SIZE RECOMMENDED

TIRE PRESSURE
MIN MAX
Carryall, 4x4 9.00x16 15 35
Pickup, 4x4,1/2 Ton 9.00x15 15 35
Pickup, 4x4,3/4 Ton 9.00x16 15 35
Pickup, Crewcab, 4x4, 1 Ton 11.00x16 15 35
Utility, 4x4,3/4 Ton 9.00x16 15 35

February 1993 - 13.0 Transportation Page 94

 Utility, Crewcab, 4x4, 1 Ton 11.00x16 15 35
Stake Truck, 4x4, 1 Ton 11.00x16 15 35
Welder's Truck, 4x4, 1 Ton 11.00x16 15 35

Maximum speed for sand tires (on hard dry road):

· 70 KPH at maximum sand tire pressure

· 20 KPH at minimum sand tire pressure

Since sand tires have a larger diameter than standard tires,

speedometer readings will not be accurate. Unless the vehicle
speedometer has been corrected to account for the oversize
tires, the driver should remember that he is traveling
approximately 10-15% faster than the speedometer reading.

13.10 Vehicle Admittance to Restricted Areas

Vehicles requiring admittance to a restricted area (e.g. hydrocarbon

facilities, refinery and terminal areas) shall be inspected by the Saudi
Aramco Transportation Department. Upon successful completion of the
inspection, a window sticker is issued for the vehicle. This sticker is valid
for three months after which the vehicle must be inspected again. If the
vehicle fails inspection, it will not be permitted entry into any restricted
area until all deficiencies have been corrected. File form 7575
(Restricted Area Access Sticker Request).

13.11 Operation of Motor Vehicles Within Saudi Aramco

Communities

All contractor, service organization and company operated vehicles must

be constructed to comply with the Saudi Arabian Traffic Regulations,
Saudi Arabian Standards Organization (SASO) and Saudi Aramco rules
for the safe operation of motor vehicles while driving within any Saudi
Aramco community.

13.11.1 Seat Belts

All vehicles shall be equipped with seat belts for each passenger
seat in accordance with Saudi Arabian Standards Organization
(SASO).

13.11.2 Traffic Regulations

All posted speed limits shall never be exceeded and all local
traffic signs shall be obeyed.

February 1993 - 13.0 Transportation Page 95

14.0 AIRCRAFT OPERATION
This section will deal with both passenger and cargo transportation for which Saudi
Aramco aircraft are used.

Although some of the safety standards imposed will seem to restrict use, these
regulations were designed not only with the safety of the passengers and aircraft
cargo in mind, but also for the safety of the aircraft and the crew.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1310.00 Transportation of Dangerous Articles Onboard Saudi Aramco Aircraft

Aircraft Guidelines For Crew Managers And Aviation Remote Airfield Operations
Personnel (February 1988)

IATA Dangerous Goods Regulations (33Rd Edition, 1992)

US Code of Federal Regulations (CFR) 49 Part 175 - "Carriage By Aircraft"

14.1 General Operating Responsibilities

14.1.1 Captain/Pilot

The Captain/Pilot is in command of the aircraft at all times and is

responsible for the safety of his passengers and cargo. He is the
sole judge and will make all decisions in determining if the
weather is acceptable for flight or if landing and take off
conditions are within Company minimum standards.

No one is allowed to "pressure" the pilot into carrying more

weight than the pilot states is acceptable.

The Captain/Pilot is authorized to follow any course of action

which he judges requires immediate decision or action in the
interests of safety.

14.1.2 Camp Supervisors

All camp supervisors in remote areas will familiarize themselves

with all the relevant instructions on the movement of aircraft to
and from their areas as detailed in the "Saudi Aramco Aviation
Department Policy and Guidelines for Camp Managers".

It is to the mutual advantage of the user department and the

pilots of the Aviation Department that rules of Aviation Safety be
reviewed and applied to all operations in remote areas.
Complete cooperation and understanding between pilots and

February 1993 - Construction Safety Manual: Aircraft Operation Page 96

 camp supervisors is essential for the safe and efficient operation
of all inbound and outbound aircraft.

14.2 Passenger Briefing/Instructions, General (All Aircraft

Types)

14.2.1

The pilot shall either orally brief his passengers or direct their
attention to the aircraft safety instructions.

14.2.2

Passengers should never approach fixed-wing aircraft for

boarding from the front, and they must keep well clear of props
and engines at all times.

14.2.3

A flight crew member or designated safety observer should

monitor passenger movement while they are boarding or leaving
an aircraft.

14.2.4

Smoking is prohibited on all Saudi Aramco aircraft and on all

ramp and apron areas.

14.2.5

Seat belts must be fastened during all flights. Do not unfasten

the seat belt until the aircraft has come to a complete stop and
you are instructed to do so.

14.2.6

Passengers will comply with all flight crew or flight attendant

instructions.

14.2.7

Ear protection is supplied by Saudi Aramco where appropriate.

14.2.8

All Saudi Aramco aircraft carry US registration. The Company

complies with US DOT, FAA, ICAO and KSA President of Civil
Aviation (PCA) regulations. Failure to comply with these
regulations and instructions could endanger the lives and
property of others and could be refused future use of the Saudi
Aramco aircraft, termination of service, or prosecution.

February 1993 - 14.0 Aircraft Operation Page 97

 14.2.9

Other areas of briefing may include the use and handling of

special material or equipment which must be declared and will
be shipped only at the Captain's discretion.

14.2.10

In the event of forced landing, the pilot and passengers will stay
with the aircraft. The Captain will direct rescue/survival
activities. The Aviation Department will conduct a day and night
search for the disabled aircraft.

14.3 Transportation of Dangerous Goods

Saudi Aramco complies with the provisions of ICAO regulations as

published in the IATA Dangerous Goods Regulations. All shippers and
passengers intending to transport dangerous goods on Saudi Aramco
aircraft are required to be familiar with and comply with the IATA
Regulations. Further requirements are contained in GI 1310.00.

Any questions on Dangerous Goods Transport should be addressed to

Central Area Loss Prevention Department, Aviation Safety Officers, or the
Terminal Supervisor of the nearest Saudi Aramco airfield terminal.

14.4 Hours of Operation for Single-Engine Helicopters

Normal hours of single-engine helicopter operations are from sunrise to

30 minutes before sunset. A helicopter is required to be at its final
destination no later than 30 minutes before sunset.

By permission from the area supervisor, a helicopter may fly overland up

to 30 minutes after sunset if warranted by extenuating circumstances.
Operations may also authorize short flights to continue until sunset if
rescue facilities are immediately available.

14.5 General Precautions for Helicopters

No loose clothing should be worn which may entangle on any aircraft

surface or impede egress or flotation in any way.

All persons shall approach the helicopter from the front in full view of the
pilot. Never walk around the rear of the helicopter. Hold onto your
headgear when approaching aircraft. Carry long objects below waist
level.

When visibility is reduced by dust or other conditions, personnel shall

exercise special caution to keep clear of the main and stabilizing rotors.

February 1993 - 14.0 Aircraft Operation Page 98

 14.5.1 Life Vests

In the event of a forced landing at sea, the float gear is capable

of supporting the helicopter. Life vest must be worn on all over-
water flights. Only the vests provided in the helicopter should be
used.

February 1993 - 14.0 Aircraft Operation Page 99

II. General And Civil

February 1993 - Construction Safety Manual: II. General And Civil Page 100
1.0 WORK PERMIT SYSTEM
The Work Permit System incorporates procedures commonly used in industrial
facilities to ensure that necessary communication takes place and hazards are
controlled.

Saudi Aramco's restricted areas are potentially hazardous. However,

knowledgeable people using proper procedures can perform work tasks efficiently
and safely. The Saudi Aramco work permit procedure is important in maintaining a
safe work environment and is a requirement for all Saudi Aramco jobs in restricted
areas.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.708 Gas Testing Procedures

GI 2.711 Fire & Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

Power Distribution Instruction:

No. 3.0 Definitions of Terms and Approved Abbreviations

No. 10.0 Power Distribution Operations

No. 11.0 Hold Orders, Clearances and Permission to Test

1.1 Definitions

1.1.1 Restricted Areas

Restricted areas are those areas or activities which have been

designated by department managers as requiring the work
permit system. These include (but are not limited to) all areas
where hydrocarbons, flammable liquids or gases, or oxidizing
agents are handled, stored, piped, or processed in significant
quantities; and critical non-hydrocarbon operations.

The following are examples of restricted areas: petroleum

processing plants; pump stations; tank farms; loading piers;
hydrocarbon pipelines; oil wells; gas plants; specified locations
on marine vessels; gasoline service stations; areas where
explosives and industrial X-ray or radioactive materials are used
or stored; work areas under or near power lines; confined space
entry; and material supply storage areas.

February 1993 - Construction Safety Manual: Work Permit System Page 101
 1.1.2 Issuer (Operation Supervisors)

Operation supervisors are those supervisors who are certified by

their division or department head to issue and approve work
permits in restricted areas under their supervision.

1.1.3 Receiver (Authorized Craftsmen)

Authorized craftsmen are the craft supervisors, craftsmen, or

others who have been certified by their division or department
head to sign and receive work permits in the case of Company
employees and by sponsoring organization heads in the case of
contractors.

1.1.4 Work Permit

There are four work permits:

1 Release of Hazardous Liquids or Gases, Form 924-1

(yellow) -

This form is required when opening lines or vessels that

may release hazardous or toxic materials.

2 Hot Work, Form 924-2 (red) -

This form is required when using spark or flame producing

equipment and for vehicle entry into a restricted area.

3 Cold Work, Form 924-3 (blue) -

This form is for work that will not produce sufficient energy
to ignite flammable atmospheres/materials.

4 Confined Space Entry, Form 924-4 (green) -

This form is required for tank cleaning, tank inspection,

work in sewers or excavations of 4 feet or deeper.

All work in restricted areas must have at least one of the listed
work permits. Work must be performed according to the
instructions and precautions specified in the work permit.

1.2 Issuance and Approval

The authorized receiver (authorized craftsman) must request a work

permit from a certified issuer (operation supervisor) before doing any
work in a restricted area.

The issuer will grant the work permit after he has visited the site with the
receiver, reviewed the hazards applicable to the particular job, and is
satisfied that the work can be done safely. If the work contemplated

February 1993 - 1.0 Work Permit System Page 102

 involves any change, addition, or deletion in the facility, the work should
be reviewed by an engineer and appropriate authorization is necessary.

Both the issuer and the receiver must hold valid work permit certificates
issued by Saudi Aramco.

1.2.1 Power Distribution Department Clearances

Power Distribution Department (PDD), issues clearances to
enable work to be accomplished on high voltage electrical
apparatus that has been de-energized and isolated from the
power system in an approved manner. These clearances are
issued by PDD dispatchers in addition to any work permits that
are required.

Usually clearance receivers are PDD employees. Non-PDD

employees and contractors should request PDD Electric System
operators for assistance.

The following instructions apply to PDD clearances:

PDD 3.0: Definitions of Terms and Approved Abbreviations

PDD 10.0: Power Distribution Operations
PDD 11.0: Hold Orders, Clearances and Permission to Test

1.3 Precautions

1.3.1 Checklist

Each permit contains a checklist of precautions against common

hazards. Such a list cannot include precautions against all
hazards. It is the duty of both the issuer and the receiver to
review the job, anticipate what hazards might arise, check for
flammable gases in the area and see that proper precautions
have been specified on the permit before it is signed.

1.3.2 Clear Area

One specific precaution applying to all work is to clear the area

of people not required for the job to avoid their being exposed to
unnecessary hazards. If people enter an area where they could
be exposed to undue danger, the work should be stopped until
they are cleared from the area.

1.3.3 Work Stoppage

If conditions change or become unsafe during the course of

work, the issuer or local supervisor may stop the work and cancel
the permit.

The receiver has the responsibility to stop the work and advise
the issuer or supervisor any time he feels the safety of the job
does not meet the conditions of the work permit.

February 1993 - 1.0 Work Permit System Page 103

1.4 Handling of Issued Work Permit

A work permit is valid for only one shift, but it may be extended for one
additional shift with proper approval. Exceptions in excess of 16 hours
may be granted in special cases, provided certain precautions are taken.
(See GI 2.100 for details.)

The receiver of the work permit must keep the permit posted at the job
location at all times.

The receiver of a work permit must keep a copy in his possession or

within view of the job site for the duration of the job, so that it may be
presented upon request. If the receiver leaves the job site, he shall give
the permit to a responsible senior crew member to keep until he returns.
The issuer, receiver and the senior crew member must sign the work
permit transferring the work permit to the senior crew member.

1.5 Closing Out and Filing the Permit

When the job is completed or at the end of the shift, each work permit
must be closed out by both issuer and receiver. The only exception shall
be when the distance and remoteness make signing impractical, and it is
so stated when the work permit is issued. The work permit will be filed
and kept by the issuing department for three months.

1.6 Certification

In order for a person to be a certified receiver of work permits, he must

attend the work permit Receivers Course conducted by the Loss
Prevention Department and pass a test on work permit System (GI
2.100) given at the end of the course.

The superintendent of the construction organization will assure Saudi

Aramco by his signature that his employee knows both the general
instruction and his job. Contact the local Loss Prevention office for work
permit certification information.

Records of current certificate holders, with their names and the dates
issued, must be kept by each superintendent or organization head.

1.7 12 Rules on Work Permit Procedure

(See below)

1.8 Hold Tags and Multiple Lockouts

1.8.1 Instructions contained in GI 6.012 outline the use of tagging and

lockout for controllers which are to be held inoperative or for work
clearance.

February 1993 - 1.0 Work Permit System Page 104

 1.8.2 The purpose for the Lockout System is to render controllers
inoperative, i.e., circuit breakers, disconnect switches, valves, etc.
on any systems (electrical, steam, hydrocarbon, water, acid, etc.),
where the operation of the control device could be hazardous to
personnel working on the system.

1.8.3 Hold tags and locks are primarily intended to protect the individual
doing the work from being injured by an inadvertent start-up.

1.8.4 Work permit issuers and operations supervisors shall ensure that
hold tags and lock outs are used and so noted on the work permit.
The use of hold tags/lock outs shall be strictly enforced.

February 1993 - 1.0 Work Permit System Page 105

TWELVE RULES ON WORK PERMIT PROCEDURE

1) Issuer and receiver must inspect job site together before signing the work
permit.

2) Issue the correct permits for the job - hot, cold, vessel or confined space
entry, and/or gas release. Two or more permits may be required for the job.

3) Issuer and receiver must both have in their possession a valid work permit
certification card (issuer and receiver respectively).

4) J-W Sniffer gas test and/or H 2S gas test and/or oxygen analysis test must be
made before issuing work permit.

5) Job description and equipment used must be clearly stated on the work
permit. Be specific, issue permits for a single pump, drum, etc.

6) All tick boxes must be correctly filled in and gas readings indicated.

7) Proper lockouts, hold tags, and blinds must be used where applicable
(multiple clips with lock, and/or chains with padlocks).

8) Work permits should be issued for the specific period of time required to
complete the job.

9) To extend time work permit beyond one shift, the oncoming shift issuer
must inspect job site, write in extended time and sign permit.

10) Special precautions such as requirements for fire watch, Scott air packs, life
lines, barricades, etc. must be written on the permit.

11) The work permit must remain on the job site in a conspicuously visible
place while work is going on. If an emergency develops, the permit must
be withdrawn immediately and all work stopped without questions.

12) The work permit must be closed out after a job is completed. Issuer and
receiver must inspect the job site and sign off the work permit.

February 1993 - 1.0 Work Permit System Page 106

LOCK OUT AND TAG

Workers may be injured while working on equipment when the controls have not
been locked and tagged in the off position. People do make mistakes and start
equipment on which maintenance men are working; vibrations and ineffective
mechanisms can cause controls to move or valves to open. Protection is simple:
lock the control in the off position and prevent an accident.

Saudi Aramco has special rules requiring the use of locks on switches and controls
when it would be unsafe to work on an energized or operating system. Each
supervisor of operations and maintenance should know the rules in GI 6.012 -
Isolation, Lock Out and Use of Hold Tags.

When more than one man is going to work on a system or on a number of pieces
of equipment within the system, the multiple lockout clip enables each man to lock
out the circuit or machine control. If your man can't get his lock on the clip, work
should not proceed until a suitable clip is found. Clips may be ordered under stock
number 21-350-487; locks under stock number 08-323-261; tags under stock
number 39-378-419. Locks belonging to contractor personnel must have one key
only and should be compatible with the Saudi Aramco system. Contractors will
establish their own lock issuing procedure complete with logging and a numbering
system.

Note: Contractors are required to establish a lock out and TAG system compatible
with the Saudi Aramco system as part of the contractor Loss Prevention
Program plan requirements of Schedule 'D'.

Tags are useful to tell who is working on the equipment and who authorized the
shutdown. Teach your men the lockout procedure and insist they follow it.

February 1993 - 1.0 Work Permit System Page 107

FIGURE II.1: HOLD TAG

Front View

Back View

February 1993 - 1.0 Work Permit System Page 108

FIGURE II.2: LOCKOUT CLIP (TYPICAL)

February 1993 - 1.0 Work Permit System Page 109

2.0 EXCAVATIONS, TRENCHING AND SHORING
Accidents due to cave-in can occur for excavations which are not shored or
otherwise supported. Even rock that looks solid from a cursory inspection can
collapse without warning. The sides of an excavation may need to be suitably
shored, benched or sloped back to a safe angle of repose, depth, and soil
composition.

Other types of excavation accidents are caused by contact with underground pipes
and cables, by falls of equipment and persons, by persons being struck by
excavating equipment, and by hazardous atmospheres.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1021.000 Street and Road Closure, Excavation Reinstatement and Traffic

Controls
(See Appendix D)

GI 2.100 Work Permit System

Saudi Aramco Engineering Standard:

SAES-A-111 Borrow Pit Requirements

OSHA Safety And Health Standards:

29 CFR 1926
Subpart P Excavations

DEFINITIONS:

1. Excavation

Any man-made cavity or depression in the earth's surface,

including its sides, walls, or faces, formed by earth removal and
producing unsupported earth conditions by reason of the
excavation.

2. Trench Excavation

A narrow excavation made below the surface of the ground. In

general, the depth is greater than the width, but the width of a
trench is not greater than 4.5 meters (15 feet).

3. Accepted Engineering and Construction Practices

Plans for excavations and protective system methods shall be

submitted to Loss Prevention before work start up.

February 1993 - Construction Safety Manual - Excavations, Trenching And Shoring Page 110
 4. Protective Systems

Methods used to protect employees from cave-ins, from

materials that could fall or roll into the excavation onto the
workers or from collapse of adjacent structures. Protective
systems include supports, sloping and benching, shields and
other means to protect workers.

5. Shoring

Hydraulic, timber or mechanical systems that support the sides

of an excavation, designed to prevent cave-ins.

6. Hydraulic Shoring

A pre-engineered support system of aluminum hydraulic

cylinders (cross-braces) used with vertical rods (uprights) or
horizontal rods designed specifically to support side walls of an
excavation to prevent cave-in.

7. Benching

A method of protecting employees from cave-ins by excavating

the sides of an excavation to form one or a series of horizontal
steps, with a vertical rise between steps.

8. Sloping

A method of excavating in which the sides of an excavation are

laid back to a safe angle to prevent cave-ins. (The safe angle
required varies with different types of soil, exposure to the
elements and superimposed loads. There is no single angle of
repose. Soil classification must be identified to select safe
sloping and benching methods.)

9. Soil Classification System

A method of categorizing soil and rock deposits as types A, B,

and C in decreasing order of stability. Soil type is determined by
analysis of the soil's properties and how it performs under
exposure to the elements and superimposed loads.

Type A:

Cohesive soils with an unconfined compressive strength of 1.5

ton per square foot (tc) (144kPa) or greater are classified as Type
A. Examples of cohesive soils are: clay, silty clay, sandy clay,
clay loam and in some cases, silty clay loam and sandy clay
loam. Cemented soils such as caliche and hardpan are also
considered Type A. However, no soil is Type A if one or more of
the following conditions are true:

February 1993 - 2.0 Excavations, Trenching And Shoring

Page 111
 (i) The soil is fissured.
(ii) The soil is subject to vibration from heavy traffic, pile
driving, or similar effects.
(iii) The soil has been previously disturbed.
(iv) The soil is part of a sloped, layered system where the layers
dip into the excavation on a slope of four horizontal to one
vertical (4H:1V) or greater.
(v) The material is subject to other factors that would require it
to be classified as a less stable material.

Type B:

Soils classified as Type B are:

(i) Cohesive soils with an unconfined compressive strength
greater than 0.5 tsf (48 kPa) but less than 1.5 tsf (144 kPa).
(ii) Granular cohesionless soils including angular gravel
(similar to crushed rock), silt, silt loam, sandy loam and, in
some cases, silty clay loam and sandy loam clay.
(iii) Previously disturbed soils except those which would
otherwise be classed as Type C soil.
(iv) Soil that meets the unconfined compressive strength or
cementation requirements for Type A, but is fissured or
subject to vibration.
(v) Dry rock that is not stable.
(vi) Material that is part of a sloped, layered system where the
layers dip into the excavation on a slope less steep than
four horizontal to one vertical (4H:1V) but only if the
material would otherwise be classified as Type B.

Type C:

Soils classified as Type C are:

(i) Cohesive soils with an unconfined compressive strength of
0.5 tsf (48 kPa) or less.
(ii) Granular soils including gravel, and loamy sand.
(iii) Submerged soil or soil from which water is freely seeping.
(iv) Submerged rock that is not stable.
(v) Material in a sloped layered system where the layers dip
into the excavation or a slope of four horizontal to one
vertical (4H:1V).

10. Trench Boxes:

A structure that is able to withstand the forces imposed on it by

cave-ins, and in the process, protects employees inside the
structure. (Plans for trench boxes are to be submitted to Loss
Prevention.)

February 1993 - 2.0 Excavations, Trenching And Shoring

Page 112
2.1 Before Work Starts

In order to begin excavation work with minimum risk to men, plant and
equipment and to enable the work to proceed without interruption, the
following factors must be considered well before the job starts:

1.) Size and purpose of the excavation.

2.) Nature of the ground including the proximity of made-up ground.
3.) Stability of adjacent structures.
4.) Position of underground obstructions such as pipes, electric cables,
and other utilities.
5.) Weather and soil moisture conditions, especially high water table.
6.) Sources of soil vibrations (highway traffic, railroads, machinery,
etc.).
7.) Adjacent roads and footpaths.
8.) Method of excavation.
9.) Excavation plan submitted to Loss Prevention.

Consideration of these factors will indicate the safety measures which

must be implemented to proceed with the job and whether the sides of
the excavation can be sloped and benched to a safe angle or whether
other protective systems will be required. It is important to provide
adequate and suitable protective systems for use whenever excavation
work is to be carried out to a depth of 1.5 meters (5 feet) or more.
Excavation work to a depth of less than 1.5 meters (5 feet) may also
require protective systems.

2.2 Work Permit

Work permits must be obtained from the appropriate operations

supervisor before excavation work is started in any Saudi Aramco facility,
including residential areas and roadways, and in any place where the
presence of underground/utility obstructions is known or suspected.
Outside of clearly defined responsibility areas, work permits shall be
obtained from the Superintendent, Utilities and the Communications
Foreman, Oil and Gas Dispatch Unit or their delegated representatives. A
Confined Space Entry Work Permit is a second work permit and is
required for trenches deeper than 1.2 meters (4 feet). (See GI 2.100 for
work permit requirements.)

All protective shoring systems and configurations, such as timber

shoring, hydraulic and pneumatic systems, sloping, benching, shielding,
sheet piling and freezing must be designed in accordance with Saudi
Aramco Loss Prevention requirements. Excavation plans must be
submitted to Loss Prevention before work start up.

2.2.1 Excavation near Saudi Telephone Cables

To avoid disruptions of service and unnecessary costs which

result from the accidental cutting of Government telephone
cables by contractors working on Saudi Aramco projects,
proponents should urge their contractors to inquire about the

February 1993 - 2.0 Excavations, Trenching And Shoring

Page 113
 location of such cables prior to excavation. Contractors may
contact the Saudi Telephone Cable Locator Division on telephone
no. 843-3247 during normal Government working hours or
telephone no. 906 at any hour. Subsequently, they may be
required to submit a written application to the Saudi Telephone
Cable Locator Division providing a site plan of the proposed
excavation and stating when it will be done. Contractor letters
may be addressed to the Director, Dammam Area
Communications, Ministry of Telegraph Post and Telephone,
Dammam.

Saudi Aramco proponent inquiries may be addressed to the

Contractor Liaison Division of Government Affairs, telephone
874-1461 (Corporate Advisor, Contractor Liaison/GAO).

2.3 Underground Obstructions

Whenever the presence of underground pipes, cables, vessels, or

structures is known or suspected, mechanical excavators shall not be
used until all such obstructions have been exposed by hand digging.
Mechanical excavators shall not be used within 3 meters (10 feet) of any
such obstruction. Pneumatic breakers shall only be used where
necessary to break concrete or other hard surfaces.

2.4 General Precautions

2.4.1 Shoring Protective Systems

As soon as an excavation reaches a depth of 1.2 meters (4 feet)

or soil banks are greater than 1.5 meters (5 feet), suitable
shoring shall be installed or the sides sloped back to a safe
angle. Shoring may be of timber or any other suitable material,
such as steel sheet piling.

The determination of the angle of slopes, benches, (See Figure

II.3) or the choice and design of other protective systems shall be
based on evaluation of pertinent factors such as: type of soil
(Type A, B, or C), depth of cut; possible variations in water
content of the material while the excavation is open; anticipated
changes in materials from exposure to air, sun, or water; loading
imposed by structures, equipment, overlying material, or stored
material; and vibrations from equipment, blasting, traffic, or
other sources.

Excavations shall not be sloped at an angle greater than one and

one-half horizontal to one vertical (34 0 measured from the
horizontal). Plans for sloping and benching systems shall be sent
to Loss Prevention for review. (See Figures II.3, II.4, II.5.)

Shoring systems shall be designed by a qualified person and

meet accepted engineering requirements. Materials used shall

February 1993 - 2.0 Excavations, Trenching And Shoring

Page 114
 be in good serviceable condition, and timbers shall be sound,
free from large or loose knots, and of proper dimensions.

2.4.2 Personnel Protection

Portable trench boxes or sliding trench shields may be used for

the protection of personnel in lieu of a shoring system or sloping.
Where such trench boxes are used, the design shall be approved
by Saudi Aramco Consulting Services Department.

Trench boxes shall be designed, constructed and maintained to

provide protection equal to or greater than the sheeting or
shoring required.

Shields shall be installed in a manner to restrict lateral or other

movement of the shield and be capable of withstanding any
sudden application of lateral loads.

Shields shall be extended above the excavation to protect

employees working inside the shields and when entering or
exiting the areas protected by shields.

Employees shall not be allowed inside the shielded areas

whenever shields are being installed, removed or moved (see
Figure II.7).

2.4.3 Inspection

All parts of an excavation, including the shoring, shall be

inspected every day by a competent person to ensure that there
is no danger of collapse and all observations shall be noted in
the site safety log book.

2.4.4 Clearance

In order to provide a safe footing at the edge, and to prevent

spoil falling into an excavation, a clear space at least 0.6 meter
(2 feet) wide shall be maintained on all sides. (See Figure II.8:
Guide to Safe Distance Back From Top Of Slope For Storage of
Materials / Equipment Placing.)

2.4.5 Mechanical Excavator

Men shall not be permitted to work underneath loads or in places

where they could be struck by any part of a mechanical
excavator.

2.4.6 Walkways

Where employees, equipment, or members of the public are

required or permitted to cross over an excavation, a close
planked bridge or walkway with standard guard rails shall be

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 provided and kept clear of excavated materials or other tripping
hazards. No sidewalk shall be undermined unless properly
shored.

2.5 Access and Egress

Safe means of getting into and out of an excavation shall be provided at

intervals not exceeding 7.5 meters (25 feet). Ladders shall conform to
the requirements set out in Section 9.2, be placed at an angle of 75 o,
and extend at least 0.9 meter (3 feet) above the stepping-off point.
Ladders shall be securely fixed.

2.6 Hazardous Atmospheres and Materials

2.6.1 Ventilation

Where there is reason to suspect oxygen deficiency or the

presence of a hazardous atmosphere in an excavation, gas tests
must be carried out by a qualified person. Where necessary,
mechanical ventilation shall be used, or other appropriate
precautions shall be taken before men enter.

Note: Toxic, oxygen and flammable gas tests are to be

conducted before entering hazardous excavations in
Restricted Areas (as mentioned in GI 2.100).

2.6.1.1 Hazardous Atmospheres

Prior to entry into excavations greater than four feet

deep, or confined spaces, a work permit shall be
issued. Gas tests shall verify that the oxygen level is
20-21%, combustible gases 0.0 LEL, and H 2S is 0 ppm.
For elevated levels of gases tested follow requirements
of GI 2.100. Corrective measurers may include use of
air movers, identification and isolation of sources from
fuel lines, sewers, open tanks or other measures to
return the breathing atmosphere to normal readings.
Subsequent testing is required to monitor the area
during the work so appropriate precautions can be
taken as necessary.

· Precautions shall be taken to prevent employee

exposure to an atmosphere containing a
concentration of any flammable gas above its lower
explosive limit (LEL).

· For an atmosphere with a concentration of any

flammable gas below its lower explosive limit (LEL),
use the guidelines given in GI 2.100 (Work Permit
System) as shown below:

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 · Above 0.0 LEL - No hot work permitted
· 0.05 LEL to 0.5 LEL - Breathing apparatus must
be used
· Above 0.5 LEL - No entry permitted

· When controls are used that are intended to reduce

the level of atmospheric contaminants to
acceptable levels, testing shall be conducted as
often as necessary to ensure that the atmosphere
remains safe.

2.6.1.2 Emergency Rescue Equipment

(i) Emergency rescue equipment, such as breathing

apparatus, a safety harness and line, or a basket
stretcher, shall be readily available where hazardous
atmospheric conditions exist or may develop during
work in an excavation. This equipment shall be
attended by a standby man outside the trench when in
use.

(ii) Employees entering bell-bottom pier holes, or other

similar deep and confined footing excavations, shall
wear a harness with a lifeline attached to it. The
lifeline shall be separate from any line used to handle
materials, and shall be individually attended at all
times while the employee wearing the lifeline is in the
excavation. Mechanical devices shall be available to
lift incapacitated employees from excavations.

2.6.2 Exhaust Gases

Where an internal combustion engine is used in an excavation,

special precautions must be taken to ensure that exhaust gases
are discharged so as not to be a hazard to men working in the
excavation.

2.6.3 Organic Lead

Where the presence of buried organic lead (TEL) sludge,

asbestos or any other hazardous chemical is known or
suspected, whether in a Restricted Area or not, excavation work
shall not be started (or continued) until the Industrial Hygiene
Service and Loss Prevention Departments have identified the
hazard and specified the precautions to be taken and a new work
permit has been issued.

2.7 Edge Protection, Markers and Fixed Lighting

Whenever it is necessary to place or operate power shovels, derricks,

trucks, materials, soil banks or other heavy objects on a level above and
near an excavation, the side of the excavation shall be sheet-piled,

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 shored, and braced as necessary to resist the extra pressure due to such
superimposed loads. When mobile equipment is utilized or allowed
adjacent to excavations, substantial stop logs or barricades shall be
installed. If possible, the grade should be away from the excavation. If
men or vehicles are in the vicinity after dark, fixed warning lights shall be
used to mark the limits of the work.

2.8 Roads, Streets, and Sidewalks

Excavation work in roads, streets, and sidewalks shall not be undertaken

without the prior approval of the relevant authorities (See Section II.1,
Work Permit System). Excavation work on public highways will have to
be cleared in advance with Government Affairs and any special
measures that they might specify must be implemented (See Section
II.8, Roadworks).

2.9 Backfilling

Backfilling and removal of trench supports shall be accomplished first by

backfilling up to a level allowing for the removal of the lower braces.
Another layer of backfill shall be positioned in the trench to the next
layer of braces to be removed. Removal of trench supports shall
progress together with the backfill from the bottom of the trench. In
unstable soil, ropes shall be used to pull out the jacks or braces from
above after employees have cleared the trench. All excavations shall be
backfilled and consolidated, and the surface shall be left in good
condition as soon as is practicable.

2.10 Borrow Pits

Location of borrow pit boundaries (i.e., residential, industrial plants, sub-

stations, highways, etc.) shall be located at the distance noted in SAES-
A-111.

2.10.1 A separate traffic flow plan is required to keep pedestrian traffic

away from vehicle traffic areas. Traffic is strictly prohibited in
borrow pit areas. Signs in Arabic and English shall be posted in
roped-off areas, warning personnel to stay out of borrow pits.

2.10.2 Dust concentration, noise levels, and security fencing

associated with borrow pit operations shall be in accordance
with Saudi Aramco Safe Operating Procedures.

2.10.3 Hydraulic Shoring For Trenches

Hydraulic shoring is provided as a method of protection against

cave-ins in trenches that do not exceed 20 feet (6.1 m) in depth.
Trench depths exceeding 20 feet (6.1 m) require Loss Prevention
review.

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 It is not intended that the aluminum hydraulic specifications
apply to every situation that may be experienced in the field.
These data were developed to apply to the situations that are
most commonly experienced in current trenching practice.
Situations that are not covered require specific designs for
specific applications and will be subject to Loss Prevention
review. (See Figures II.9, II.10, II.11, and II.12.)

2.10.4 Timber Shoring For Trenches

Timber shoring is provided as a method of protection from cave-

ins in trenches that do not exceed 20 feet (6.1m) in depth. Loss
Prevention requirements must be used when timber shoring
protective systems are designed. (See Figures II.13, II.14, II.15
and II.16.)

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TABLE II.1: MAXIMUM ALLOWABLE SLOPES

SOIL OR ROCK TYPE MAXIMUM ALLOWABLE SLOPES (H:V)

[1] FOR EXCAVATIONS LESS THAN
20 FEET DEEP [3]

STABLE ROCK VERTICAL (90O)

TYPE A [2] 3/4 : 1 (53O)
TYPE B 1:1 (45O)
TYPE C 1-1/2 : 1 (34O)

NOTES:

1. Numbers shown in parentheses next to maximum

allowable slopes are angles expressed in degrees
from the horizontal. Angles have been rounded
off.

2. A short term maximum allowable slope of 1/2H :

1V (63O) is allowed in excavations in Type A soil
that are 12 feet (3.67 m) or less in depth. Short-
term maximum allowable slopes for excavations
greater than 12 feet (3.67 m) in depth shall be 3/4
H : 1V (53O).

3. Sloping or benching for excavations greater than

20 feet deep shall be reviewed by Loss Prevention.

Slope Configurations

(All slopes stated below are in the horizontal to

vertical ratio)

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FIGURE II.3: EXCAVATIONS MADE IN TYPE A SOIL

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FIGURE II.3A

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FIGURE II.3B

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FIGURE II.4: EXCAVATIONS MADE IN TYPE B SOIL

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FIGURE II.4A

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FIGURE II.5: EXCAVATIONS MADE IN TYPE C SOILS

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FIGURE II.6: EXCAVATIONS MADE IN LAYERED SOILS

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FIGURE II.6A: EXCAVATIONS MADE IN LAYERED SOILS

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FIGURE II.7: EXAMPLES OF TRENCH SHIELDS

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FIGURE II.8: GUIDE TO SAFE DISTANCE BACK FROM TOP OF SLOPE FOR STORAGE OF
MATERIALS OR PLACING EQUIPMENT

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FIGURE II.9: EXAMPLES OF SCREW TRENCH JACKS

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FIGURE II.10: A LUMINUM HYDRAULIC SHORING TYPICAL INSTALLATIONS

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FIGURE II.11: A LUMINUM HYDRAULIC SHORING

Vertical Shores for Soil Type A

Hydraulic Cylinders
Width Of Trench

Depth of Maximum Maximum Up to 8 Over 8 up Over 12 up

Trench Horizontal Vertical to 12 to 15
Feet Spacing Spacing
Over 5 8 4 2 inch 2 inch 3 inch
up to 10 diameter diameter diameter
Over 10 8 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
Over 15 7 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

Over 20 Loss Prevention Review

Vertical Shores for Soil Type B

Hydraulic Cylinders
Width Of Trench

Depth of Maximum Maximum Up to 8 Over 8 up Over 12 up

Trench Horizontal Vertical to 12 to 15
Feet Spacing Spacing
Over 5 8 4 2 inch 2 inch 3 inch
up to 10 diameter diameter diameter
Over 10 6.5 4 2 inch 2 inch 3 inch
up to 15 diameter diameter diameter
Over 15 5.5 4 2 inch 2 inch 3 inch
up to 20 diameter diameter diameter

Over 20 Loss Prevention Review

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FIGURE II.12: A LUMINUM HYDRAULIC SHORING WALER SYSTEMS FOR SOIL TYPE B

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FIGURE II.13: EXAMPLE OF TIMBER SHORING PROTECTIVE SYSTEMS

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FIGURE II. 14: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

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FIGURE II.15: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

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FIGURE II.16: TIMBER TRENCH SHORING - MINIMUM TIMBER REQUIREMENTS*

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3.0 DEMOLITION
Numerous factors must be taken into account before the method of demolition is
decided. Of prime importance are the age of the structure, the method of
construction, the state of preservation, its previous use, and the surrounding
environment. These factors must be known before any planning can begin.

Many problems are peculiar to the demolition of tanks, vessels, and ancillary pipe
work associated with the oil industry. For instance, many serious accidents have
resulted when due consideration was not given to the cleaning and gas-freeing of
this equipment before work began.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.711 Fire and Safety Watch

GI 6.012 Isolation, Lockout And Use Of Hold Tags

GI 8.001 Safety Requirements For Scaffolds

GI 150.001 Asbestos Regulation

GI 402.001 Operational Chemical Cleaning of Boilers

Refinery Instruction Manual:

No. 10.185 Precautions for Working in Leaded Product Tanks

American National Standards Institute:

ANSI A 10.6-83

Safety Requirements for Demolition

ANSI Z 88.2-80

Standard Practice for Respiratory Protection

ANSI Z 117.1-89

Safety Requirements for Working in Tanks and Confined Spaces

American Petroleum Institute:

API 2217-84 Guidelines for Confined Space Work in Petroleum Industry

API 2015-91 Safe Entry And Cleaning Of Petroleum Storage Tanks

February 1993 - Construction Safety Manual: Demolition

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3.1 Before Work Starts

The contractor shall submit a Hazard Identification Plan as a part of his

loss prevention program to the Company Representative. All such
programs must be reviewed and concurred with by the Loss Prevention
Department before start-up. (See Chapter I, Section 1.3.2.)

3.1.1 Responsible Supervisor

Before any demolition work is started, a competent supervisor

must be appointed in writing as the person responsible for all
work on site. The man appointed should be experienced in
demolition operations. His duties will include the direct
supervision of the work force, ensuring that work permit
requirements are met, and liaison with other contractors working
in the general area and with operators and construction or
maintenance engineers.

3.1.2 Original Drawings

The original drawings of the structure to be demolished should

be obtained. An examination of them should be made to
ascertain whether any major changes from the original
construction have been made and where utility connections may
be found.

3.1.3 Disconnections

All utility services such as electricity, gas, and water must be

shut off and the main supplies disconnected outside the line of
the demolition work. Tanks, vessels, and paperwork must be
completely disconnected from inlet, outlet, and overflow points.

3.1.4 Adjacent Structures and Public Areas

Adjacent structures, public buildings, pedestrian walkways,

parking lots, etc. shall be protected from demolition debris that
can likely cause hazards to the general public. Also, bracing
must be installed to insure stability of adjacent structures.

3.1.5 Barricades/Signs

Barricades must be erected around the work area. Signs bearing

the words "Danger - Demolition in Progress" in Arabic and
English must be erected at each approach to the barricade.

3.2 Method of Demolition

The method of demolition to be used should be decided upon in

consultation with the Saudi Aramco representative, Loss Prevention and
all contractors involved. The re-use of salvage materials should be
considered prior to this decision. It should be remembered that the

February 1993 - 3.0 Demolition Page 140

 safest and most efficient method is to start at the top and dismantle in
the reverse order of construction. There are, however, cases where such
a method is impractical or uneconomical and where other methods have
to be considered. Any portion of the job which contains asbestos
insulation should be cleared under the general procedures (See Section
II.4), and Industrial Hygiene Services, Preventive Medicine Services
Division, shall be contacted.

3.2.1 Demolition of Equipment Containing PCB: Polychlorinated

Biphenyl (ASKAREL)

Before equipment containing or suspected of containing PCB(s)

is removed in demolition work, the Loss Prevention Department
and the Industrial Hygiene Unit shall be notified to ensure safe
procedures are used. Proper personnel protection equipment
and disposal systems must be utilized. (See GI 355.004.)

3.2.2 Demolition Of Buildings With Asbestos / Insulation

Materials

Before demolition of buildings with asbestos and insulation,

notify Loss Prevention and Industrial Hygiene Services to ensure
safe procedures are followed. Proper personnel protective
equipment and disposal systems must be utilized. (See Chapter
4 and GI 150.001.)

3.3 Stability During Demolition

As work progresses, continuing inspections must be made to detect

hazards arising through weakened or overloaded floors, unsupported
walls, or loose material. Immediate steps shall be taken by bracing or by
other means to prevent the premature collapse of the whole or any part
of the structure.

3.3.1

Lateral support should not be removed from more than one story
of wall at any time before starting to demolish it. When a wall
from which support has been removed must be left standing at
anytime, including overnight and off-shift work hours, adequate
bracing (guying) must be provided to prevent collapse and to
guard against wind pressures.

3.4 Working Place Clearance

3.4.1 Access

A safe means of access to and egress from all working places

must be provided. Work places and the areas around ladders
and stairways must be kept clear of material and debris.

February 1993 - 3.0 Demolition Page 141

 3.4.2 Glass Removal

Nails in timber must be removed or bent over, or the timber must

be stacked where it will not be a source of danger. All glass in
windows, doors, partitions, etc. should be completely removed
prior to structural demolition.

3.5 Structural Steel Removal

All steel construction should be demolished column length by column

length and tier by tier. A structural member being removed must not be
under any stress other than its own weight. Members being cut or
dismantled should be chained or lashed in place to prevent uncontrolled
swinging or dropping.

3.6 Tanks, Vessels and Pipe Work (Explosion Prevention)

3.6.1 Welding and Hot Cutting

No tank, vessel, or pipe work which has contained explosive or

flammable material shall be subjected to welding or hot cutting
operation until all steps have been taken to remove the
substance and any vapors. When hot cutting is planned, the
advice of the area Fire Chief and the Loss Prevention Department
should be sought.

3.6.2 Cold Cutting

The use of cold cutting techniques for the dismantling of tanks,

vessels, and pipe work, can substantially reduce the risk of
explosion. Although this is often more costly and laborious,
there are times when it is the only safe method which can be
used.

3.6.3 Steaming and Ventilation

In the case of vessels and tanks up to about 22,712 liters (6000

gallons) capacity, both vapors and residues can usually be
removed by steaming out; however, with larger tanks the
problems are somewhat different. Because of the high capacity
of a large tank, steaming cannot be relied on to volatilize all
residues unless very large quantities of steam are available. It
is, however, relatively easy to eliminate explosive concentrations
of vapor within the tank by forced ventilation using a blower or
eductor system approved for hazardous locations.

3.6.4 Residue Cleaning

With volatile materials, use of such methods as in 3.6.3 above

will rapidly reduce vapor concentrations. With materials less
volatile, the main danger lies in the hot cutting setting fire to any

February 1993 - 3.0 Demolition Page 142

 residues in the tank. It is, therefore, essential that any residues
are removed before work starts.

3.7 Protective Clothing and Equipment

All demolition workers should be provided with and make use of the
following protective equipment:

1 Safety helmet
2 Goggles
3 Heavy duty gloves
4 Appropriate respiratory equipment (whenever necessary to prevent
inhalation of dust and fumes)
5 Safety boots with steel toe caps and preferably with penetrant
resistant soles.

Safety belts or harnesses (with lifelines where required) shall be used by

men working in isolated or dangerous locations where there is the
possibility of them falling and where other preventive measures are
impractical.

3.8 Mechanical Equipment Guards

Mechanical equipment such as cranes and bulldozers should be

equipped with wire mesh guards over windows and with solid protection
over the driving position so that there is no danger of the operator being
struck by flying debris.

February 1993 - 3.0 Demolition Page 143

4.0 ASBESTOS AND OTHER FIBERS
Asbestos is the generic name given to a number of naturally occurring inorganic
fibrous silicate minerals. Asbestos materials have been widely used in the
construction industry and may be present in a number of manufactured products
such as cement sheeting, molded insulation, gaskets, ropes, blocks, fire resistant
boards, etc. For the purpose of these regulations, asbestos is defined as any of the
minerals crocidolite, amosite, chrysotile, fibrous anthophyllite or any mixture
containing any of these minerals.

The use of asbestos is restricted. At present, the Saudi Aramco Industrial Hygiene
Unit must approve the use of asbestos materials, under GI 150.001.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 8.003 Breathing Apparatus

GI 150.001 Asbestos Regulations

American National Standards:

ASTM C460-88

Standard Definitions of Terms Relating to Asbestos - Cement

4.1 Types of Asbestos

These exist in two main rock-forming mineral groups: 1) Serpentine

group, which includes chrysotile (white asbestos); and, 2) Amphibole
group, which includes crocidolite (blue asbestos) and amosite (brown
asbestos). These two main groups were the most widely used asbestos
minerals. However, fibrous anthophyllite has also been used in industry
in a few applications. Chrysotile was commonly used as the reinforcing
material in asbestos-cement products. Because crocidolite has high
resistance to acids, it has been extensively used in chemical plants. Due
to the superior heat resistance of amosite it has been used principally for
the manufacture of fire-resistant insulation boards. The majority of
asbestos products has been made of white asbestos, but some products
contain blue asbestos (crocidolite). Of the asbestos products
manufactured blue asbestos has the higher health risk. Blue asbestos
can usually be recognized by its dark lavender blue color; however, its
presence could be masked by other materials. Since prolonged exposure
to heat, as would be the case with boiler or hot-pipe lagging, may
change the characteristic blue color of crocidolite to a white or fawn
color.

February 1993 - Construction Safety Manual: Asbestos And Other Fibers Page 144
4.2 Health Risks

Over a period of time, breathing asbestos dust can cause asbestosis

(scarring of the lung), which may go undetected for years after exposure.
All forms of asbestos are capable of causing asbestosis. The most
important factors in the development of the disease are the amount of
dust to which the individual is exposed, duration of exposure, and the
personal susceptibility of the individual to the asbestos fiber. In addition,
asbestos fibers can penetrate the skin, causing small tumors, warts, or
corns. These asbestos tumors are usually found on the palms or fingers.
They may not be cured unless every minute fiber is removed.

The maximum allowable concentration of airborne asbestos dust shall

not exceed 0.2 asbestos fibers longer than five microns in length per cc
of air on a time-weighted average (TWA) exposure for an eight-hour work
day.

4.3 Before Work Starts

The contractor shall submit a Hazard Identification Plan to Loss

Prevention Department and to the Industrial Hygiene Service, Preventive
Medicine Services Division for review and concurrence prior to job start-
up, when removing or using asbestos materials. (See Administration I,
Section 1.3.4.) Unless approved of in advance by the Industrial Hygiene
Unit, asbestos products shall not be used in new construction.

4.3.1 Air Sampling

Where the contractor knows that some part of an operation

requires the use or removal of asbestos materials, he must
notify, in writing, the Industrial Hygiene Services, Preventive
Medicine Services Division. When informed, the Industrial
Hygiene Services will take random samples of air at the point of
operation during the working period. Bulk samples may be sent
for the analysis and identification of asbestos to either Industrial
Hygiene Services or to the Laboratories Department.

4.3.2 Job Details

The contractor shall then inform the Industrial Hygiene Services

of details of the work involved, the number of persons employed,
the anticipated duration of the operation, the type of asbestos
being used, and the type of equipment being used to work the
asbestos material.

4.3.3 Chest X-rays

It is the contractor's duty to ensure that each man employed on

asbestos work be given a chest X-ray prior to commencement of
the job and thereafter at two-year intervals. Detailed records
shall be kept by the contractor of all persons employed in the

February 1993 - 4.0 Asbestos And Other Fibers Page 145

 process. These records shall be available to Saudi Aramco upon
request.

4.4 Storage and Transportation

All asbestos materials removed from or used on a job shall be stored in

an approved container at all times. For new construction, only that
amount of asbestos material that is immediately required for the
operation shall be moved to the work area.

Approved containers shall be used during the transportation of asbestos

materials. All such containers that contain asbestos shall be clearly
marked in English and Arabic: "Caution: Health Hazard - Contains
Asbestos".

4.5 Work Area

The work area shall be clearly defined and where feasible roped off and
notices displayed warning persons of the presence of asbestos dust.
Signs shall be posted at all approaches to the work area. These signs
shall be posted at readily visible locations near work areas and these
notices shall read in both English and Arabic:

Caution:
ASBESTOS HEALTH HAZARD
Respirator and protective overalls must be worn when entering
this area.

Only persons directly concerned with the operation shall be permitted

inside the area.

4.6 Handling and Use

4.6.1 Wetting/Ventilation

The handling, mixing, applying, removing, cutting, and spraying

of asbestos materials shall be done in a wet state so as to
prevent the emission of harmful fibers in excess of allowable
concentration.

Before removing asbestos cement mortar, coating, grouting,

plaster, or similar material containing asbestos from bags,
cartons, or shipping containers, the material shall be wetted or
enclosed, or the operation shall be carried out under total
exhaust ventilation.

Work practices for using or removing asbestos are given in

Section 4, GI 150.001.

February 1993 - 4.0 Asbestos And Other Fibers Page 146

 4.6.2 Cutting

Shearing or punching shall be used in preference to sawing or

drilling of asbestos. Where it is necessary to cut or saw
materials containing asbestos using hand or power tools, it shall
be done in a separate cordoned off area with an approved
exhaust and dust collection system.

4.6.3 Protective Equipment

Protective equipment shall be required for all instances where

asbestos is used regardless of ventilation, wetting, etc.

4.7 Protective Clothing

4.7.1 Types

The contractor shall provide approved disposable overalls, head

covering, foot protection, and gloves to prevent any airborne
asbestos fibers from coming into contact with the body.

The contractor shall provide a sufficient amount of clothing to

each employee working with asbestos to ensure that a complete
change of clean protective clothing is available for the start of
each shift.

4.7.2 Contamination

At the end of each shift, contaminated personal protective

equipment shall be collected and disposed of in accordance to GI
150.001. Under no conditions shall contaminated clothing be
worn from the work site. Employees shall be careful to prevent
contamination of street clothes from work clothes.

Asbestos-contaminated clothes shall be packed and carried in

sealed impermeable bags or containers and disposed of in
accordance to Section 6, GI 150.001.

4.7.3 Review

The Loss Prevention Department and Industrial Hygiene Services

shall review the types and applications of contractor's protective
clothing for its' acceptability to Saudi Aramco.

4.8 Respiratory Equipment

Where there is an unavoidable emission of asbestos dust, the contractor

shall supply a respirator approved by Industrial Hygiene Services and
Loss Prevention Department to each employee.

February 1993 - 4.0 Asbestos And Other Fibers Page 147

 4.8.1 Type

In normal circumstances, an approved filter type dust respirator

will be adequate protection; however, dusty jobs (e.g. stripping,
delogging, demolition, etc.) involving asbestos materials require
air-supplied positive pressure respiratory equipment.

4.8.2 Use

All employees shall be properly trained in the use of respiratory

equipment before being engaged in any work with asbestos.
Also, it is the contractor's responsibility to make sure that each
worker be supplied with equipment that provides the level of
protection required and of the proper fit.

4.8.3 Care

All respiratory equipment shall be thoroughly checked, cleaned,

disinfected and stored at the end of each work period and before
use by other persons.

4.9 Washing and Changing Facilities

The contractor shall provide showering/washing facilities for all

employees engaged in asbestos work.

The contractor must ensure that employees use these facilities before
leaving the job site at the end of each shift.

The contractor shall provide suitable changing accommodations,

disposal facilities for protective clothing worn during asbestos work and
separate accommodations for street clothing not worn during working
hours.

4.10 Disposal of Waste Asbestos Materials/Clothing

All waste asbestos materials and disposal clothing shall be disposed of in

sealed impermeable bags or containers.

All bags and containers shall be marked in both English and Arabic:
"Caution: Health Hazard - Contains Asbestos". The bags and containers
shall be handled and disposed of in accordance to Section 6, GI
150.001.

4.11 Cleanliness of Work Areas and Equipment

The contractor shall ensure that all machinery, equipment, work areas,
and adjacent areas are kept free from asbestos dust and waste as
provided in Section 5, GI 150.001.

February 1993 - 4.0 Asbestos And Other Fibers Page 148

5.0 WELDING, CUTTING, AND BRAZING
This section outlines the principles involved and the precautions to be taken in gas
welding, cutting, and brazing and electric arc welding operations.

Welding/cutting 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

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 355.020 Control of Compressed Gas Cylinders

GI 401.081 Performance Qualifying Tests Of Welders And Welding Operations

Saudi Aramco Engineering Standards:

SAES W-4 Welding Alloy Steels

SAES W-5 Field Stress Relieving

Saudi Aramco Bottled Gas Manual:

Section 6 Safe Handling of Compressed Gases

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Oxygen and Acetylene Equipment and Electric Arc Welding
Equipment

American National Standards:

ANSI Z49.1 Safety In Welding and Cutting

ANSI Z87.1 Practice For Occupational And Educational Eye And Face Protection

NFPA 70 National Electrical Code

5.1 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.

February 1993 - Construction Safety Manual: Welding, Cutting, And Brazing Page 149
 5.1.1 Gases

Oxygen (O2) is odorless. 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 (2.5% - 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.

5.1.2 Color Coding of Cylinders

Color coding can be of great help but also a potential source of

danger as there is no internationally recognized standard color
code. Refer to GI 355.020-4, Control of Compressed Gas
Cylinders, for Saudi Aramco color coding requirements.

5.1.3 Storage Of Cylinders

5.1.3.1

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 6.6 meters (20 feet) apart or separated by a fire
proof, 1.6 meters (5 feet) high partition.

All storage areas shall have Arabic and English "No

Smoking Permitted" signs prominently displayed.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 150

 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. (See GI
355.020.)

5.1.3.2

Cylinders shall not be stored at temperatures

exceeding 54 oC (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.

5.1.3.3

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.

5.1.3.4

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 "No Smoking" as in Section
5.1.3.1 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.

5.1.4 Handling of Cylinders

Serious accidents may result from the misuse, abuse, or

mishandling of cylinders.

5.1.4.1

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.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 151

 5.1.4.2

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.

5.1.4.3

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.

5.1.4.4

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.

5.1.4.5

When in doubt as to the proper handling of a

compressed gas cylinder or its contents, the supplier of
the gas, the Bottled Gas Coordinator (Central Area
Storehouse Department), or Loss Prevention
Department 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.

5.1.5 Inspecting Equipment

All equipment should be examined immediately before use and

regularly maintained. All welding operations shall be conducted
in well ventilated areas.

5.1.5.1

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.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 152

 5.1.5.2

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.

5.1.5.3

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.

5.1.5.4

Means of torch ignition should be readily available. A

friction lighter shall be used for this purpose.

5.1.5.5

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.

5.1.5.6

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. "Empty" drums
which have contained low flash point liquids are known
to have become lethal bombs when a hot welding torch
was laid down on them.

5.1.5.7

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.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 153

 5.1.6 Faults

It is not uncommon for minor "explosions" 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 Snapout 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
· Re-light

3 A flashback is very dangerous. Flashback is caused by

gases being mixed in the hose(s). 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

February 1993 - 5.0 Welding, Cutting, And Brazing Page 154

 · 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

5.1.7 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 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.

5.2 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.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 155

 5.2.1 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.).

5.2.2 Welding Connections

In each welding circuit there are three main connections:

1) the welding lead;

2) the welding return;
3) the welding ground.

5.2.2.1

The welding lead is the conductor carrying the welding

current from the point of supply to the electrode holder.

5.2.2.2

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.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 156

 5.2.2.3

A continuous welding ground is essential and

indispensable for conductors since electric currents as
low as 50 milliamperes 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 the
welding ground be bonded to the ground of the main
supply system by a separate substantial conductor.

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).

5.2.2.4

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. If
joints become necessary, standard plug and socket
coupling shall 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.

5.2.2.5

Electrode holders shall be constructed to accommodate

all sizes of electrodes and with an ejector for hot, spent
stubs.

5.2.2.6

February 1993 - 5.0 Welding, Cutting, And Brazing Page 157

 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.

5.2.2.7 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.

5.3 Protective Measures

5.3.1

The need for the operator to take safety precautions and

preventive measures during the operation of welding machines
to ensure that no safety-related incident occurs cannot be
overemphasized. The following is a list of precautions and
operating considerations to take into account when operating a
400 amp arc welding machine, for example. All users are
strongly encouraged to read the equipment's operating manual
to ensure reliable and safe operation.

1. Keep all doors, covers and panels in place when operating

the machine: the arc welding machine is designed to
operate with all its doors, covers and panels in place. They
ensure the optimum flow of cooling air, and removal of
these covers and panels will reduce the cooling of the
engine and generator, resulting in overheating and
premature failure of the unit.

2. Ensure that the engine protection push button 'pops out'

when the engine is switched off. Under normal
circumstances, this button will 'pop out' once the engine is
switched off. However, if the unit becomes clogged with
dirt, dust or sand, it may not return to its 'off' position
without assistance. If the button remains depressed, it will
quickly drain the unit's battery. The resulting failure to start
will delay your work while a new battery is fitted, a 'jump
start' arranged, or a recharge cycle is completed.

3. Maintain welding and ground cables and connections in

good condition. A major source of safety hazards, poor and
inconsistent welding performance, and loss of point-of-use
welder capacity is a set of welder leads in poor condition, or
of the wrong size for the length of cable being run. Other
sources of safety hazards related to cables and connections
are:

February 1993 - 5.0 Welding, Cutting, And Brazing Page 158

 · cracked insulation is an obvious source of hazard producing
shorts to ground eventually leading to increase of
conductor resistance. With no-load voltages approaching
100+ volts, significant hazard of electrocution to personnel
exists, especially in wet areas or when working on metal
structures.
· combining sets of low capacity cables to reach a distant
welding site can greatly reduce the effective welding power
available to the welding machine. Larger-capacity cables
must be used to reach distant sites, because of the buildup
of resistance from the extra length of the leads.
Inadequate or weak cable connections can also introduce
sparking hazards, potential shorts to ground, and extra
resistance which reduces effective welding machine
capacity. Cable sizes and lengths must be as
recommended by the manufacturer, as follows (for 400
amp machine):

Combined length of Minimum Cable

electrode and work cable Size
up to 150 feet 2/0
150-200 feet 3/0
200-250 feet 4/0

4. When welding is in progress, the full length of cable must

be stretched out on the ground. Leaving the cable coiled
on the machine alters the current flow and disrupts the
welding process.

5. Do not adjust the 'current control' while welding is in

progress. This can damage the control.

5.3.2

Sparks and molten or hot metal coming from the work area can
easily set fire to combustible materials near or below the working
area. Wherever possible, all combustible material should be
removed from the work area. If it cannot be removed, it should
be covered with fireproof material. Gas cylinders should be
protected from falling sparks.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 159

 5.3.3

Operators of arc welding equipment must always switch off the

current to the electrode holder and remove the electrode
whenever it is to be set down and is not actually in use.

5.3.4

When welding or cutting material that is supported by a crane, a

shield or an effective screen should be provided to protect the
suspension ropes or chains. Grounding cables shall only be
connected to the work, not to the crane or rigging.

5.3.5

Forced ventilation shall be arranged wherever work is to be

carried out in a confined area. Suitable metal bins shall be
provided for spent electrode stubs as they are usually hot when
discarded and can easily cause a fire. Dry chemical fire
extinguishers should be kept available while work is in progress.
All completed work should be marked "HOT".

5.4 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 vapors 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. (See
General And Civil II.1, Work Permit System.) Welding and cutting on
drums is strictly controlled and, in most cases, prohibited. Contact area
Loss Prevention for guidance and information.

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

5.5 Confined Spaces

It is vital that forced ventilation be maintained in confined spaces at all

times. Air line 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. (See General
And Civil II.1, Work Permit System. )

February 1993 - 5.0 Welding, Cutting, And Brazing Page 160

5.6 Personnel Protection

5.6.1

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.

5.6.2

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 side pieces. These goggles should
also be worn under the regular welding hoods.

5.6.3

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 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.

5.6.4

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.

5.6.5

Safety 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.

5.7 Health Hazards

Apart from the obvious hazards of physical burns, health hazards in

welding operations fall into two classes: hazards from radiant energy
and hazards from dusts and fumes.

5.7.1 Radiant Energy

The process of welding produces radiant energy in the form of

visible light, ultra-violet rays, and infrared rays. The risk of this
energy harming the operator or other personnel can be
minimized by the proper use of protective clothing and shielding.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 161

 Exposure of the skin to infrared and ultraviolet rays can result in
irritation and burning. The risk of exposure is lessened by
wearing protective clothing, shielding, and distance.

Arc-eye or flash burn is a well known condition in welding

operations and is due to the eyes being exposed to ultraviolet
rays. This condition is a superficial burn on the outer layer of the
eye.

The effects normally wear off within two days, and generally no
permanent damage is caused. The condition is, however,
extremely painful and can easily be avoided by the use of eye
protective lens or shields.

Welding protective lens shall be tempered glass. Lens shall be

distinctively marked to identify approved lens shade.

Lens Shade Guide:

1. Arc Welding- 10 to 14
2. Torch Brazing- 3 to 6
3. Gas Welding- 4 to 8

5.7.2 Respiratory Effects

The risk of being gassed in normal welding operations is slight;

however, when working in confined areas, a forced ventilation
system should be in operation to remove any build up of
hazardous gases.

5.7.2.1

Oxy-acetylene welding operations can cause the

oxygen and nitrogen of the air to unite to form nitrogen
oxides. In well ventilated areas this does not cause
any problems; however, in confined areas or where the
welder is working very close to the job, the amount of
nitrogen oxides breathed can rapidly reach toxic levels.
The main problem with this gas is that the welder does
not appear to be affected at the time; the real effects
take place some 6 to 24 hours after exposure.

5.7.2.2

All welding operations produce quantities of ozone, a

highly toxic gas. In oxy-acetylene and electric arc
welding, the amount produced is small and providing
adequate ventilation is used, the risk is negligible.
Significant and sometimes dangerous amounts of
ozone can be formed when inert gas shielded welding
is being carried out.

There are many other dangers which can arise when

welding or cutting under specific conditions or on

February 1993 - 5.0 Welding, Cutting, And Brazing Page 162

 particular metals. Hazardous operations include:
welding on manganese steel, galvanized material,
material which has been degreased or on material
which has been painted with lead, copper-bearing, or
chromate-containing paint. These problems must be
recognized before the job starts, and safe practices for
dealing with them must be established.

Although welding cannot be regarded in general as an

extremely hazardous occupation, exposure to
concentrated fumes may be irritating and in some
cases dangerous. It is essential that each operation be
analyzed before work starts and that the control
measures are correctly applied.

February 1993 - 5.0 Welding, Cutting, And Brazing Page 163

6.0 EXPLOSIVE MATERIALS
The use of explosive materials within construction is extensive and, whether large
or small quantities are handled, the responsibilities falling upon supervisory staff
are considerable. Those responsible must consider the acquisition, storage,
transporting, handling and use of explosive materials, as well as the emergency
procedures to be adopted in the case of misfire, accident, fire, etc. The acquisition
and use of explosive materials in Saudi Arabia are strictly controlled by the Saudi
Arab Government, whose requirements must be adhered to at all times. All
blasting operations in Saudi Aramco are strictly controlled and the use of explosive
materials by contractors is prohibited without prior written approval by Company
representatives. For contractor In-Kingdom blasting operations, contact the
Resources Planning Department, Project Support Services Division, Blasting
Services Unit for all blasting requirements.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 355.015 Requisitioning, Receiving, Storing and Issuing Explosives

GI 475.001 Blasting Near Existing Facilities

GI 475.002 Use Of Explosives In Construction

GI 610.001 Special Regulations for the Use of Explosives in Seismic Operations

GI 1183.215 Transporting Explosives on Company Owned/Leased/Rented Motor

Transport Vehicles

GI 1310.00 Transportation Of Dangerous Articles Aboard Saudi Aramco Aircraft

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements

American National Standards:

ANSI A10.7-89 Safety Requirements for Transportation, Storage, Handling,

and Use of Commercial Explosives and Blasting Agents in
Construction and Demolition

NFPA 495-90 Explosive Materials Code

National Safety Council Industrial Data Sheets:

I-644-90 Treatment Of Extraneous Electricity In Electric Blasting

I-730-86 Ammonium Nitrate / Fuel Oil Mixtures As Blasting Agents

February 1993 - Construction Safety Manual: Explosive Materials Page 164

7.0 PILING OPERATIONS
Piling operations attract many of the problems associated with other types of
construction work: access, unguarded machinery, housekeeping, etc. Heavy
equipment and the stress and vibration imposed upon that equipment give rise to
hazards peculiar to piling operations. The standard of supervision should be high,
as well as the standard and maintenance of equipment.

Piling operations fall into two categories: driving load-bearing piles, which may be
driven vertically or raked; and, driving sheet piles. Piles may be of steel, concrete,
timber or any combination of the three. Piling equipment can vary from a simple
air-operated hand-held hammer to a large complex rig.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Crane and Heavy Equipment Accident Reporting Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection And Testing Requirements Of Elevating / Lifting

Equipment

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Excavations

Crane Safety Handbook (Page 99)

National Safety Council Data Sheet:

Special Hazard Bulletin X128. Property Damage from Blasting, Pile

Driving, and Similar Sources

ASME Standard:

Section I Power Boilers

Section VII Pressure Vessels

7.1 Before Work Starts

In order that piling operations may be undertaken with the minimum risk
to men and equipment, the following factors should be considered
before work starts.

February 1993 - Construction Safety Manual: Piling Operations

Page 165
 · The nature and purpose of the operation.

· Soil investigation reports of the area.

· Location and nature of any underground services in the area, which

should be checked with the various departments through the Saudi
Aramco Construction Engineer; then, precisely located by careful
hand digging, under competent supervision.

Where piling operations are within a restricted area, the proper Work
Permits should be obtained before any work is undertaken.

Competent supervision, experienced in piling operations, is essential for

piling work.

Equipment of adequate capacity to perform the operation should be

assembled. All equipment must be carefully inspected before being
used with particular attention to the following. (See GI 7.030.)

7.1.1 Cranes

Cranes used for both lifting and piling operations should be of an

adequate size and capacity to perform the work safely. Where
cranes are to be used for driving raking piles with a drop
hammer or driving piles below the level of the crane using
extended leaders, the hammer will be suspended from the crane
at a greater radius than the boom angle indicator will show. In
all such cases, the distance of the hammer from the center point
of the crane must be calculated and this distance used to
ascertain the safe working load.

Outriggers, counterbalances, etc., shall be provided to maintain

stability of the pile driver rig.

7.1.2 Pile Gates

Sufficient timber or steel must be available for the construction

of pile gates. Proper ladder access must be provided to the pile
gates, and where they are over 1.8 meters (6 feet) high,
handrails or rigger's belts must be provided.

7.1.3 Inspection

Air compressors or steam boilers must be carefully examined

and all hoses and couplings checked both for leaks and general
condition. All steam and air hoses should be fitted with a
regulator valve and a quick acting shut-off valve for emergency.

February 1993 - 7.0 Piliing Operations Page 166

 7.1.4 Wedges

An adequate supply of hardwood wedges should be obtained for

adjusting piles while pitching. Softwood wedges are likely to split
and must not be used.

7.1.5 Timber Block

Stop blocks shall be provided for the leads to prevent the

hammer from being raised against the head block.

Guards shall be provided across the top of the head block to

prevent the cable from jumping out of the sheaves.

Fixed leads shall be provided with ladder and adequate

attachment points so that the loft worker may engage his safety
belt lanyard to the leads. If loft platforms are provided, they
shall be protected with standard guardrails.

Steam/air hose leading to the hammer or jet pipe and all hoses
shall be securely attached with 1/4" chain or cable to prevent
whip lash.

7.1.6 Ground Support

The ground upon which the crane or rig will stand should be firm
and level. Digger mats or a hard-core standing should be
provided if the ground is likely to subside under the high ground
loading imposed by driving or extracting piles.

7.2 Driving Piles

7.2.1 Pitching

Piles should only be lifted and positioned in the pile gate or onto
the leaders or rig with sound lifting gear adequate for the
purpose. Quick release shackles should be examined before
each use. Where hollow section or concrete piles are lifted with
chains or wire slings, timber or burlap packing should be placed
between the lifting gear and the pile. Adequate access, such as
a cradle or a properly secured ladder, must be provided for the
topman when pitching sheet piles. The topman must wear stout
gloves when pitching.

7.2.2 Driving

Workmen should stand clear of the operation while driving is in

progress. The emergency shut-off valve and the crane or winch
controls must be manned at all times during driving. The
foreman must be present and so positioned that he can be seen
by the crane or winch operator and the man standing by the
valve. When driving raking piles, the pile, leaders, and machine

February 1993 - 7.0 Piliing Operations Page 167

 must all be in the same line. Under no circumstances should any
man touch the hammer until all valves are closed. A system of
signals must be arranged between the foreman, the winch or
crane operator, and the valve operator, so that the emergency
shutdown does not depend on verbal communication. Where the
head of a pile becomes distorted through driving, no attempt
should be made to clear it from the leaders by lifting or booming
up. The pile head should be cut off and the debris cleared from
the leaders.

7.3 Pile Extraction

No attempt should be made to extract piles which have been hammer-

driven by lifting or booming up with a crane. A steam, air, or electric
operated extractor should be used. Particular attention should be paid to
the extractor wedges and the condition of the gripping faces, which
should not be smooth. Workmen must not walk under piles that are
suspended from extractors.

7.4 General Precautions

7.4.1

Men handling piles or working on piling operations should always

wear safety helmets, safety shoes, safety glasses, stout gloves,
and be equipped with ear protection, preferably of the muff type.

7.4.2

At the start of each shift, hammers and extractors should be

carefully checked for loose bolts, etc.

7.4.3

All other equipment should be inspected daily for defects.

7.4.4

Piling operations should never be undertaken except under

competent supervision and with a crew experienced in this class
of work. Crane operators shall have a valid Saudi Arab
Government heavy equipment license and a valid Saudi Aramco
certificate (See GI 7.030).

7.4.5

Piling operations are a construction process with special hazards.

In addition to these special hazards, men are exposed to the
hazards commonly associated with all types of construction
work, and precautions against these general hazards must not
be neglected.

February 1993 - 7.0 Piliing Operations Page 168

8.0 ROADWORKS
A contractor engaged in roadwork is not only responsible for the safety of his own
men, he also has an obligation to protect the public from potential construction
hazards, during the day, at night and in all weather conditions. Consequently, the
marking of construction sites and the safe and efficient diversion and control of
traffic must be properly planned and executed. Road closure plans must be
submitted to Loss Prevention before roads are closed.

Failure to do this can have disastrous results.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1021.000 Street and Road Construction, Excavation, and Maintenance of

Traffic Controls (Appendix D)

GI 2.100 Work Permit System

8.1 General

8.1.1

Saudi Aramco organizations can obtain barriers, lights, etc. from

the Maintenance Department during normal working hours.
Contractors shall provide their own barriers, lights, etc..

8.1.2

To avoid creating a traffic hazard, warning devices must not be

put in place until they are needed. They must be promptly
removed when work is complete.

8.1.3

Activities which produce dust shall be kept to a minimum.

8.1.4

Permanent road signs and striping shall be restored before the

roadway is returned to service.

8.1.5

The surface of any highway, street, or sidewalk shall be level and

in good condition before any barriers and markers are removed.

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 8.1.6

Should there be any doubt as to the type of marking and

protection required for roadwork in any location, the Loss
Prevention engineer for the area should be consulted.

8.1.7

A flagman, equipped with a safety vest and a red flag, shall be

posted at least 50 meters (165 feet) from the work site at the
entrance barricade and another flagman at the exit barricade. It
shall be the duty of the flagmen to control the flow of traffic in a
safe manner. Both flagmen shall be in sight of each other. If
conditions do not permit this, then a third man shall be
positioned where he can see and be seen by the other two men
in order to signal them to start or stop traffic. Traffic control
signals shall be in accordance with GI 1021.000. At night,
flagmen shall wear light-reflecting vests and gloves, and use
reflective signs or flags. Flagmen shall be stationed in an
illuminated area.

8.1.8

During darkness, the work area will be marked by lights spaced

10 meters (30 feet) apart. Warning lights used in oil operations,
industrial, or company housing areas shall be weather proof and
positioned 0.6 meter (2 feet) and 0.9 meter (3 feet) above grade.

8.1.9

In addition to the foregoing, excavation work in residential areas

shall be entirely enclosed, covered over, or roped-off.

8.1.10

Excavations in sidewalks or areas of expected pedestrian traffic

shall be provided with close-planked walkways or bridges 0.9
meters (3 feet) wide and equipped with standard guardrails.
8.2 Street and Road Construction, Excavations, and
Maintenance Traffic Controls

See Appendix D (GI 1021.000).

February 1993 - 8.0 Roadworks Page 170

9.0 WORKING PLACES, LADDERS, AND
SCAFFOLDING
Every contractor and every employer of workmen has a legal and contractual
responsibility to ensure that each place at which his men work is safe and that it
remains safe so long as men work there. Similarly, each supervisor is responsible
for ensuring that every man working under his direction or control has a safe
working place and a safe means of getting to and from every working place.

Where work cannot safely be done on the ground or from part of a building or
permanent structure, scaffolds, ladders, or other means of support shall be
provided and properly maintained.

INSTRUCTIONS AND STANDARDS

The Standards used for guidance in this section of the Construction Safety Manual
are those of the American National Standards Institute, Inc. (ANSI) and US Code of
Federal Regulations (CFR) 1910.28. Where scaffold manufacturers products
meet other scaffold standards that are equivalent to or higher than ANSI
requirements, then those products can be used. Scaffold products from different
manufacturers shall not be mixed on a scaffold, unless they are specifically
designed to be used together.

Saudi Aramco Instructions and Standards:

GI 2.100. Work Permit System

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 8.001. Safety Requirements For Scaffolding (formerly 1009.006)

SAES-P-123. Lighting Utilization

Schedule 'D':
Saudi Aramco Safety, Health and Environmental Requirements -
Ladders; Scaffolding; Personal Flotation Devices for Work Over,
On or Near Water.

American National Standards Institute:

Uniform Building Code

ANSI A10.8 - 1988

Scaffolding-Safety Requirements

ANSI A14.1 - 1982./ANSI A14.1a- 1985

Ladders - Portable Wood Safety Requirements

ANSI A14.2 - 1990

Portable Metal Ladders

ANSI A14.3 - 1984

February 1993 - Construction Safety Manual: Working Places, Ladders, and Scaffolding Page 171
 Ladders - Fixed-Safety Requirements

ANSI A92.2 - 1990

Vehicle - Mounted Elevating and Rotating Aerial Devices

US. Code of Federal Regulations, 29. CFR Part 1910.28, Safety Requirements for
Scaffolding

National Safety Council Data Sheets:

Data Sheet 568. Job-Made Ladders

NFPA 70 - 90 National Electrical Code (NEC)

9.1 Working Places, General

9.1.1 Falls

Within Saudi Aramco, every working place shall be safe and of

adequate dimensions. Where men, tools, or materials could fall
1.8 meters (6 feet) or more, a guardrail system (consisting of
toprails and midrails) and toeboards shall be provided. Should
the provision of these safeguards be impracticable, other means
of preventing falls, such as safety belts, etc. shall be used. For
further information, see Personal Protective Equipment, Section
I.9, (9.6.5 and 9.6.6) of this Manual.

9.1.2 Access and Egress

A safe means of getting to and from a working place shall be

provided and used. Ladders shall conform to the requirements
set out in 9.2.

9.1.3 Lighting

Every working place and every means of getting to and from a

working place shall be provided with adequate lighting which
shall be properly maintained. (See SAES-P-123)

9.1.4 Prevention of Falls

Permanent decking, parts of a structure, walkways, footbridges,

etc., which men use in the course of their work or for a
permanent or temporary access, shall be provided with a
guardrail system and toeboards (permanent or temporary) at all
edges from which men, tools, or materials could fall 1.8 meters
(6 feet) or more. Holes and gaps shall be guarded or securely
covered. Stairs (permanent or temporary) shall have all treads
properly secured and shall be fitted with handrails throughout
their length and conform to the Uniform Building Code.

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 9.1.5 Ramps

Where the slope of a ramp exceeds 1 vertical to 4 horizontal,

the ramp shall be fitted with stepping cleats at 0.3 meter (1
foot) intervals. When a ramp is to be used by the general
public, its slope shall not exceed 1 vertical to 4 horizontal.
Handrails shall be provided.

9.1.6 Falling Material

Where there is danger of men being struck by falling material,

protective coverings shall be erected or No. 18 gauge wire, 1/2
inch mesh or equivalent, shall be securely fixed between the
toeboard and midrail to prevent falling objects.

9.1.7 Hot Surfaces

Suitable precautions shall be taken to prevent men coming into

contact with any hot surface.

9.1.8 Slipping and Tripping

Contractors are responsible for maintaining good housekeeping

to prevent slipping, tripping, and falling. Oil spills, mud, scrap,
and other debris must be cleared up immediately. Men shall not
be permitted to walk or work on steel work or other surfaces on
which paint or cement wash is still wet.

9.1.9 Roof Work

Where work is done on or from the roof of a building or

structure, or where men have to cross, work on, or work from
fragile roofs or surfaces, adequate protection in the form of
crawling boards, roof ladders, or other suitable covering must
be provided to prevent men and materials falling from or
through the roof. Temporary guardrails shall be placed to
prevent workers from falling. If roof work is accomplished on
pitched roofs with a slope greater than 1:4, workers shall be
equipped with safety belts that are securely anchored to the
structure. During storms or high winds, workers shall not be
working on a roof or scaffold that is exposed to the weather.

9.1.10 Insecure Structures

Unstable or weak structures shall be supported by guys, stays,

supports, or other fixings where necessary. If work being done
is likely to reduce the stability of an existing structure or
building, bracing or other means of support shall be used.
Unstable structures shall not be left unsupported over night.

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 No wall sector which is more than one story in height, shall be
permitted to stand alone without lateral bracing, unless such
wall was originally designed to do so and is in a safe condition
to be self-supporting. All walls shall be left in a stable condition
at the end of each shift by bracing support jacks, timbers and/or
guy-wired, taking wind force and storm conditions into
consideration.

9.1.11 Work Over Water

9.1.11.1

Where men work on, over or near water, a guardrail

system and toeboards, fencing or other suitable
barriers shall be provided for the protection of the
worker.

9.1.11.2

Wherever the provision of a guardrail system and

toeboards, fencing or other suitable barriers is
impracticable, or if for any reason men are outside the
protection of these safeguards, suitable life vests shall
be worn and a safety belt or harness securely fixed to a
dropline.

9.1.11.3

Approved rescue equipment that meets the

requirements of GI 6.020 in the form of life rings with
life lines, etc.; where necessary, a suitably equipped
rescue boat shall be readily available, and properly
maintained. Men shall be thoroughly trained in the use
of all protective and rescue equipment, first aid and
cardiopulmonary resuscitation (CPR).

9.2 Ladders and Stepladders

The safety of a ladder depends on four important factors: selection,

condition, position and use. Ladders shall comply with the referenced
ANSI or equivalent codes.

9.2.1 Selection

9.2.1.1

A ladder must be of the proper length for the job to be

done. If it is to be used for access or as a working
place, it shall rise to a height of 36 inches to 42 inches
above the landing place or above the highest rung to
be reached by the feet of the man using the ladder.

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 9.2.1.2

Metal ladders, ladders with metal reinforced side rails,

and ladders which are wet shall not be used near
electrical equipment with exposed live conductors.
Such ladders shall have a warning notice attached to
guard against use near electrical equipment.

9.2.1.3

Aluminum ladders shall not be used where there is a

likelihood of contact with materials harmful to
aluminum, such as caustic liquids, damp lime, wet
cement, etc.

9.2.2 Condition

9.2.2.1

Each ladder shall be examined before use. Those with

split or broken side rails, missing, broken, loose,
decayed or damaged rungs or cleats, or with other
faulty equipment shall be tagged and removed from
service.

9.2.2.2

Rungs shall be properly mortised into side rails. Cleats

shall be inset by 2.25 centimeters (7/8 inch), or filler
blocks used on the side rails between the cleats.
Cleats shall be uniformly spaced 30.5 centimeters (1
foot) between centers.

9.2.3 Position

9.2.3.1

The side rails of a ladder shall be equally supported on

a firm level surface. Boxes, blocks, barrels, etc. shall
not be used as a means of support. The area at the
base of a ladder must be kept clear. Ladders shall not
be used in a horizontal position as platforms, runways
or scaffolds.

9.2.3.2

Ladders shall not be supported on their rungs or cleats.

Rungs or cleats shall not be used to support planks.

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 9.2.3.3

Whenever possible, ladders shall be set at an angle of

75o to horizontal ground (i.e., one meter out to four
meters up).

9.2.3.4

Metal reinforcing shall be on the underside of the rungs

and where reinforcing is on only one side of the side
rails, that too shall be on the underside.

9.2.3.5

Both side rails of a ladder shall be evenly supported at

the upper resting place. Side rails must be securely
tied off to prevent movement. Where secure fixing is
impracticable, other measures must be taken to
prevent movement by securing at the base, using side
guys, or stationing a man at the base. It must be
understood, however, that a man stationed at the base
will be unable to control a ladder more than 6 meters
(20 feet) in length.

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 9.2.3.6

Where there is a possibility of a ladder being struck by

moving vehicles or equipment, a man should be placed
on guard or a space at the base should be securely
fenced off. If a ladder is erected close to a doorway,
the door should either be locked, shut, or be secured in
the open position with a man on guard or properly
barricaded.

9.2.3.7

Ladder landing places shall be provided at least every

9 meters (30 feet) of height and shall be fitted with a
guardrail system and toeboards. Holes in decking
through which ladders pass shall only be enough to
permit passage of the man using the ladder.

9.2.3.8

A ladder should always be placed so that there is space

behind each rung or cleat for a proper foothold. There
should be no obstruction in the way of a man's foot,
particularly at the landing platform. Here the rung or
cleat should be level with the platform.

9.2.3.9

Where ladders have to be suspended, both side rails

shall be lashed top and bottom so as to provide equal
support. Where long ladders are used, they shall also
be lashed at the center to prevent lateral movement.

9.2.4 Use

9.2.4.1

Where an extension ladder is used fully extended, the

minimum overlap depends on the extension ladder
length, and overlap should be as follows (examples):

9.75 to 10.97 meters (32 to 36 feet) = 1.22 meters (4

feet) overlap

10.97 to 14.63 meters (36 to 48 feet) = 1.52 meters (5

feet) overlap

Splicing or lashing ladders together shall not be

permitted.

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 9.2.4.2

Before mounting a ladder, personnel shall check their

shoes for freedom from grease, oil or mud. They shall
always step through, not around, the rail extensions at
the top of the ladder.

9.2.4.3

Single rung and single cleat ladder should be used by

only one man at a time. When ascending or
descending personnel shall face the ladder and keep
both hands on the ladder. Personnel shall not run up or
down or slide down a ladder at any time. The width of
single cleat ladders shall be at least 38.1 centimeters
(15 inches) but not more than 50.8 centimeters (20
inches) between rails at the top.

9.2.4.4

Men ascending or descending ladders shall not carry

tools and materials in their hands. Tools may be
carried in pockets or on special belts provided there is
no risk of injury and movement is not impaired.
Materials shall be raised or lowered using a handline
after being securely tied or placed in a basket.

9.2.4.5

A man working on or from a ladder must always have a

secured handhold and both feet on the same rung or
cleat. If the work to be done requires the use of both
hands, a safety belt is required, securely fixed to a
dropline (life line). Only one person shall be on a
ladder at a time.

9.2.4.6

Job-made ladders shall be constructed for intended

use. If a ladder is to provide the only means of access
or exit from a working area for 25 or more employees,
or if simultaneous two-way traffic is expected, a double
cleat ladder shall be installed.

Double cleat ladders on Saudi Aramco construction

sites shall not exceed 4.5 meters (15 feet) in length.

Single cleat ladders shall not exceed 4.5 meters (15

feet) in length between supports (base and top
landing). If ladders are to connect different landings,
or if the length required exceeds this maximum length,
two or more separate ladders shall be used, offset with
a platform between each ladder. A guardrail system

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 and toeboards shall be erected on the exposed sides of
the platforms.

5.08 by 10.16 centimeters (2 by 4 inches) lumber shall

be used for side rails of single cleat ladders up to 4.5
meters (15 feet) long.

5.08 by 10.16 centimeters (2 by 4 inches) lumber shall

be used for side and middle rails of double cleat
ladders up to 3.6 meters (12 feet) in length; 5.08 by
15.24 centimeters (2 by 6 inches) lumber for double
cleat ladders from 3.6 by 4.5 meters (12 to 15 feet) in
length.

Wood cleats shall have the following minimum

dimensions when made of woods that meet ANSI
requirements for ladders:

LENGTH OF CLEAT THICKNESS WIDTH

Up to and including 1.9 cm (.75 in) 7.62 cm (3 in)
50.8 cm (20 inches)
Over 50.8 cm (20 in.) and 1.9 cm (.75 in.) 9.52 cm (3.75
up to in.)
and including 76.20 cm
(30 in.)

Cleats may be made of species of any other group of

wood provided equal or greater strength is maintained.

Cleats shall be inset into the edges of the side rails

one-half inch, or filler blocks shall be used on the rails
between the cleats. The cleats shall be secured to
each rail with three 10d common wire nails or other
fasteners of equivalent strength. Cleats shall be
uniformly spaced, 30.48 centimeters (12 inches)
between centers.

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 9.2.4.7

Metal ladders shall not be used for work on electrical

systems unless the ladders are specifically designed
for that application.

9.2.5 Stepladders

Generally, the foregoing remarks on selection, condition and use

of ladders apply equally to stepladders. The following
requirements also apply:

9.2.5.1

To ensure stability, stepladders shall be spread to their

fullest extent limited by manufacturer's braces when in
use. Whenever possible, they should be placed at right
angles to the work with either the front or back facing
the work.

9.2.5.2

Do not stand, climb or sit on the stepladder top, pail

shelf, braces or back section.

9.2.6 General

9.2.6.1

Ladders and stepladders shall be maintained in good

condition at all times. Joints shall be tight, all hardware
and fittings shall be securely attached, and movable
parts shall operate freely without binding or undue
play.

9.2.6.2

Ladders and stepladders must not be painted.

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 9.2.6.3

Where a ladder is carried by one man, the front end

should be kept high enough to clear men's heads and
special care shall be taken at corners and blind spots.

9.3 Scaffolding Components

9.3.1

All scaffold structures shall be erected with metal components

approved per ANSI requirements or equivalent. Scaffolds shall
be stored to prevent damage and to permit easy access for use.
Scaffold erection plans (drawings) shall be submitted to Loss
Prevention Department for review prior to men being allowed to
work on the scaffold.

9.3.2 Tubing

Ordinary scaffold tubing is 4.8 centimeters (1-29/32 inches) in

diameter and nominal wall thickness 0.4 centimeter (5/32 inch)
and is referred to as two-inch nominal diameter tubing. It is
mild steel and normally supplied in lengths of 6.4 meters (21
feet). Tubes must meet ANSI or equivalent requirements and
must be free from cracks and surface flaws, laminations,
excessive rust and other defects. The ends shall be cut square
and cleanly. A tube shall not deviate from a straight line by
more than 1/600 of its length measured at the center of the
tube length.

9.3.3 Aluminum Tubing

9.3.3.1

Although the aluminum tubing is dimensionally

interchangeable with steel tubing, it must not be used
in the same structure; the difference in the elastic
modulus of the two materials results in greater
deflection in aluminum tubing for the same loading
conditions.

9.3.3.2

Aluminum tubing shall not be used where there is

likelihood of contact with materials harmful to
aluminum such as caustic liquids, damp lime, wet
cement and sea water.

9.3.4 Fittings

All fittings (couplers, clamps, etc.) shall be of a metal type

approved to ANSI or equivalent requirements. They shall be

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 examined regularly and care must be taken to ensure that
moving parts are sound and well lubricated and that threads are
not stripped.

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 9.3.5 Typical Scaffold Fittings

(Figures II.17 - II.22)

Base Plate: A 15 centimeter (6 inch) by 15 centimeter (6

inch) steel plate greater than 0.64 centimeters (1/4 inch) thick
providing a flat bearing surface for load distribution from posts.
It has an integral spigot and fixing holes for use with sills.

Screwjacks: Used for compensating variations in ground

levels.

Standard Coupler: Also known as a Right Angle or 90 o

Coupler. A load bearing coupler used for connecting two tubes
together at right angles.

Adjustable Coupler: Used for connecting two tubes together

at any angle through 360 o. Not to be used where a load
bearing standard coupler is required.

End-to-End Coupler: Also known as a Sleeve Coupler. Used

for connecting two tubes end-to-end.

Reveal Pin: Inserted into the end of a tube and adjusted to

form a rigid horizontal or vertical member between two
opposing surfaces. It forms a solid anchorage to which a
scaffold can be tied.

9.3.6 Planks

9.3.6.1

Planks shall be of rough timber and graded as scaffold

planks without defects (2" x 9"), 5 centimeters (2
inches) thick by 23 centimeters (9 inches) wide, and
shall conform to the following specifications:

1 All planking shall be Scaffold Grade to ANSI

requirements.

2 On the face of the plank, the ends shall not be split

up more than 30.5 centimeters (1 foot), without
fixed banding or the end bolted through.

3 On the face of the plank, not more than one third

the width in any one place shall be knot wood.

4 On the edge of the plank, not more than half the

depth shall be knot wood.

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 5 On the edge of the plank, the grain shall not cross
from face-to-face within a distance of less than 30.5
centimeters (1 foot).

6 From end-to-end, the plank must not be twisted by

more than 1.3 centimeters (1/2 inch).

7 Scaffold planks shall meet the loading requirements

of Table II.2.

9.3.6.2

Planks shall not be painted or treated in any way that

would conceal defects.

9.3.6.3

Planks which are split, decayed or warped shall not be

used, but the parts affected may be cut off to produce
shorter planks with the ends banded or bolted through.

9.3.6.4

Planks should be stacked on a suitable foundation.

Where the height of a stack exceeds 20 planks,
measures should be taken to tie or bond succeeding
layers.

9.3.6.5

Planks should not be stood on end unattended.

9.3.6.6

Scaffold planks shall not be used for shuttering for

concrete, shoring for trenches, or as sills for
scaffolding. Planks shall be inspected for defects,
including decay, prior to each use.

9.3.6.7

The design working load of each platform unit (i.e.,

plank) shall be capable of supporting without failure
one or more 91 kg (200 lb) person with 22.7 kg (50 lb.)
of equipment.

9.3.6.8

Platform units rated for one person capacity shall be

designed and constructed to carry 113.6 kg (250 lb.) at
the center of the span.

9.3.6.9

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 Platform units rated for two persons shall be designed
and constructed to carry a working load of 227 kg (500
lb.) : 113.6 kg (250 lb.) placed at 0.46 meters (18
inches) to the left and right of the center of the span.

9.3.6.10

Platform units rated for three persons shall designed

and constructed to carry a working load of 341 kg (750
lb.) : 113.6 kg (250 lb.) placed at 0.46 meters (18
inches) to the left and right of the center of the span,
and at the center of the span.

9.3.6.11

The design loads in sections 9.3.6.7 to 9.3.6.10 are

not to be added to uniformly distributed loads for light,
medium and heavy duty scaffold (i.e., 25, 50 and 75
lb./ft2 respectively), but are shown as alternates.

9.3.6.12

Each platform, where applicable, shall be designed and

constructed to carry a uniformly distributed load as an
alternate to the person loading of 9.3.6.7 to 9.3.6.10.
Uniformly distributed loads and person loading are not
cumulative and the most restrictive loading shall be
used for platform design.

9.3.6.13

Light, medium and heavy duty uniformly distributed

load requirements shall be 25, 50 and 75 pounds per
square foot respectively. Greater uniformly distributed
loads shall be specially designed.

TABLE II.2: WOOD SCAFFOLD PLANK LOADING CHART

Permissible Span (ft)

Douglas Fir or Spruce

Southern Pine Rough Sawn

2 in x 10 in 1-7/8 in x 9-7/8 in

Nominal or or

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 Loading Condition 1-1/2 in x 9-1/4 in 2 in x 9 in
Actual

One worker or 10 ft 8 ft
medium-duty

Two workers or heavy- 8 ft 7 ft

duty

Three workers 5 ft 5 ft

REFERENCE: ANSI A10.8-1988

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FIGURE II.17: STANDARD COUPLER FIGURE II.18: A DJUSTABLE
COUPLER
(Bearers, Runners) (Braces Only)

FIGURE II.19: TYPICAL END TO END COUPLER FIGURE II.20: SCREWJACK

FIGURE II.21 TYPICAL REVEAL PIN FIGURE II.22 TYPICAL BASE PLATE

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9.4 Requirements Common to All Scaffolding

9.4.1 Foundations

9.4.1.1

A sound base is essential; therefore, the ground or floor

on which a scaffold is going to stand must be carefully
examined. Sand or made-up ground may need
compacting to ensure there are no cavities. Such
bases as floors, roofs, etc. may need shoring from
underneath.

Scaffolds, including components, shall be capable of

supporting without failure at least 4 times the
maximum intended load.

9.4.1.2

Timber sills at least 23 centimeters (9 inches) wide by

3.8 centimeters (1-1/2 inches) thick (not scaffold
planks) will be required to spread the load on sand,
made up ground, asphalt pavement, wooden floors,
and slippery surfaces. A sill shall extend under at least
two posts.

9.4.1.3

Where scaffolding is erected on a solid bearing such as

rock or concrete, small timber pads may be used in
place of sills and nailed to prevent the base plates
sliding off.

9.4.1.4

Concrete blocks, barrels, and other loose or unsuitable

material shall not be used for the construction or
support of scaffolding.

9.4.1.5

If used to compensate for variations in ground level,

the screwjack shall not be adjusted to more than two-
thirds of the total length of the thread. The base plate
shall be of a type approved for supporting scaffolding
posts. (See manufacturer's specifications.)

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 9.4.2 Posts

9.4.2.1

Posts shall be pitched on 15 centimeters (6 inches) by

15 centimeters (6 inch) steel base plates and at least
0.64 centimeter (1/4 inch) thick. Joints in posts should
be staggered, i.e., joints in adjacent posts should not
occur in the same lift. All posts shall be vertical.

9.4.2.2

The inner row of posts shall be placed as close as

possible to the face of the building or structure. To
avoid projections, the posts may be up to 41
centimeters (16 inches) away from the wall or structure
as necessary, provided that, where there is room to do
so, the gap between the wall or structure and the inner
posts shall be closed with planks on extended board
bearers. The outer row of posts shall be positioned
from the inner row of posts depending on the load
requirements of the scaffold, and the working platform
shall be fully decked out.

9.4.3 Runners

9.4.3.1

Runners shall be securely fixed to posts with standard

couplers and shall be horizontal. Joints in runners
should be staggered, i.e., joints in adjacent runners
should not occur in the same bay. Runners should be
secured end-to-end by sleeve couplers, not by joint
pins.

9.4.3.2

Runners shall be vertically spaced no more than 2.0

meters (6 feet, 6 inches) to give adequate headroom
along the platforms.

9.4.4 Bearers

Bearers should be installed between posts and securely fixed to

the posts bearing on the runner coupler and secured with
standard couplers. When coupled directly to the runners, the
coupler must be kept as close to the posts as possible. These
bearers must remain in position as they are a structural part of
the scaffold.

9.4.5 Board Bearers

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 Board bearers shall be installed between bearers to
accommodate differences in plank lengths.

Board bearers shall be secured to the runners between bearers

where necessary to support platform units (planks). These may
be removed when no longer required to support platform units.

9.4.6 Bracing

9.4.6.1

Cross bracing shall be installed across the width of the

scaffold at least every third set of posts horizontally
and every fourth runner vertically. Such bracing shall
extend diagonally from the inner and outer runners
upward to the next outer and inner runners. These
braces should be fixed to the runners with standard
couplers as close to the posts as possible. Where such
a fixing is impracticable, adjustable couplers may be
used to fix the braces to the posts. (See Figures II.23
and II.24.)

9.4.6.2

Longitudinal diagonal bracing shall be installed at

approximately 45-degree angle from near the base of
the first outer post upward to the extreme top of the
scaffold. Where possible, such bracing shall be
duplicated at every fifth post. On short but high runs,
diagonal bracing shall be installed at an angle of 45
degrees from the base of the first outer post to the last
outer post and shall alternate directions to the top of
the scaffold. When bracing cannot be attached to the
posts, this bracing may be attached to the runners, as
close as possible to the posts. Only standard couplers
or adjustable couplers may be used. Joints in braces
shall be made with end-to-end or parallel couplers.

9.4.6.3

Temporary rakers (inclined load-bearing tube supports)

brace the scaffold against the ground when setting out.
These rakers are replaced by permanent braces when
the scaffold has been plumbed, leveled and tied.
Rakers must be secured with proper couplers at the
scaffold and coupled to a ground stake.

9.4.7 Ties

9.4.7.1

It is essential that all scaffolds, with the exception of

certain tower and mobile scaffolds (See 9.7 and 9.8),

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 be securely tied to the building or structure throughout
their length and height to prevent movement of the
scaffold either towards or away from the building or
structure. This should be done by connecting a tie
tube to both runners or posts and coupling this to a
two-way tie or column box tie assembly. (See Figures
II.25 and II.26.)

9.4.7.2

Where the foregoing is impracticable, tubes may be

securely wedged between opposing surfaces on the
building or structure by the use of reveal pins and
coupled to the tie tubes (Figure II.27). Where reveal
ties are used, they shall not exceed 50% of the total
number of ties. Two-way ties or column box ties shall
be evenly distributed over the scaffold area. To ensure
the security of reveal ties, it is necessary to check
frequently for tightness.

9.4.7.3

Ties shall occur at the top of the scaffold and at least

every 7.9 meters (26 feet) vertically and 9.1 meters (30
feet) horizontally and at each end of the scaffold. All tie
assembly connections shall be made with standard
couplers.

9.4.8 Platform Units

9.4.8.1

All platform units (i.e., planks, fabricated decks, etc.)

shall be closed planked with, whenever practicable,
each plank resting on at least three supports. Planks
shall extend over their end supports by not less than
15 centimeters (6 inches) and not more than 30.5
centimeters (12 inches).

9.4.8.2

Supports for scaffold planks shall be spaced with due

regard to the nature of the platform and the load it will
bear. (See Table II.2.)

9.4.8.3

Except on platform units adjacent to the surface of a

cylindrical or spherical structure, planks shall be laid
flush.

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 9.4.8.4

Planks shall be secured in position to prevent

displacement by high winds.

9.4.8.5

Adequate space for men to pass in safety shall be

provided and maintained wherever materials are
placed on platform units or if any higher platform is
erected thereon.

9.4.8.6

Platform units shall be kept free of unnecessary

obstructions, materials, and projecting nails.

9.4.8.7

Platform units which have become slippery with oil or

any other substance shall be cleaned, or otherwise
removed and replaced.

9.4.8.8

Slopes in platform units shall not exceed 1 vertical to 4

horizontal and stepping cleats at 0.3 meter (1 foot)
intervals shall be provided.

9.4.8.9

All platform units shall be closed planked for the full

width of the scaffold structure.

9.4.9 Guardrail Systems and Toeboards

9.4.9.1

Guardrail systems (consisting of toprails and midrails)

and toeboards shall be installed at all open sides and
ends of all scaffolds and supports on no more than 3-
meter (10-foot) centers from which men or materials
could fall a distance of more than 1.8 meters (6 feet).
Toprails shall be no less than 0.91 meter (36 inches)
and no more than 1.14 meters (45 inches) above the
working surface; midrails shall be installed equidistant
between the working surface and the toprail.
Toeboards shall not be less than 10 centimeters (4
inches) in height by 2.5 centimeters (1 inch) thick.
Guardrail systems and toeboards shall be securely
fixed to the inside of posts to withstand a lateral thrust
of 200 pounds.

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 9.4.9.2

Landings: Safe landings shall be provided at the top of

all ladders. Rings shall be eliminated above the
landing level, and side rails shall extend 36 to 42
inches above the landing for mounting and
dismounting. Where multiple ladders are required,
solidly decked platforms shall be provided. Guardrails,
intermediate rails and toeboards shall be erected on
the outside edges and exposed sides of the platform.

9.4.10 Access

Access to a working platform is best achieved by providing a

separate ladder tower or a cantilevered access platform so as
not to obstruct the working platform and to minimize the risk of
persons falling through gaps in the guardrail system or platform
units. Access must be provided to working platforms.

9.4.11 Scaffold Ladders

Scaffold ladders provide the means of access and egress for

scaffolds. They can generally be classified as follows:

9.4.11.1 Portable Straight and Extension Ladders

(Figure II.24)

A straight ladder is a portable ladder that only consists

of one section which determines its overall length. It
cannot support itself or be adjusted in length.

An extension ladder is a portable ladder that cannot

support itself but can be adjusted in length. It consists
of two or more sections which are arranged to permit
length adjustment. Its overall length is the sum of the
length of all its sections measured along the side rails.

Portable straight and extension ladders shall have a

firm base and be positioned with a slope of 1:4.

9.4.11.2 Vertical Ladder

A vertical ladder is a type of fixed ladder which is

permanently attached to the horizontal or vertical
components of a scaffolding.

The main criteria to consider in the use of a vertical

ladder is clearance. The following clearance guidelines
shall be used.

· General:

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 Safe clearances shall be maintained to prevent
workers from bumping into, or snagging onto,
projecting objects while ascending or descending
the ladder.

· Climbing Side:

Ladders shall have a minimum clear perpendicular

distance of 30 inches from the rungs to the nearest
projecting object on the climbing side. When
unavoidable obstructions are encountered, the
minimum clearance distance may be reduced to 24
inches if deflector plates are provided.

· Back Side Of Ladder:

The perpendicular distance from the face of the

rung on the climbing side to the nearest fixed
object on the back side of the ladder shall not be
less than 10 inches. When unavoidable, horizontal
obstructions (e.g. beams, pipes, etc.) are
encountered, the vertical toe clearances specified
in the following sections, shall apply.

· Side Clearance:

The minimum clear distance to the nearest fixed

object shall be 15 inches on each side of the
centerline of single rung ladders.

· Vertical Clearance:

The minimum vertical toe clearance from horizontal

obstructions shall be 1 1/2 inches below and 4 1/2
inches above the top edge of the rung.

· Multiple Ladders:

When two or more separate ladders are used with a

landing platform, the side-step distance shall be a
minimum of 15 inches from the centerline of the
upper ladder to the near side of the lower ladder.

9.4.12 Workmanship

9.4.12.1

Scaffolding shall be erected, altered, and dismantled

by experienced men working under the direction of a
competent supervisor.

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 9.4.12.2

Posts shall be set accurately in place and checked

vertically by using a spirit level or by using vertical
lines on the building or structure.

9.4.12.3

Scaffolding couplers should be tightened with proper

scaffolding spanners. The use of an ordinary spanner
or tool giving greater leverage could damage the screw
threads and render the coupler unserviceable.

9.4.12.4

Scaffolding materials shall not be thrown or dropped

from heights.

9.4.13 Inspections

All scaffolds shall be inspected regularly by a competent

Supervisor and after adjustments, modifications, adverse
weather conditions, etc. Erected scaffolds and platforms should
also be inspected continuously, by those using the scaffold, to
insure that the scaffold has not been altered and is in a safe
working condition.

9.5 Fabricated Tubular Frame and System Scaffolding

Fabricated tubular frame and system scaffolding are composed wholly

or partly of prefabricated sections. There are many types of fabricated
tubular frame and system scaffolding available which vary in design
and methods of erection; however, the same basic principles set out in
9.4 apply and the following matters warrant particular attention. All
scaffolds must be erected as per manufacturer's direction and
limitations. A scaffold plan needs to be submitted to Loss Prevention
Department for review. (See Figures II.28 to II.31)

9.5.1

To be erected, altered and dismantled by experienced men,

under the direction of a competent Supervisor.

9.5.2

Periodic inspections shall be made of all parts and accessories.

Broken, bent, altered, excessively rusted or otherwise
structurally damaged frames or accessories shall not be used.

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 9.5.3

All fabricated tubular frame and system scaffolding shall be

constructed and erected to support four times the maximum
intended loads.

9.5.4

Scaffold posts shall be pitched on steel base plates and on

timber sills or pads as necessary. Screwjacks shall be used to
compensate for variations in ground level.

9.5.5

Scaffolds shall be properly braced by cross braces and

longitudinal diagonal braces for securing vertical members
together. The cross braces shall be of such length as will
automatically square and align vertical members so that the
erected scaffold is always plumb, square, and rigid. All brace
connections shall be made secure.

9.5.6

The frames or posts shall be placed one on top of the other with
coupling or stacking pins to ensure proper vertical alignment of
the legs.

9.5.7

The frames and posts shall be locked together vertically by pins

or other equivalent suitable means.

9.5.8

Fabricated tubular frame and system scaffolding over 38 meters

(125 feet) in height shall be specially designed by a Professional
Engineer. In Saudi Aramco, scaffold heights are limited to a
maximum height of 12.2 meters (40 feet), unless a scaffold plan
has been reviewed by the Area Loss Prevention Division
representative prior to construction. Scaffolds above 12.2
meters (40 feet) should be constructed using scaffold
contractors; however no scaffolds shall exceed 38.1 meters (125
feet) unless the design has been reviewed by an Area Loss
Prevention Division representative, Consulting Services
Department and approved by a qualified engineer. (See also GI
8.001, section 6.1.1.)

9.6 Tube and Coupler Scaffolds

(Tube and Coupler Construction - Figure II.23)

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 9.6.1 Independent Tied Scaffold

An independent tied scaffold (also commonly known as a double

pole scaffold) consists of a double row of posts connected
together longitudinally with runners and with bearers at right
angles to the runners. Braces and ties are essential for stability.
Independent tied scaffold is the most common form of tube and
coupler scaffolding and is divided into three groups.

In Saudi Aramco the height limitation of the tube and coupler

scaffold shall not exceed 12.2 meters (40 feet) unless a scaffold
plan proposing to use such a scaffold at a greater height has
been reviewed by the Loss Prevention Department per the
provisions of Section 9.5.8.

1 Light Duty: for painting, cleaning, etc.

2 Medium Duty: when materials are deposited on the
platforms.
3 Heavy Duty: where the deposited material is of a more
substantial nature.

9.6.2 Light Duty Tube and Coupler Scaffolds

(For general requirements, see 9.4 and 9.5)

9.6.2.1 Design, Loading and Dimensions

A light duty tube and coupler scaffold can have up to

three working platforms in use at any one time, and the
maximum distributed load on the platform shall be 1.2
kPa (25 lb./sq. ft) with posts 3.05 meters (10 feet) apart
longitudinally and 1.83 meters (6 feet) transversely.
TABLE II.3: TUBE AND COUPLER SCAFFOLDS--LIGHT DUTY

Uniformly distributed load Not to exceed 25 p.s.f.

Post Spacing (longitudinal) 10 ft. 0 in.

Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Planked Maximum Height

Levels

1 8 125 ft.

2 4 125 ft.

3 0 91 ft. 0 in.

Reference: CFR 1910.28

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 9.6.2.2 Platform

The platform between posts should be decked out with

23 centimeters (9 inches) wide by 5.1 centimeters (2
inches) thick planks. Bearers may be cantilevered for
use as brackets to carry not more than two planks
between the building and inner post.

9.6.2.3 Limitations

Light duty tube and coupler scaffolds erected in

accordance with these directions may be used up to a
maximum height of 38.1 meters (125 feet) and limited
to a uniformly distributed load of 25 lb./ft 2. Light duty
tube and coupler scaffolds departing from these
directions shall be specially designed or designed to a
higher rating such as medium or heavy duty.

9.6.3. Medium Duty Tube and Coupler Scaffold

(For general requirements, see 9.4)

9.6.3.1 Design, Loading, and Dimensions

A medium duty tube and coupler scaffold may have up

to two working platforms in use at any one time. The
maximum distributed load on each platform shall not
exceed 2.39 kPa (50 lb./sq. ft) with posts not more than
2.4 meters (8 feet) apart longitudinally and 1.83
meters (6 feet) transversely.
TABLE II.4: TUBE AND COUPLER SCAFFOLDS--MEDIUM DUTY

Uniformly distributed load Not to exceed 50 p.s.f.

Post Spacing (longitudinal) 8 ft. 0 in.

Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Planked Maximum Height

Levels

1 6 125 ft

2 0 78 ft. 0 in.

Reference: CFR 1910.28

9.6.3.2 Platform

The platform between posts should be decked out with

23 centimeters (9 inches) wide by 5.1 centimeters (2

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 inches) thick planks. Bearers may be cantilevered for
use as brackets to carry not more than two planks
between the building and inner post.

9.6.3.3 Limitations

Medium duty tube and coupler scaffolds erected in

accordance with these directions may be used up to a
maximum height of 38.1 meters (125 feet) and limited
to a uniformly distributed load of 50 lb./ft 2. Medium
duty tube and coupler scaffolds departing from these
directions shall be specially designed or designed to a
higher rating such as heavy duty.

9.6.3.4 Bearers

Bearers on medium duty tube and coupler scaffolds

shall be 6.35 centimeters (2.5 inches) outside diameter
steel tube and of nominal wall thickness of 0.4
centimeter (5/32 inch).

9.6.4 Heavy Duty Tube and Coupler Scaffolds

(For general requirements, see 9.5)

9.6.4.1 Design, Loading and Dimensions

A heavy duty tube and coupler scaffold has one

working platform with a maximum distributed load of
3.6 kPa (75 lb./sq ft) on the platform. The posts shall
be no more than 2.0 meters (6 feet, 6 inches) apart
longitudinally and 1.8 meters (6 feet transversely).
TABLE II.5: TUBE AND COUPLER SCAFFOLDS--HEAVY DUTY

Uniformly distributed load Not to exceed 75 p.s.f.

Post Spacing (longitudinal) 6 ft. 6 in.

Post Spacing (transverse) 6 ft. 0 in.

Working Levels Additional Planked Maximum Height

Levels

1 6 125 ft.

Reference: CFR 1910.28

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 9.6.4.2 Platform

The platform between the posts shall be decked out

with 23 centimeters (9 inches) wide by 5.1 centimeters
(2 inches) thick planks.

9.6.4.3 Limitations

Heavy duty tube and coupler scaffolds erected in

accordance with these directions may be used up to a
maximum height of 38.1 meters (125 feet). Heavy
duty tube and coupler scaffolds departing from these
directions shall be specially designed.

9.6.4.4 Bearers

Bearers on heavy duty tube and coupler scaffolds shall

be 6.35 centimeters (2.5 inches) outside diameter steel
tube and be of nominal wall thickness 0.4 centimeter
(5/32 inch).

9.7 Free-Standing Tower Scaffolds

A free-standing tower scaffold consists of four or more posts connected

together longitudinally with runners and bearers at right angles to the
runners, forming a square or rectangular tower (see Figure II.32).
Alternatively, a free-standing tower scaffold may be constructed of a
fabricated tubular frame or system scaffolding (see 9.5). A free-
standing tower scaffold has a single working platform and is a common
form of access scaffolding for painters and others who do work of a light
nature and of short duration.

9.7.1 General Requirements

For general requirements, see 9.4 and where a fabricated

tubular frame or system scaffolding is to be used, see 9.5.

9.7.2 Design, Loading and Dimensions

A free-standing tower scaffold shall have only one working

platform and the maximum distributed load shall not exceed the
load rating which is determined by the platform unit type and
the scaffold duty.

The height from the base to working platform of a free-standing

tower scaffold shall not exceed four times the minimum base
dimension. In no case shall the minimum base dimension be
less than 1.2 meters (4 feet).

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 9.7.3 Runners and Bearers

The vertical spacing of runners and bearers shall be 2.0 meters

(6 feet, 6 inches). The lowest runners and bearers shall be as
near to the base as possible. Runners and bearers shall be
secured to the posts with standard couplers.

9.7.4 Bracing

Sway bracing is necessary on all four elevations to the full

height of the scaffold. Plan bracing is also required at the base,
at the top, and at every third lift to prevent racking.

9.7.5 Ties

Free-standing tower scaffolds more than 9.8 meters (32 feet) in

height shall be adequately tied to a building or structure.
Where tying to a building or structure is impracticable, one of
the following methods of ensuring stability shall be used (see
Figures II.33 to II.35):

1 Guy wires at a slope of approximately 45 o connected to

the working platform level of the tower.
2 Bottom corners of the tower securely anchored.
3 Outriggers extending to the ground.

The strength of the guy wires or of the anchorage used shall be

calculated, having due regard to the horizontal wind forces and
other known forces which may be applied to the tower. These
calculations shall be reviewed by Loss Prevention Department.

9.7.6 Platform

The single working platform of a free-standing tower scaffold

shall not project beyond the base area and the platform unit(s)
shall be securely fixed in position.

9.7.7 Access

Where the means of access to the working platform is outside

the tower structure, due consideration must be given to the
effect of such means of access on the stability of the scaffold.
Where a sloping ladder would cause instability, a securely fixed
vertical ladder may be used.

9.7.8 Limitations

Free-standing tower scaffolds erected and used in accordance

with these directions and with one working platform may be used
up to a maximum height of 12 meters (40 feet) to the work
platform. Free-standing tower scaffolds departing from these
directions shall be specially designed.

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9.8 Mobile Tower Scaffolds
(Figure II.31)

The requirements for free-standing tower scaffolds in 9.7 also apply to

mobile tower scaffolds with the exception that wheels are used in place
of base plates and sills.

9.8.1 Foundations

Wheels or casters, not less than 12.7 centimeters (5 inches) in

diameter, and fitted with brakes, which cannot be released
accidentally, shall be securely fixed to the bases of the posts by
lock pins or dowels.

A mobile tower scaffold shall only be used and moved on

surfaces sufficiently firm and level to ensure stability. Where
the scaffold is to be used on a suspended floor, it shall be
designed to apply loads no greater than the bearing capacity of
the floor.

Temporary foundations or track laid on soft or uneven ground to

facilitate the erection and movement of the tower shall be
constructed and anchored so that its bearing capacity is not
exceeded due to imposed loading from the tower. The track
shall be level and properly secured.

9.8.2 Operation

A mobile tower scaffold shall be moved only by pushing or

pulling at the base. Force must not be applied at a height
greater than 1.4 meters (4 feet, 6 inches) above the base. No
men, equipment or materials shall be on the working platform
or elsewhere on the structure while it is in motion. Wheel
brakes shall be applied at all times when men are on the
stationary mobile tower scaffold.

9.8.3 Limitations

Mobile tower scaffolds, erected and used in accordance with

these directions, supported on four wheels and with one
working platform, may be used up to a maximum height of 12
meters (40 feet). Mobile tower scaffolds departing from these
directions shall be specially designed and properly secured (See
9.7.5).

9.9 Scaffolds for Tanks and Vessels

Tube and coupler scaffolds for tanks and vessels shall be erected in
accordance with 9.6. Secure tying to the structure is essential for
stability.

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 9.9.1 Bracket Scaffolds

9.9.1.1

Brackets and bracket straps shall be constructed, fixed

and erected in accordance with the manufacturer's
instructions.

9.9.1.2

It is essential that the brackets, straps and welds are of

sufficient strength to support the weight of the scaffold,
men, tools and materials.

9.9.1.3

The bracket straps shall be welded to the wall of the

tank by a certified welder. The weld shall be a full 5
millimeters (3/16 inch) fillet. Prior to welding on any
tank, approval is required from Saudi Aramco
Consulting Services Department.

9.9.1.4

The weld shall be made with the same type of

electrode as used for the main tank weld joints. Before
the bracket is attached to the strap, the weld shall be
inspected by a competent welding inspector or welding
supervisor who will approve and accept the weld.

9.9.1.5

Brackets shall be inspected prior to each use and

damaged or defective brackets shall be removed from
service. Brackets shall be vertical and horizontal
spacing shall not exceed 2.5 meters (8 feet) on
centers.

9.9.1.6

A rigid guardrail system and toeboards shall be

securely fixed to the uprights of the brackets (see
Section 9.4.9). Alternatively, 3/8 inch diameter wire
ropes may be used in place of toprails and midrails
providing that they are securely fixed and kept taut by
the use of turn buckles.

9.9.1.7

Whenever men are working, the platform shall be fully

decked.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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 9.9.1.8

Excessive storage or accumulation of materials or

platform units (planks) shall not be permitted.

9.9.1.9

The scaffold shall be designed to support a minimum

load of 1.2 kPa (25 lb./sq. ft). No more than two
persons shall occupy any given 2.5 meters (8 feet) of
bracket scaffold at any one time. Tools and materials
shall not exceed 34 kg (75 lb.) in addition to person(s)
occupying the area.

9.10 Special Scaffolds

Scaffolds to suit special applications and those required for unusual

heights or for use in abnormal circumstances shall be of a special
design, which has been reviewed by the Loss Prevention Department as
per the provisions of section 9.5.8.

Vehicle-mounted elevating and rotating aerial devices shall comply with

ANSI A92.2-1990.

9.11 Scaffold Terminology

Where possible, the scaffold terminology used in this document is based

on ANSI A10.8-1988: Scaffolding - Safety Requirements. A list of
common ANSI scaffold terms is included, and in brackets are equivalent
British Standard (BS 5973: 1990 scaffold terms, where an equivalent
term exists.

(1) Base Plate. A metal plate with a spigot or screwjack for distributing
the load from a post or other load bearing tube.

(2) Bearer (Transom). A horizontal tube across runners to form the

support for a platform or to connect the outer posts to the inner
posts.

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 (3) Brace. A tube placed diagonally with respect to the vertical and
horizontal members of a scaffold and fixed to them to give stability.

(4) Coupler. A device for locking together component parts of tube and
coupler scaffold.

(5) Design Load. The maximum intended load; that is, the total of all
loads including the worker(s), material and the equipment placed
on the unit.

(6) Dropline. A vertical line from a fixed anchorage, which is

independent of the work platform and its rigging, and to which the
lanyard is affixed.

(7) Fabricated Tubular Frame Scaffold. A system of tubular frames

(panels) field erected with bracing members.

(8) Guardrail System. A rail system erected along open sides and ends
of platforms. The rail system consists of a toprail and midrail and
their supports.

(9) Lanyard. A flexible line to secure the wearer of a body belt or

harness to a dropline or a fixed anchor.

(10) Load Ratings. Maximum loading for the following categories:

(a) Heavy Duty: Scaffolding constructed to carry a working

load of 75 lb./ft2 such as for masonry work, with storage of
materials on the platform.
(b) Medium Duty: Scaffolding constructed to carry a working
load of 50 lb./ft2 such as for bricklayers with the weight of
materials in addition to workers.
(c) Light Duty: Scaffolding constructed to carry a working
load of 25 lb./ft2 and is intended for workers only, with no
material storage other than the weight of tools.
(d) Special Duty: Scaffold designed and constructed to carry
specific types of objects.

(11) Mobile Scaffold. A scaffold assembly supported by casters and

moved along manually.

(12) Midrail. A horizontal rail approximately midway between the toprail

and platform of a guardrail system.

(13) Plank. A wood board or fabricated component that is a flooring

member.

(14) Platform. An elevated work surface composed of one or more

platform units.

(15) Platform Unit. Individual wood planks, fabricated planks, fabricated

decks, and fabricated platforms.

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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 (16) Post (Standard). Vertical scaffold tube that bears the weight of the
structure.

(17) Putlog (Truss). A fabricated tube upon which the platform rests, the
putlog has a flattened end, to rest in or on part of the brickwork.

(18) Rated Load. The manufacturer's recommended maximum load.

(19) Runner (Ledger). A horizontal scaffold tube that extends from post
to post, that supports putlogs or bearers and that forms a tie
between the posts.

(20) Scaffold. A temporary elevated or suspended work unit and its

supporting structure used for supporting worker(s) or materials, or
both.

(21) Scaffold Access. A separate, attachable or built-in means of access

to and from a scaffold or work unit.

(22) Scaffold Deck 'Fabricated'. A work unit equipped with end hooks
that engage the scaffold bearer.

(23) Sill (Sole Plate). A timber, concrete or metal spreader used to

distribute the load from a post or base plate to the ground.

(24) Tie. A device used between scaffold components and the building
or structure to enhance lateral stability.

(25) Toeboard. A barrier secured along the sides and the ends of a
platform unit to guard against the falling of material, tools and
other loose objects.

(26) Toprail. The uppermost horizontal rail of a guardrail system.

(27) Tube and Coupler Scaffold. A scaffold system consisting of tubing

that serves as posts, bearers, braces, ties and runners; a base
supporting the posts; and special couplers that serve to connect the
uprights and join the various members.

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FIGURE II.23: A TYPICAL INDEPENDENT TIED SCAFFOLD CONSTRUCTED USING TUBE AND COUPLER SCAFFOLDING

February 1993 - 9.0 Working Places, Ladders, and Scaffolding Page 207
FIGURE II.24: A TYPICAL TUBE AND COUPLER SCAFFOLD

February 1993 - Working Places, Ladders, and Scaffolding Page

208
FIGURE II.25: PLAN VIEW OF TWO-WAY TIE

FIGURE II.26: PLAN VIEW OF COLUMN BOX TIE

FIGURE II.27: PLAN VIEW OF REVEAL TIE

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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FIGURE II.28: A TYPICAL SYSTEM SCAFFOLD

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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FIGURE II.29: A TYPICAL SYSTEM SCAFFOLD BEING ASSEMBLED

FIGURE II.30: A TYPICAL SYSTEM SCAFFOLD BASE IN THE PROCESS OF BEING

ASSEMBLED AND LEVELED

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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FIGURE II.31: A TYPICAL FABRICATED TUBULAR FRAME MANUALLY PROPELLED MOBILE
SCAFFOLD

Working Platform Guard Rail System Spring Loaded Access

Gate

End Frame Toeboard

Locking Pins Coupler

Cross Bracing Access Ladder

Horizontal Diagonal Brace Caster Fastening Pins Locking Casters

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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FIGURE II.32: A TYPICAL TUBE AND COUPLER MOBILE ACCESS TOWER

February 1993 - 9.0 Working Places, Ladders, and Scaffolding

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FIGURE II.33: CROSS TUBE ANCHOR

FIGURE II.34: OUTRIGGERS IN USE FIGURE II.35: DRIVEN TUBE

ANCHOR

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10.0 HAND TOOLS AND POWER TOOLS
Hand tools are those tools for which the hand provides the motive force, e.g.,
picks, shovels, axes, crowbars, wrenches, saws, chisels, hammers, screwdrivers,
etc. It is the contractor's duty to ensure that his workmen are properly instructed
in the selection and use of the correct tool for the job. Tools constructed of good
quality materials should always be used. Poor quality tools increase the risk of
accidents and also reduce the efficiency of work.

Power tools, however, allow many jobs to be carried out more efficiently and with
greater speed and accuracy. The correct use of power tools can only be achieved
by the proper training of workmen, by proper maintenance, and by adequate site
supervision. Many accidents have occurred because unskilled and untrained labor
have been allowed to operate power tools in an incorrect manner.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions And Standards:

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Cartridge Operated Tools

United States Code of Federal Regulations 29, Part 1910, Subpart "0", Machinery
And Machine Guarding

American National Standards Institute:

ANSI A10.3-1985

Safety Requirements For Powder Actuated Fastening Systems

ANSI A10.9-1983

Safety Requirements For Concrete Construction and Masonry Work

ANSI B7.1-1988

Safety Code For The Use, Care, And Protection Of Abrasive Wheels

ANSI B15.1-1984

Safety Code For Mechanical Power Transmission Apparatus

NFPA - 70-90

National Electrical Code (NEC)

February 1993 - Construction Safety Manual: Hand Tools And Power Tools Page 215
10.1 Hand Tools, General

10.1.1 Quality

The contractor shall ensure that the finest quality tools shall be
provided for all jobs where hand tools are used.

10.1.2 Cleanliness

The contractor shall ensure that hand tools are regularly cleaned
and, where necessary, lightly oiled as a protection against
corrosion.

10.1.3 Repair and Storage

All hand tools shall be regularly inspected before and after use,
and before storage. If wear or damage is observed, the tool
should be withdrawn from use for repair or disposal. The
contractor shall ensure that the storekeeper maintains a record
of all tools issued, repaired, and withdrawn from use. Proper
racks and boxes shall be provided for the storage of hand tools.

10.1.4 Selection

The majority of accidents are caused by using an incorrect tool

for the job. It is essential that the correct type, size, and weight
of tool should be decided upon before any work is carried out.

10.1.5 Electrical Risks

All uninsulated metal tools are conductors of electricity. Where

work takes place on or near electrical operations, only properly
insulated and non-conductive tools should be used. Insulation
should be checked at regular intervals by a competent
electrician.

10.2 Individual Hand Tools, Precautions

10.2.1 Screwdrivers

It is essential that a screwdriver has the correct size of tip to fit

the slot of the screw. If the screwdriver fits the screw correctly,
the screw will be drawn into the correct position without
unnecessary force being applied. Over-tightening of screws can
lead to possible hand injury if the screwdriver slips.

Screwdriver shanks are not designed to withstand the twisting

strain applied by a pair of pliers or more grips in order to obtain
additional leverage. On no account should screwdriver handles
be subjected to blows from a hammer or similar instrument.

February 1993 - 10.0 Hand Tools And Power Tools Page 216
 Screwdrivers should never be carried in the pockets of coveralls
or other clothing. A screwdriver can produce a serious wound.

10.2.2 Hammer

It is essential that the right kind of hammer be selected for the

job. Hammer handles should be made from smooth timber or be
made of an integral head and shaft of steel. Hammer heads
should be secured to wooden handles with proper wedges.

10.2.3 Chisels

Cutting edges should be kept sharp at all times, and the original
shape and angle should be maintained. Re-sharpened cold
chisels should be suitably hardened and tempered to maintain
them in a safe working condition. The chisel heads will
mushroom in use. As soon as mushrooming is observed, the
head should be reground with a slight taper around the edge to
prevent chipping and reduce the tendency to re-mushroom. Eye
protection should be worn at all times when a cold chisel is used.

On jobs where it is necessary to use a sledge hammer for striking

the chisel, the chisel should be held by a second person using a
pair of tongs.

Wood chisels should also be maintained in a sharp condition so

that minimum pressure is exerted when making a cut. If the
chisel is to be struck, only a wooden or soft mallet should be
used.

10.2.4 Picks and Shovels

Picks and shovels shall be maintained in a serviceable condition

at all times. Shovel blades should not be allowed to become
blunt, turned, split, or jagged. Pick head points should be kept
sharp and heat-treated so that the metal wears down in use and
does not splinter or chip off. Shafts of picks and shovels should
be kept free from cracks and splinters.

10.2.5 Spanners and Wrenches

Only spanners and adjustable wrenches of the right size should

be used. When possible, use box-end rather than adjustable
wrenches. The jaw should first be checked for any sign of
opening out or splitting. Spanner and wrench lengths are graded
to provide sufficient leverage on the nuts for which they are
designed. Improvised extension to these tools is an unsafe
practice and may cause the bolt tread to strip or cause shearing
of the bolt. On no account should ordinary wrenches be struck
by a hammer when tightening nuts. For heavy work of this
nature, a properly designed slugging wrench should be used.

February 1993 - 10.0 Hand Tools And Power Tools Page 217
 10.2.6 Pipe Wrenches

Pipe wrenches must be large enough for the job, the jaw teeth
must be kept clean and sharp, and the knurl, pin, and spring
should be kept free from damage. Pipe wrenches should never
be struck with a hammer, nor should they be used as a hammer.

10.2.7 Pliers

Pliers should only be used when there are no other tools for the
job. They are meant only for gripping around objects and should
not be used as a wrench.

Care should be taken when cutting soft metal with pliers to

ensure the scrap portion does not fly off and cause injury. If wire
is cut under tension, then long handled pliers should be used.
Where pliers are used for electrical work, they must be fitted with
insulated handles. All pliers should be kept free from dirt and
grit, and the movable parts should be lightly lubricated.

10.2.8 Jacks

Jacks should be marked with rated capacity and must be heavy

enough and strong enough to raise and maintain the load. They
should be placed on a firm and solid support, and the load
should be positioned on the center line of the jack.

Once a load has been raised, it must be shored or blocked. The

jack should never be relied upon to hold the raised load in
position by itself. Extreme care should be taken when working
under or near a raised load.

10.2.9 Hacksaws

The correct type of blade should be selected to suit the material

to be cut. The blade should be set in a hacksaw frame so that
the teeth are pointing in the forward direction, and sufficient
tension should be applied to ensure blade is maintained rigid.

10.2.10 Hand saws

Many kinds of woodworking hand saws are available, and care

should be taken to select the correct saw. All hand saws shall be
regularly examined to ensure that the saw teeth are properly set
so as to avoid binding in the timber which can cause the blade to
buckle. The teeth should be kept sharp, clean, and lightly oiled.
When the saw is not in use, the blade should be protected by a
slotted piece of timber or a sheath.

Two-man saws should be operated by pulling only. The cut

should be kept straight to avoid the blade buckling. The cut

February 1993 - 10.0 Hand Tools And Power Tools Page 218
 should be wedged open to prevent the timber from pinching the
blade.

10.3 Power Tools, General

10.3.1 Quality

The contractor shall ensure that all portable power tools do not
exceed 125 volts rating, are manufactured of sound materials,
and are free from defects and properly grounded.

10.3.2 Repair and Storage

All portable power tools shall be stored in clean, dry conditions.

The contractor shall provide a schedule of systematic inspection
and maintenance for all power tools. All tools shall be returned
to the storekeeper at the completion of each individual job.
Power tools must not be left lying around the job site where they
could be damaged.

Rotating tools should be switched off and held until rotation has
completely stopped before they are set down. Tools must be
disconnected before changing bits, blades, cutters, or wheels.

Power for tools can be supplied by compressed air, explosive

cartridge, or electricity. All portable power tools must be
equipped with properly functioning "dead man" switches.

10.4 Pneumatic Tools

10.4.1 General

10.4.1.1

An air compressor shall always be under the

supervision of a competent person. It should always
be sited in such a place so as to have adequate
ventilation. Compressors shall not be permitted to
operate in confined spaces without the provision of
adequate exhaust ventilation.

10.4.1.2

All compressed air hoses shall be of the correct size to

fit the tool being used. Any joint in the hoses shall be
made with a proper coupler and secured by safety wire.
The hose length shall be kept as short as possible and
placed so as not to be subjected to damage.

February 1993 - 10.0 Hand Tools And Power Tools Page 219
 10.4.1.3

Pneumatic tools require clean air to operate efficiently.

In every line feeding a power tool, there shall be an
adequate filter and lubricator.

10.4.1.4

During operation all air tools should be held firmly to

prevent them spinning and jumping. This pressure
should be maintained during the stopping process to
prevent injury to the operator's feet and hands.

10.4.2 Individual Tools, Precautions

10.4.2.1 Jack Hammer and Concrete Breakers

The tool bit retaining spring shall always be securely

in position to prevent the bit from dropping out. The
bit must be kept sharp.

Ear, eye and foot protection shall be required when

working with this type of equipment. See I.9 for other
personal protective equipment requirements.

10.4.2.2 Rock Drill

It is extremely important that the operator maintains a

firm grip with both hands and stands in a balanced
position. Any other method of using the tool can
cause serious bodily injury.

10.4.2.3 Grinding Machine

This tool is probably the most misused of all the power

tools. Care should always be taken to ensure that the
grinding wheel is free from defect before mounting.
Any defect may cause the wheel to disintegrate as it
gains momentum.

Only persons who have been instructed in the proper

selection and fitting of grinding wheels should be
allowed to install wheels on tools.

The proper size and type of wheel should be fitted to

the tool so that the maximum permissible running
speed of the spindle does not exceed the maximum
periphery speed displayed on the grinding wheel. No
grinding machine shall be used unless the maximum
speed is clearly marked on the case. All wheels shall
be fitted with adequate guards in conformance with
ANSI B7-1-1988. (See Figure II.36.)

February 1993 - 10.0 Hand Tools And Power Tools Page 220
 Floor stand and bench mounted abrasive wheels, used
for external grinding, shall be provided with safety
guards (protection hoods). The maximum angular
exposure of the grinding wheel periphery and sides
shall be not more than 90 o, except that when work
requires contact with the wheel below the horizontal
plane of the spindle, the angular exposure shall not
exceed 125 o. In either case, the exposure shall begin
not more than 65 o above the horizontal plane of the
spindle. Safety guards shall be strong enough to
withstand the effect of a bursting wheel. (See Figures
II.37 and II.38.)

Floor and bench-mounted grinders shall be provided

with work rests which are rigidly supported and readily
adjustable. Such work rests shall be kept at a distance
not to exceed one-eighth inch from the surface of the
wheel. (See Figure II.37.)

Cut type wheels used for external grinding shall be

protected by either a revolving cup guard or a band
type guard in accordance with the provisions of the
American National Standards Institute, B7.1-1988
Safety Code for the Use, Care, and Protection of
Abrasive Wheels. All other portable abrasive wheels
used for external grinding, shall be provided with
safety guards (protection hoods) meeting the
requirements of this paragraph, except as follows:

· When the work location makes it possible, a wheel

equipped with safety flanges shall be used.

· When wheels 2 inches or less in diameter which are

securely mounted on the end of a steel mandrel are
used.

Portable abrasive wheels used for internal grinding

shall be provided with safety flanges (protection
flanges) except as follows:

· If the wheels are entirely within the work being

ground while in use.

· When wheels 2 inches or less in diameter which are

securely mounted on the end of a steel mandrel are
used.

When safety guards are required, they shall be so

mounted as to maintain proper alignment with the
wheel, and the guard and its fastenings shall be of
sufficient strength to retain fragments of the wheel in
case of accidental breakage. The maximum angular

February 1993 - 10.0 Hand Tools And Power Tools Page 221
 exposure of the grinding wheel periphery and sides
shall not exceed 180 o.

When safety flanges are required, they shall be used

only with wheels designed to fit the flanges. Only
safety flanges of a type and design and properly
assembled so as to ensure that the pieces of the wheel
will be retained in case of accidental breakage, shall be
used.

All abrasive wheels shall be closely inspected and ring-

tested before mounting to ensure that they are free
from cracks or defects. (See Figure II.39.)

Grinding wheels shall fit freely on the spindle and shall

not be forced on. The spindle nut shall be tightened
only enough to hold the wheel in place. (See Figure
II.40.)

All employees using abrasive wheels shall be protected

by eye protection equipment.

Materials that require grinding shall be placed on the

tool rest with moderate head-on pressure applied.
Materials should not be forced or jammed into the
wheel. Grinding the materials on the sides of the
wheel is an unsafe practice which can damage the
wheel. A grooved or damaged wheel must be
replaced.

February 1993 - 10.0 Hand Tools And Power Tools Page 222
FIGURE II.36: A BRASIVE/GRINDING WHEEL

1 Dimensions

2 Nature of the Abrasive

3 Abrasive Grain Size

4 Grade

5 Structure

6 Bond

7 Maximum Speed

8 Color Stripe = Speed

February 1993 - 10.0 Hand Tools And Power Tools Page 223
FIGURE II.37: GRINDER GUARDS

1. Work rests shall be kept adjusted to the wheel with a maximum gap
of 1/8 inch.

2. Tongue guards shall be kept adjusted closely to the

wheel with a maximum opening of 1/4 inch.

3. The maximum angular exposure of the grinding wheel periphery

should not exceed 90o. This exposure shall begin at a point not
more than 65o above the horizontal plane.

4. Whenever the nature of the work requires contact with the wheel
below the horizontal plane, the exposure shall not exceed 125 o.

February 1993 - 10.0 Hand Tools And Power Tools Page 224
FIGURE II.38: BENCH GRINDER - MACHINE GUARDING

February 1993 - 10.0 Hand Tools And Power Tools Page 225
10.5 Cartridge Operated Tools

10.5.1 General

Cartridge operated tools have a great advantage in that they can

be used in almost any situation without the inconvenience of
trailing leads or hoses. However, it is essential that these tools
be operated only by properly trained personnel who are over 18
years of age. The contractor shall ensure that each man
required to operate such a tool will undergo a thorough training
period and be certified by the tool vendor. Use of cartridge
operated tools will be in accordance with Saudi Aramco GI
2.100, ANSI A10.3-1985 and the manufacturer's specifications
and shall be subject to review and concurrence by the Loss
Prevention Department.

10.5.2 Storage

Safe and secure storage for cartridges and tools must be

provided on the job site. Storage must be fire proof, dry, must
be capable of being locked and should be sited in a clear, but
easily accessible location where constant supervision can be
maintained.

Cartridges and tools must not be stored together. A storage unit

providing positive physical separation of cartridges and tools
(i.e., a wall or partition) is required.

Warning to be posted where cartridges are stored: "DANGER -

NO SMOKING Cartridge Storage".

Ventilation must be provided in the store. Cartons of cartridges

must not be stacked against the wall and ventilation spaces must
be left around the cartons. Only one carton of each strength
cartridge shall be open at any one time. All empty cartons, and
intermediate packing, must be removed at once.

Tools must be stored in their carrying cases. No loose cartridges

must be in the carrying cases; all cartridges must be in their
color coded boxes.

Only authorized personnel must be allowed access to the store.

10.5.3 Selection and Training of Personnel

No person may operate, clean, maintain, or repair any cartridge

tool without possessing a certificate of competency, issued by an
accredited tool vendor or manufacturer's representative, which
identifies the particular model that the person is qualified to
handle.

February 1993 - 10.0 Hand Tools And Power Tools Page 226
 Personnel for training must be selected with the following points
in mind:

1 Must be over 18 years of age.

2 Must be physically fit and have full use of both hands and
both eyes.
3 Should ideally be a tradesman, e.g. plumber, mason,
electrician, joiner/carpenter, etc.
4 Storemen may also need to be trained if they are required
to clean and maintain the tools.

Training, both theoretical and practical, must be given by a

competent instructor.

The training must follow the manufacturer's instructions as

contained in the handbook of each particular model.

10.5.4 Personal Protective Equipment

Eye Protection shall be worn by the operator and his assistant

whenever using the tools. Goggles must be of a satisfactory
standard designed to withstand high speed impacts and/or,
penetrations.

Ear muffs will be available for use at any time and shall be used
in confined spaces.

Safety belts may be required in certain situations where the

recoil from the tool could cause an operator to loose his balance.

February 1993 - 10.0 Hand Tools And Power Tools Page 227
 10.5.5 Issue and Returns

Contractors will ensure that a full register of the serial numbers

of each tool is made and kept up to date.

A log inventory system of issuing and returning cartridges and

tools against signatures must be initiated and maintained. See
Figure II.47: Cartridge/Tool Issuance Control.

Only personnel in possession of a user certificate will be allowed

to withdraw tools or cartridges from the store.

Only the minimum number of cartridges required for that

particular shift's operation should be issued at any one time.

Cartridges and tools must not be left on the job site at lunch
break or at end of shift but must be returned to the store for
safekeeping.

Any loss, either of tools or cartridges, must be reported, at once,

to Saudi Aramco project proponent.

10.5.6 Work Permits

Work Permits will not normally be required for use on job sites.

Where tools will be used in restricted areas (as defined in GI

2.100 Work Permits), a Hot Work Permit must be obtained before
work commences.

10.5.7 Use

No person may operate, clean, maintain or repair any cartridge

tool without possessing a certificate of competency which
identifies the particular model that person is qualified to handle.

The manufacturer's operating instructions must be followed at all

times.

Cartridges are manufactured in different calibers and strengths.

There are three sizes: .25 short, .27 short, and .27 long; and, four
strengths, as follows:

POWER NUMBER COLOR CODE LETTER

LEVEL CODE
Low 3 Green L
Low/Medium 4 Yellow LM
Medium/High 5 Red MH
Extra High 6 Purple/Black EX

It is, therefore, imperative that the correct size and strength of

cartridge required for the tool, the fixing, and the material to be

February 1993 - 10.0 Hand Tools And Power Tools Page 228
 fixed onto be properly determined. A wrongly sized cartridge will
cause a stoppage or misfire.

Using a cartridge which is too powerful could cause a ricochet or

a spalling or fracture of the material.

The following General Safety and Operating Rules are common

to all types of tools:

1 As soon as the tool is removed from its carrying case, check

to make sure that a cartridge is NOT LOADED.

2 Inspect the tool before use each day to ensure that it is

complete, in good condition (e.g., clean), and that the
safety devices are in proper working condition.

3 Any tool that is not in proper working order or that develops

a defect during use, shall be immediately withdrawn from
service and not used until properly repaired.

4 Tools shall not be loaded with a cartridge until just prior to

the intended firing time. When loading a tool, point it away
from you and anyone else. Never walk around with a
loaded tool; load it where you are working. Never leave the
tool loaded when not in use. Loaded tools shall not be left
unattended.

5 Never try to operate the tool without the end of the barrel
hard against the fixing surface.

6 All tools shall be used with the correct shield, guard, or

attachment recommended by the manufacturer.

7 Fasteners shall not be driven into very hard or brittle

materials including, but not limited to, cast iron, glazed tile,
surface hardened steel, glass blocks, hollow tile, terra cotta,
marble, granite, slate, etc.

8 Driving into soft or easily penetrable materials shall be

avoided unless materials are backed by another material
that will prevent the pin from passing completely through
and creating a flying missile hazard on the other side.
Careful inspection of all materials should be made before
deciding on the use of a cartridge tool.

9 No pins shall be driven into a spalled area caused by an

unsatisfactory shot, or into any existing hole in the
material. Care should be taken to ensure that the new
fixing is at least two inches away from any previous hole,
and a similar distance from any welded joint.

10 Pins must not be fired into corner bricks, mortar joints, and
must be at least four (4) inches (100 mm) away from the

February 1993 - 10.0 Hand Tools And Power Tools Page 229
 edge of concrete or brick work and one-half inch (12 mm)
from the edge of steel.

11 Ensure that the correct strength cartridge is used for the

pin, fixing and material involved. For the first, or test firing
use the weakest cartridge. Too strong a cartridge may
result in over penetration, or the fastener may rebound or
ricochet.

12 The tool must be held at right angles to the job when firing.

13 In the event of a misfire, the tool should be re-triggered

without moving the tool from the work face. If the shot
again fails, then the tool must be held firmly in the firing
position for at least 30 seconds to allow for a possible
"Hang Fire" in the cartridge. The removal of the misfired
cartridge must be as per the manufacturer's instructions.
Do not use nails, knives, etc., to pry the cartridge loose.

14 Recoil from firing can throw an operator off balance,

especially when working from ladders or scaffolds. Care
must be taken to ensure that the operator has a secure and
safe work area. Safety belts should be used if necessary.

15 Do not leave cartridges loose on the job site or in the

carrying case or carry them in your pockets. Cartridges are
of the 'Rim Fire' type and could explode accidentally if in
receipt of a knock from a pin, fixing, or even a bunch of
keys.

16 Before returning the tool to the stores, ensure that it is

clean and complete and that all cartridges are in their
correct color coded box.

10.5.8 Maintenance and Repair

Before any repair/maintenance work is carried out, check to

make sure that the tool is NOT LOADED with a cartridge.

No person may operate, clean, maintain or repair any cartridge

tool without possessing a certificate of competency which
identifies the particular model that the person is qualified to
handle.

Tools must be dismantled, as far as the manufacturer's

instructions indicate, at least once every week and checked for
defects and excessive wear before being cleaned and oiled. If
any defect is found, the tool must be made serviceable before
being issued for use.

February 1993 - 10.0 Hand Tools And Power Tools Page 230
 Only manufacturer's authorized spare parts are to be used for
repair/replacement.

NO CARTRIDGES must be allowed in the repair/maintenance

area. Test firing of repaired tools must be done in a safe location
away from work and store or office areas.

10.6 Electrically Operated Tools

10.6.1 General

10.6.1.1

All electrically operated hand tools shall be rated and

used at a voltage not exceeding 125V to ground.

10.6.1.2

Before any electrical tool is used, a careful check shall

be made by the supervisor to ensure that the supply
voltage is within the range marked on the information
plate on the tool. Ground Fault Circuit Interrupters
(GFCIs) are required for all 120 volt, single phase, 15
and 20 ampere receptacle outlets on construction sites
which are not a part of the permanent wiring system.

10.6.1.3

All electrical power hand tools shall be of the double

insulated type or properly grounded.

External metal parts of double insulated tools (drill

chucks, saw blades, etc.) are insulated from the
electrified parts inside the tool and, under normal
conditions, contact with electrified parts of the tool
does not take place. However, under wet conditions,
rain, condensation, high humidity, damp locations, etc.,
the hazards are as great as with faulty grounded tools.
All electrical tools are hazardous when used damp or
wet, but with double insulated tools the moisture
coupled with metal dust, carbon dust, etc. can form a
conductive path from inside the tool to the surface
through the ventilation holes or cracks. Since there is
no ground wire to carry this current away, the user can
receive an electric shock. Double insulated tools, like
all electric tools, must be kept dry and should not be
used without a ground fault circuit interrupter.

10.6.1.4

All tools shall be used with extension cords which are

as short as possible. All extension cords shall be fitted
with grounding pin and blades to fit the socket outlet

February 1993 - 10.0 Hand Tools And Power Tools Page 231
 on the distribution board. Extension cords shall be of
the three-wire conductor type. Plugs and sockets must
meet the National Electrical Code requirement with
respect to grounding and polarity.

Overcurrent protection shall be provided to extension

cords in accordance with the requirements of the
National Electrical Code Article 240. Factors to be
considered for adequate overcurrent protection are:
type of conductors, size, and length of run.

Example: Consider electrical equipment being used on

a construction site that may require 15 or 18 ampere
(amp.) capacity. Construction plans call for three No.
12 AWG (wire size) copper conductors which run to a
20 amp. receptacle (120 v) 40 feet from the electrical
panel box. This circuit is protected by a 20 amp. circuit
breaker. Is this a problem? Yes - There may be three
problems: (1) the size of the conductors, (2) the length
of cable run and, (3) the circuit breaker size.

In order to prevent an employee from receiving an

electric shock, the breaker size and receptacle should
be reduced to 15 amp. or the conductors changed to a
No. 10 AWG so that the breaker can function at 20
amp. when required. Leaving the circuit the way it is
would allow considerable electrical leakage without
tripping the circuit breaker. Also conductor insulation
would be subject to heat damage causing electrical
leakage and fire. Heavy duty construction type
extension cords are required for 20 ampere circuits, No.
14 AWG or larger size for 100 feet of run length. (See
Figure II.41.)

10.6.1.5

Where it is necessary to make electrical splices, these

shall be made with proper connector blocks or by plug
and socket connectors. Taped joints shall not be
permitted.

10.6.2 Maintenance and Storage

A proper inspection and maintenance routine shall be

established by the contractor for all electrical tools. The
inspection and maintenance of all tools shall be carried out at
least once in every working week by a competent electrician.

All tools shall be stored in a clean, dry place, and a record of

issue and receipt shall be maintained by the storekeeper.

February 1993 - 10.0 Hand Tools And Power Tools Page 232
 10.6.3 Personal Protective Equipment

The contractor shall ensure that all operators are provided with
eye, head, and ear protection. If there is any likelihood of
harmful dust being emitted, dust respirators should be used.

10.6.4 Individual Tools, Precautions

10.6.4.1 Grinders

All grinders shall be equipped with a protective guard

which allows only the working part of the wheel to be
exposed. This guard must not be removed.

Grinders shall be clearly marked with their maximum

running speed. The maximum running speed of the
spindle must not exceed the maximum periphery
speed marked on the grinding wheel. Wheels should
be checked for defects before mounting. All defective
wheels must be destroyed. (See Figure II.40.)

10.6.4.2 Drills

Care should be taken not to drill too large a hole at

one time. Drilling of large holes should be done in
stages by using small bore drills and gradually
increasing the size as necessary. If this is not done,
the drill may bind on breakthrough, and the torque set
up could twist the tool against the user's wrist.

10.6.4.3 Saws

Hand operated circular saws shall be fitted with spring

loaded guards which allow only the working part of the
blade to be exposed. (See Figure II.42.)

Portable table saws shall be provided with adjustable

guards, anti-kick-back devices, and push-type
start/stop buttons within easy reach of the operator.
(See Figures II.43 and II.44.) Fixed table saws shall be
hard wired to an emergency electrical disconnect
switch that has the capability of locking out in addition
to having start/stop buttons at the operator's location,
etc. Portable table saws must be unplugged for repair,
maintenance, or when not in use.

Where a provision is made for a table saw riving knife

to be fitted, it shall be kept clean and properly
adjusted to the work at all times. Push sticks must be
provided and used when necessary on all bench saws.

The work area shall be cleaned to prevent excessive

build-up of sawdust and scrap wood.

February 1993 - 10.0 Hand Tools And Power Tools Page 233
 Operators shall wear eye and hearing protection.

10.6.4.4 Radial Saws

(Figure II.45)

Radial saws must be provided with:

· An upper hood to enclose the top portion of the

blade down to a point that includes the end of
the saw arbor. The sides of the lower, exposed
portion of the blade must be guarded to the full
diameter of the blade by a device that
automatically adjusts to the thickness of the
stock being cut.

· Anti-kickback dogs (on both sides of saw)

designed to provide adequate holding power
for all thicknesses of ripping stock.

· An adjustable stop limiting the forward travel of

the blade beyond the distance necessary to
complete the cut in repetitive operations.

· A saw housing which automatically returns to

the starting position.

· A marking on the hood showing the direction of

the saw rotation. In addition, a permanent
label must be affixed to the rear of the guard,
reading: "DANGER. DO NOT RIP OR PLOUGH
FROM THIS END."

· Start/stop buttons at the operator's position.

Additionally, in the case of fixed saws, each
saw must be wired to an emergency electrical
disconnect isolation switch capable of locking
out the saw.

February 1993 - 10.0 Hand Tools And Power Tools Page 234
FIGURE II.39: "RING TEST"

February 1993 - 10.0 Hand Tools And Power Tools Page 235
FIGURE II.40: CORRECTLY MOUNTED GRINDING WHEEL

February 1993 - 10.0 Hand Tools And Power Tools Page 236
FIGURE II.41: WIRE CONVERSION CHART

* Middle Ring American Wire * Outer Ring Allowance

Gauge Ampacities Of Insulated
Conductors Rate 0-2000
Volts, 60o To 90o
("THWN" 75oC Cable
Temperature Ratings)

* Inter Ring Metric or MM2

Note: Ambient Temperature Corrections Factors Must Be Applied As Per

SAES-P-104

February 1993 - 10.0 Hand Tools And Power Tools Page 237
 CMills = MM2 Example 500 mcm AWS 500000 = 250MM2 (Reference N.E.C. Table
310-60)
19735 19735

February 1993 - 10.0 Hand Tools And Power Tools Page 238
FIGURE II.42: SELF ADJUSTING GUARD

As the blade moves up through the

stock,
the guard rises up to the stock surface.

February 1993 - 10.0 Hand Tools And Power Tools Page 239
FIGURE II.43: TABLE SAWS

· Table saws must be provided with a hood that covers the saw at all
times.
· Table saws used for ripping must be equipped with an anti-kickback
device and spreader.
· The exposed part of the saw underneath the table must be guarded.
· Table must be secured in position.
· Guarded start/stop buttons shall be provided at the operator's
position.
· All fixed table saws shall be hard wired to an emergency electrical
disconnect switch capable of locking out the saw.

February 1993 - 10.0 Hand Tools And Power Tools Page 240
FIGURE II.44: TABLE SAWS - MACHINE GUARDING

February 1993 - 10.0 Hand Tools And Power Tools Page 241
FIGURE II.45: RADIAL SAWS

Radial Saws must be provided with:

· An upper hood to enclose the top portion of the blade down to a

point that includes the end of the saw arbor. The sides of the lower,
exposed portion of the blade must be guarded to the full diameter of
the blade by a device that automatically adjusts to the thickness of
the stock being cut.

· Anti-kickback dogs (on both sides of the saw) designed to provide

adequate holding power for all thicknesses of ripping stock.

· An adjustable stop limiting the forward travel of the blade beyond

the distance necessary to complete the cut in repetitive operations.

· A saw housing which automatically returns to the starting position.

· A marking on the hood showing the direction of the saw rotation. In

addition, a permanent label must be affixed to the rear of the guard,
reading: "DANGER. DO NOT RIP OR PLOUGH FROM THIS
END."

· Guarded start/stop buttons shall be located at the operators

position.

· Saw stand shall be secured in position.

· All fixed radial saws shall be hard wired to an emergency electrical

disconnect switch capable of locking out the saw.

February 1993 - Construction Safety Manual: Hand Tools And Power Tools Page 242
FIGURE II.46: THE WOODWORKING MACHINE REGULATIONS

Circular saws are included under types specified as woodworking machines.

Training:
· No person should be employed on a woodworking machine who has not been
trained and instructed in its operation.

Duties Of Employed Persons:

· Employees using woodworking machines must use and keep properly
adjusted guards and other safety devices and use push sticks, jigs, holders
and backstops provided.

Working Environment:
· Sufficient space to be provided around machine to allow work without risk of
injury.
· Floors to be level, in good condition, free of loose material, and not slippery.

Guards:
· Cutters to be guarded to the greatest practicable extent.
· Guards to be of substantial construction, properly secured and adjusted, and
constantly in position while cutters are in motion.

Top Guard:
· Guard to be strong and easily adjustable.
· Adjusted to extend from top of riving knife to a point as close as practicable to
the surface of the material being cut; or to a point not more than 12 mm
above the material being cut where squared stock is being hand held.

Bottom Guard:
· Blade below table to be guarded to the greatest extent practicable.

Push Sticks:
· Must be available for use on every hand-fed circular saw, and used to feed
material-
a) throughout any cut of 300 mm or less
b) during the last 300 mm of any cut more than 300 mm in length
Push sticks should also be used to remove cut material from between the
saw blade and the fence.

February 1993 - 10.0 Hand Tools And Power Tools Page 243
FIGURE II.47: CARTRIDGE/TOOL ISSUANCE CONTROL

Cartridge Quantity Received By

Dat Issue Return Return Returne Tool Cert Name/ Issued By Remarks
e d ed ed d Un- Issued No. Signatu
Used Unused explode (Type/MD re
d L)

Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety Officer:

February 1993 - 10.0 Hand Tools And Power Tools Page 244
11.0 PAINTS AND COATINGS
In addition to the usual hazards associated with construction activities, workmen
engaged in surface preparation and paint application can be exposed to the
dangers of fire, explosion, chemical burns, toxic fumes, dust, and insufficient air.
This section of the manual discusses these hazards and how to minimize them.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 6.021 Safety Requirements For Abrasive Blast Cleaning

GI 8.003 Breathing Apparatus

Saudi Aramco Engineering Standards:

SAES-A-105 Noise

SAES-B-067 Safety Identification and Color Coding

SAES-H-102 Safety Requirements for Painting

Steel Structures Painting Council. Steel Structures Painting Manual, Volumes 1 and
2.

United States of America Code of Federal Regulations, 29 CFR 1910.1000 Air

Contaminants.

11.1 Flammability Hazards of Coating Materials

11.1.1 Flammable Materials

In paint systems, it is normally the organic solvent vapor that is

flammable. In the Saudi Aramco paint system, all the solvents
(except for the water based paints) present a fire hazard.

11.1.2 Flash Point (Definition)

The flash point is defined as the lowest temperature at which a

liquid will give off sufficient vapor to ignite when exposed to an
open flame. For most paint solvents in the Saudi Aramco
system, the flash point is less than the normal ambient
temperatures in Saudi Arabia. The danger of fire exists virtually
always when solvents are in use.

February 1993 - Construction Safety Manual: Paints And Coatings Page 245
 11.1.3 Flammable (Explosive) Limits (Definition)

The lower and upper flammable (explosive) limits define the

range of vapor/air concentrations that are potentially explosive.
The lower flammable (explosive) limit (LEL) is typically on the
order of 1% to 2% by volume, a level readily obtained in the area
near opened solvent containers and near the nozzle of a spray
painting gun in operation.

11.1.4 Fire Precautions

Solvents in paints constitute a significant fire and explosion

hazard when in the presence of ignition sources. No painting
should be carried out within 75 feet of potential ignition sources,
e.g., welding, flame-cutting, smoking areas, or sparking tools,
unless conditions warrant greater clearance.

Ventilation equipment should be used to maintain a maximum

level of solvent concentration, typically below 10% of the LEL.

All electrical lighting and equipment shall be explosion-proof

when required in areas where solvent vapors are likely to be
present.

All electrical equipment such as switches, panel boards,

electrical motors and associated equipment must be de-
energized before spray painting to eliminate explosion hazards.

Solvents and solvent based paints shall not be applied to

surfaces exceeding Saudi Arabia summer ambient temperatures.

The use and storage of flammable paints and solvents shall be

kept to restricted areas and these areas should be suitably
marked with the appropriate warning signs. Flammable paints
should be kept in a special building or in a sun shelter.

Fire extinguishers should be located at the work area and the

area Loss Prevention representative/Fire Chief shall agree upon
their suitability.

Work areas should be kept as clean as practicably possible.

11.2 Health Hazards Associated With Paints

Many paint ingredients are harmful to humans; most people can

withstand these materials over a short time and in small quantities.
However, some people are immediately sensitive to some ingredients
and almost everyone will be affected to some degree if exposed for
sufficient time.

There are two major groups of irritants: toxic materials and dermatitic or
skin irritating materials.

February 1993 - 11.0 Paints And Coatings Page 246

 11.2.1 Toxic Materials

The most abundant toxic materials found in paints and coatings

are solvents. Other toxic materials in paints include pigments
(lead), binders (epoxies, polyesters) and additives (organotin).
Also, dust from cleaning operations or application of the paint
can generate toxic materials. These toxic materials can enter
the body through breathing, ingestion or skin absorption. Most
solvents are toxic to some degree depending on exposure. The
degree of toxicity can be measured by the Permissible Exposure
Limit (PEL) expressed as parts per million (ppm) or milligrams of
particulate per cubic meter (mg/M 3) of solvent in air over an
exposure of 8 hours a day five days a week with no ill effects.

11.2.2 Dermatitic Materials

Dermatitic materials irritate the skin which, if left untreated, can

cause infections or ulceration.

Solvents have a tendency to dissolve and remove natural oils

and fats from skin. Certain binders such as epoxy resins may
also irritate the skin.

Other chemicals used in paint related work should be handled

with care (e.g. paint removers, acid and alkaline cleaners).

11.2.3 Prevention of Health Hazards

Many solvents and coatings contain hazardous ingredients. A

copy of the appropriate Material Safety Data Sheet (MSDS)
should be obtained for all materials used, studied carefully, and
the required safety precautions implemented.

The following precautions should minimize health hazards:

· Identify and seal all toxic and dermatitic materials when not
in use.

· Adequately ventilate all painting areas and provide National

Institute for Occupational Safety and Health (NIOSH), Mine
Safety and Health Administration (MSHA)-approved or
equivalent respiratory protection where necessary. All
workmen spray painting shall wear chemical cartridge
respirators or airline hoods depending upon the hazards of
the paint.

· Minimize dust during surface preparation, and dispose of

coating residue in accordance with the recommendations of
the Environmental Engineering Division, Process and
Control Services Department.

February 1993 - 11.0 Paints And Coatings Page 247

 · Wear the appropriate personnel protective equipment for
the work being carried out.

· Avoid touching any part of the body and wear protective

equipment (e.g. gloves, Tywag suits, etc.) when handling
dermatitic materials. Personnel involved in painting shall
wash thoroughly before eating and at the end of the day.

· Use ventilation control or respirators when working with

paint removers containing toxic solvents.

11.3 Ventilation in Confined Spaces

A supply of clean air is a necessity for all operations involving the

application of coating materials, and the paint curing/drying process. A
high quality air supply is also required for life support (refer to GI 8.003 -
Breathing Apparatus).

Ventilation is a necessity when painting in confined areas because

solvents tend to be heavier than air and migrate to lower levels. The
fresh air inlet of the ventilation system should be located near the top of
the confined space, and the discharge should be located near the
bottom, positioned to eliminate dead air spaces. Supplementary fans
may be necessary to ensure good air circulation.

Natural ventilation through open man ways, etc. is rarely sufficient to

keep local vapor concentrations to a safe level in terms of PELs or LELs.
As a general rule, forced ventilation shall be used, especially in small
enclosures and always during spray painting.

Ventilation requirements are proportionally greater for vessels with a

capacity smaller than 1580 m 3 (10,000 BBL's or 56,000 cu ft). The
recommended ventilation requirements for various vessel capacities are
shown in Table II.6; ref. SAES-H-102.

Ventilating to 10% of the LEL considerably reduces the likelihood of fire

or explosion; however, this level will no doubt exceed the Permissible
Exposure Limits for toxic materials. Hence, supplied air respiratory
protection is required in confined spaces.

The preparation of air used for life support involves the following factors:
PEL's of nuisance and toxic dusts; fume, gas and vapor content; air
temperature. Air required for breathing apparatus shall meet the
requirements of GI 8.003, Breathing Apparatus.

TABLE II.6: VENTILATION REQUIREMENTS FOR CONFINED SPACES

February 1993 - 11.0 Paints And Coatings Page 248

 Volume of Confined Required Air
Area Mover
Capacity
m3 BBL L/s 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

11.4 Surface Preparation

Equipment and materials that are used in surface preparation for paints
and coatings can be hazardous if used carelessly. There are several
methods for preparing surfaces and these include:

· Blast cleaning where abrasives in the form of sand, iron shot, grit,
slag, etc. are used. Other types of blast cleaning use high pressure
water or steam.

· Hand or power tool cleaning includes grinders, sanders, rotary wire

brushes, impact tools, chisels, hammers.

· Chemical cleaning using paint removers, or solvents, alkali, acids or

detergents.

11.4.1 Abrasive Blast Cleaning

This section covers blast cleaning using abrasives in the form of

sand, iron shot, grit, slag or similar materials.

Abrasive blast cleaning operators shall have pre-placement

physical examinations, including chest X-ray and pulmonary
function tests with repeat tests at least every two years.

The abrasive blast cleaning operator shall wear an air supplied

protective hood approved (NIOSH/MSHA or equivalent) for the
type of abrasive material being used and any other toxic
contaminants (lead, zinc, etc.) that are present. Where blast
cleaning assistants could be exposed to silica sand dust or toxic
contaminants, then self-contained or air supplied breathing
apparatus shall be worn by the assistant. The breathing
apparatus and air quality specification shall meet the standards
referenced in GI 8.003, Breathing Apparatus. Personnel (e.g.
maintenance, workers handling abrasive supplies or clean up
crews) within the range of rebound abrasive contaminants shall
wear approved (NIOSH/MSHA or equivalent) dust-filter respirators
for the specific airborne hazards.

February 1993 - 11.0 Paints And Coatings Page 249

 A bonding system that bonds nozzle, hose, blasting equipment
and the material being cleaned shall be provided, and this
bonding system shall be grounded to prevent a build up of static
charges. Ground continuity tests shall be conducted periodically
to ensure proper grounding.

To prevent ignition of hydrocarbons in classified areas, the

appropriate precautions listed in GI 2.100, Work Permit System,
must be followed.

11.4.2 Hydroblast and Steam Cleaning

Hydroblast cleaning uses a high pressure ambient temperature

water jet and steam cleaning uses a high pressure and high
temperature steam jet. Extra caution should be exercised when
using such equipment. These types of equipment are used for
removing dirt or rust scales and the personal protective
equipment requirements are shown in Table II.7.

11.4.3 Hand and Power Tool Cleaning

This section briefly covers the safety aspects of hand and power
tools used for surface preparation.

Particular attention should be paid to eye protection to guard

against flying particles, and where necessary, ear protection
should be provided to prevent long term hearing loss per SAES-
A-105, Noise.

Tools should be correctly selected for the purpose, and also

operated and maintained to the manufacturer's instructions.

Suitable respirators should be used if contaminant levels exceed

Permissible Exposure Limits.

Extreme care should be used if tools have the ability to create

sparks.

11.4.4 Chemical Cleaning

This section is concerned with four types of chemical cleaners

(organic solvents, alkalines, acids and detergents) used to assist
in the removal of surface contaminants such as light oils,
greases and rust.

Solvents such as kerosene, mineral spirits, and turpentine are

used to dissolve and remove oil contaminants. Hazards
associated with solvents include their flammable, toxic and
dermatitic characteristics. Safety precautions regarding these
solvents are included in sections 11.1 and 11.2.

February 1993 - 11.0 Paints And Coatings Page 250

 Alkaline cleaners are composed of highly alkaline salts with
wetting agents and/or soaps. They function by wetting,
emulsifying, dispersing and solubilizing surface contaminants,
and are generally used at elevated temperatures.

Acid cleaners are generally composed of strong acids. They

remove contaminants by chemical attack and are primarily used
to remove metal scales such as rust.

Detergent cleaners are comparable to alkaline cleaners except

they are generally used at low temperatures (60 to 100 degrees
Celsius).

For all of the above chemical cleaners, personal safety

precautions must be taken to protect personnel from materials
and conditions that present fire hazards or cause personnel to
experience dermatitic or toxic effects (such as inhalation effects,
skin burns, or eye irritants).

When using chemical cleaners, appropriate eye and body wash

facilities shall be available in the immediate area to minimize the
effects of chemical burns in the event of an accident.

Chemical cleaning agents such as solvents shall not be used for

cleaning personnel.

The following solvents shall not be used for cleaning purposes

due to the very toxic nature: benzene, gasoline, carbon
tetrachloride, and chlorinated hydrocarbons.

11.4.5 General Safety in Surface Preparation

Instruction and training of operators about correct use of the

cleaning agents and equipment are essential.

Surfaces other than those receiving preparation should be

protected from damage due to cleaning operations.

Where operators are using equipment such as blast cleaners or

power tools, they must have safe footing. Extra caution should
be taken on scaffoldings.

Never point a cleaning gun or nozzle at anyone or any part of

your body.

Equipment such as blast guns and power tools must have

automatic controls that shut off the flow of abrasive and
propellant if for any reason the operator releases the control
switch.

Power tools should be properly grounded to prevent electric

shock.

February 1993 - 11.0 Paints And Coatings Page 251

 All manufacturers recommendations on protective guards shall
be implemented.

Fire and explosion hazards always exist when using solvents,

especially in confined areas. Adequate ventilation must be
provided.

11.5 Personal Protective Equipment

Personal protective equipment is required for the majority of operations

that involve surface preparation or paint application. The amount and
type of personal protection depends on the work being carried out and
the location. Table II.7 gives a summary of essential personal protective
equipment that must be worn by personnel carrying out specific duties.
In addition, all personnel on Saudi Aramco industrial facilities and
potentially hazardous areas must wear safety shoes, a hard safety hat
and safety spectacles. Other protective details such as gloves, face
shields, overalls and hearing protections should be addressed to either
the area Loss Prevention or Industrial Hygiene offices.

February 1993 - 11.0 Paints And Coatings Page 252

TABLE II.7: PERSONAL PROTECTIVE EQUIPMENT TO BE WORN OR USED
DURING SURFACE PREPARATION AND PAINT APPLICATION

TYPE OF WORK PERSONAL PERSONAL

PERFORMED PROTECTIVE PROTECTIVE
EQUIPMENT EQUIPMENT TO BE
TO BE WORN WORN (Confined
(Outside) See key space) See key
Surface preparation
Hand or power tool 3,4,5,9,10,11 3,4,9,10,11
operations
Abrasive blast cleaning
Operator 1,9,10,11 1,8,9,10,11
Other workmen in the 3,4,5,9,10,11 1,8,9,10,11
vicinity
Hydroblast and steam 3,4,5,9,10,11 3,4,5,8,9,10,11
cleaning
Chemical cleaning 4,7,10,11 1,4,7,10,11
Paint application (spray)
Epoxy and coal tar 2,4,6,10,11 1,6,10,11
epoxy
(SAPCS - 1,2 and 3)
Alkyd (SAPCS - 4 and 6) 2,5,6,10,11 1,5,6,10,11
Inorganic zinc 2,5,6,10,11 1,5,6,10,11
(SAPCS -1A, 11A and
17)
Chlorinated rubber 2,5,6,10,11 1,5,6,10,11
(SAPCS - 9)
Bituminous (SAPCS - 10) 2,5,6,10,11 1,5,6,10,11
Polyurethane (SAPCS - 2,5,6,10,11 1,5,6,10,11
25)
Paint application (brush)
Epoxy and coal tar 4,6,10,11 2,4,6,10,11
epoxy
(SAPCS - 1,2 and 3)
Alkyd (SAPCS - 4 and 6) 6,10,11 2,6,10,11
Inorganic zinc 6,10,11 4,6,10,11
(SAPCS -1A, 11A and
17)
Chlorinated rubber 6,10,11 2,6,10,11
(SAPCS - 9)
Bituminous (SAPCS - 10) 6,10,11 2,6,10,11
Polyurethane (SAPCS - 6,10,11 6,10,11
25)

Note: Safety belts / harnesses shall be used when these operations are performed
above ground levels (1.82 m - 6 ft or more) if a guard rail system is not in
place, and / or in confined spaces.
The workman should always refer to the MSDS for complete details.

February 1993 - 11.0 Paints And Coatings Page 253

 Key to Table II.7:

1. OSHA-approved, respirable air fed hood and filter, SAMS No. 21-444-
934
2. Respirator; chemical cartridge, SAMS No. 21-370-800/810/820
3. Dust respirator, SAMS No. 21-370-500
4. Face shield (1), SAMS No. 21-426-121
5. Goggles, safety impact, SAMS No. 21-434-249
6. Gloves, SAMS No. 21-432-XXX
7. Gloves; rubber, SAMS No. 21-432-630
8. Ear protection, SAMS No. 21-327-110
9. Gloves (leather and fabric), SAMS No. 21-432-353
10. Helmets (hard hats), SAMS No. 21-441-055 (MSA) / SAMS No. 21-
441-050 (American Optical)
11. Safety Shoes, SAMS Nos. 21-472-200 / 21-472-221 / 21-472-300 /
21-472-350

11.6 Paint Application

There are numerous hazards associated with paint application and this
section is concerned with air and airless spraying, together with brush
and roller painting.

11.6.1 Paint Materials

The majority of paint solvents, many pigments and some binders

are toxic in addition to having potential dermatitic hazards.
Refer to the Material Safety Data Sheet (MSDS) for information
concerning the hazards associated with their use.

In that, solvent based painting materials also present a fire and

explosion hazards, painting shall not be carried out near an
ignition source. Also, additional care should be taken to provide
adequate ventilation in confined spaces.

Spraying paint using air or airless systems can be very

hazardous and should only be used by trained operators.

11.6.2 General Safety In Paint Application

All personnel involved with the application of paint to surfaces

should wear the appropriate personal protective equipment for
the work being carried out at a given location. For some paint
jobs personal protective equipment may have to exceed the
requirements specified in Table II.7 due to the nature of the work
being performed. Some examples of these jobs are above
ground and water operations, use of special paints, etc.

All pressurized equipment should be handled carefully. Operators

and their assistants should know how to operate and de-energize
the equipment in accordance to manufacturer's
recommendations.

February 1993 - 11.0 Paints And Coatings Page 254

 No spray gun should be pointed at anyone or part of the user's
body.

The spray painting operation should be conducted from the

upwind side of the object being coated, wherever practicable.

Before using airless spray equipment, all guards recommended

by the manufacturer shall be in place and the system shall be in
good order and correctly grounded to prevent static build-up.

Prompt professional medical aid shall be available to any person

receiving paint injuries.

The area around spray painting activity should be enclosed by

hardboard fence or equivalent to protect outside personnel from
paint over spray.

11.7 Scaffolding and Ladders

Details concerning the use and hazards associated with scaffolding and
ladders are included in Section II.9 of the Construction Safety Manual.

Only good condition, correctly erected equipment shall be used that

meets industry standards (ANSI) or equivalent. Users and erectors of
such equipment should be trained about its use and limitations.

11.8 Tarring Operations

Tarring operations are commonly used in roof work, and hazards

associated with this type of work include body burns, fire and toxicity.
Precautions that are required for tar operations include:

· The heating of tar shall not be carried out on roof tops or in similar
potentially hazardous locations.

· Tar heating operations shall be carried out using approved fuel gas
in the correct cylinders. The heating operations shall be at ground
level and at a minimum distance of 4.5 m (15 feet) away from fuel
gas cylinders, buildings or similar structures.

· The transferring of hot tar to its required location shall be carried out
using the safest mode of transport available (preferably pumped).
Lifting of hot asphalt in buckets is not allowed.

· The temperature of the asphalt shall be monitored with a

temperature gauge and must not exceed 450 0F at any time during
the tarring operations.

In addition to personal protective equipment (safety shoes, safety

glasses and hard hats), the following shall be provided for all personnel
directly involved in tar operations: face shields, leather gloves, cotton

February 1993 - 11.0 Paints And Coatings Page 255

 overalls, and heat resistant aprons. Also, respiration protection may be
required in confined spaces.

11.9 General Safety for Paints and Coatings

Safety precautions concerning various stages of paints and coatings are

mentioned under their respective sub-headings of Section 11. This
section is provided to highlight areas of paints and coating operations
not covered under an individual sub-heading.

* Colors - All color coding shall conform to the requirements in SAES-

B-067: Safety Identification and Color-Coding. Colors reserved for
safety use within Saudi Aramco are red, green, yellow and black,
orange and blue. Some equipment identified by color coding that
may be required by painters include:

Fire protection: red.

Emergency stops: red.
Danger signs: red.
Emergency safety equipment and instructions (eye wash,
showers, first aid): green.
Hazards (physical and radioactive): yellow/black.
Potable water: blue.

* Breathing Air - Before breathing air used for respiration purposes, it

must be checked to ensure it meets the quality requirements
referenced in GI 8.003. Once compressors providing breathing air
have conformed to the requirements of GI 8.003, they shall be re-
tested every quarter to ensure that air quality remains satisfactory.

* Personal Protective Equipment - Depending on the work being

carried out and its location, appropriate personal protective
equipment must be worn that meets both the manufacturers
requirements and those of Saudi Aramco. Personal protective
equipment shall be in good condition.

* Blast Cleaning - Abrasive blast cleaning equipment and abrasive

materials shall be suitable for the work to be carried out;
substandard products will be removed from Saudi Aramco facilities.

* Signs and Barricades - Areas where hazardous work is being carried

out (such as abrasive blast cleaning and airless spraying) shall be
suitably barricaded to keep personnel out of the hazardous area, or
the timing of the work shall be such that only the work crew doing
the job is present at the site, or a lookout is posted around the site.
Warning signs shall be posted in hazardous areas with suitable
warnings of the potential dangers (i.e., "No entry, sand blasting in
progress").

* Paints and Solvents - The amount of paints and solvents stored at

the site shall be restricted to a day's requirements. Bulk storage of
paints and solvents shall be in a designated, well marked safe area
away from the work area and protected from the sun's heat.

February 1993 - 11.0 Paints And Coatings Page 256

 * Work Permits - The Saudi Aramco work permit system shall always
be used where necessary for all aspects of paints and coatings
(reference GI 2.100).

* Equipment - Before any equipment is used, operators and assistants

shall be trained on the equipment's use and operation. Also, the
equipment shall be in good working order, have an automatic shut-
off system and all safety guards installed.

* Personal Health - Personnel involved with using paints, solvents and

cleaning equipment (i.e., sand blasting) shall be in good health and
have medical examinations by professional medical staff at least
every two years.

* Assistants - No one shall work alone in hazardous areas. An

assistant shall always be available or the "buddy" system used.

February 1993 - 11.0 Paints And Coatings Page 257

12.0 CONCRETE, CONCRETE FORMS, AND SHORING

12.1 General

All equipment and materials used in concrete construction and masonry

work shall meet the applicable requirements for design, construction,
inspection, testing, maintenance, and operations.

12.2 Reinforcing Steel

Employees working more than 1.8 meters (6 feet) above any adjacent
working surfaces, placing and tying reinforcing steel in walls, piers,
columns, etc., shall be provided with proper work platforms with a
guardrail system. When work is to be accomplished outside a work
platform, a safety belt shall be worn that is securely fixed to a dropline or
anchor.

Employees shall not be permitted to work above vertically protruding

reinforcing steel unless it has been bent over or capped.

Guying: Reinforcing steel for walls, piers, columns, and similar vertical
form work structures shall be guyed and supported to prevent collapse
and to guard against possible wind pressures.

Wire mesh rolls: Wire mesh rolls shall be secured at each end to
prevent dangerous recoiling action.

12.3 Bulk Concrete Handling

Bulk storage bins, containers, or silos shall have conical or tapered

bottoms with mechanical or pneumatic means of starting the flow of
material.

12.4 Concrete Placement

12.4.1 Concrete Mixers

Concrete mixers equipped with 0.75 cubic meter (1 cubic yard)

or larger loading skips shall be equipped with a mechanical
device to clear the skip of concrete.

12.4.2 Guardrails

Mixers of 0.75 cubic meter (1 cubic yard) capacity or greater

shall be equipped with protective guardrails installed on each
side of the skip.

February 1993 - Construction Safety Manual: Concrete, Concrete Forms And Shoring Page 258
 12.4.3 Bull Floats

Handles on bull floats, used where they may contact energized

electrical conductors, shall be constructed of non-conductive
material, or insulated with a non-conductive sheath whose
electrical and mechanical characteristics provide the equivalent
protection to a handle constructed of non-conductive material.

12.4.4 Powered Concrete Trowels

Powered and rotating-type concrete troweling machines that are

manually guided shall be equipped with a control switch that will
automatically shut off the power whenever the operator removes
his hands from the equipment handles. The rotating blades shall
be guarded at the top and outer perimeter.

12.4.5 Concrete Buggies

Handles of buggies shall not extend beyond the wheels on either

side of the buggy. Installation of knuckle guards on buggy
handles is recommended to protect the hands.

12.4.6 Pumpcrete Systems

Pumpcrete or similar systems using discharge pipes shall be

provided with pipe supports designed for 100 percent overload.
Compressed air hose in such systems shall be provided with
positive fail-safe joint connectors to prevent separation of
sections when pressurized.

12.4.7 Concrete Buckets

Concrete buckets equipped with hydraulic or pneumatically

operated gates shall have positive safety latches or similar
safety devices installed. Prevent aggregate and loose material
from accumulating on the top and sides of the bucket.

Riding of concrete buckets for any purpose shall be prohibited,

and vibrator crews shall be kept out from under concrete buckets
suspended from cranes or cable ways.

12.4.8 Discharging on Slope

When discharging on a slope, the wheels of ready-mix trucks

shall be blocked and the brakes set to prevent movement.

12.4.9 Back-Up Man, Truck Spotter

Back-up man, ready-mix truck spotter shall be used to back

ready-mix trucks.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 259
 12.4.10 Pneumatic Hose

Nozzleman applying a cement, sand, and water mixture through

a pneumatic hose shall be required to wear protective head and
face equipment.

12.5 Vertical Shoring

12.5.1 General Requirements

When temporary storage of reinforcing rods, material, or

equipment on top of form work becomes necessary, these areas
shall be strengthened, shored to meet the intended loads.

The sills for shoring shall be sound, rigid, and capable of carrying
the maximum intended load.

All shoring equipment shall be inspected prior to erection to

determine that it is as specified in the shoring layout. Any
equipment found to be damaged shall not be used for shoring.

Erected shoring equipment shall be inspected immediately prior

to and immediately after the placement of concrete. Any shoring
equipment that is found to be damaged or weakened shall be
immediately reinforced or re-shored.

Re-shoring shall be provided when necessary to safely support

slabs and beams after stripping, or where such members are
subjected to superimposed loads due to construction work done.

12.5.2 Tubular Welded Frame Shoring

Metal tubular frames used for shoring shall not be loaded beyond
the safe working load recommended by the manufacturer.

All locking devices on frames and braces shall be in good

working order; coupling pins shall align the frame or panel legs;
pivoted cross braces shall have their center pivot in place; and
all components shall be in a condition similar to that of original
manufacture.

When checking the erected shoring frames with the shoring

layout, the spacing between towers and cross brace spacing
shall not exceed that shown on the layout, and all locking
devices shall be in the closed position.

Devices for attaching the external lateral stability bracing shall

be securely fastened to the legs of the shoring frames.

All base plates, shore heads, extension devices, or adjustment

screws shall be in firm contact with the footing sill and the form.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 260
12.6 Forms and Shoring

12.6.1 General Provisions

Form work and shoring shall be designed, erected, supported,

braced, and maintained so that it will safely support all vertical
and lateral loads that may be imposed upon it during placement
of concrete.

Personnel shall not be allowed under or in close proximity of the

form work during pour operations.

Personnel not engaged in the pour operation shall stay clear of

the pour area. A clear area shall be maintained at 1-1/2 times
the highest point of the form work.

Drawings or plans showing the jack layout, form work, shoring,

working decks, and scaffolding, shall be available at the job site.

Stripped forms and shoring shall be removed and stockpiled

promptly after stripping, in all areas in which persons are
required to work or pass. Protruding nails, wire ties, and other
form accessories not necessary to subsequent work shall be
pulled, cut, or other means taken to eliminate the hazard.

Imposition of any construction loads on the partially completed

structure shall not be permitted unless such loading has been
considered in the design and approved by the engineer-architect.

12.6.2 Vertical Slip Forms

The steel rods or pipe on which the jacks climb or by which the
forms are lifted shall be specifically designed for the purpose.
Such rods shall be adequately braced where not encased in
concrete.

Jacks and vertical supports shall be positioned in such a manner

that the vertical loads are distributed equally and do not exceed
the capacity of the jacks.

The jacks or other lifting devices shall be provided with

mechanical dogs or other automatic holding devices to provide
protection in case of failure of the power supply of the lifting
mechanism.

Lifting shall proceed steadily and uniformly and shall not exceed
the predetermined safe rate of lift or concrete cure.

Lateral and diagonal bracing of the forms shall be provided to

prevent excessive distortion of the structure during the jacking
operation.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 261
 During jacking operations, the form structure shall be maintained
in line and plumb.

All vertical lift forms shall be provided with scaffolding or work

platforms completely encircling the area of placement with
intermittent tie breaks to ensure that superimposed loads on the
scaffold/work platforms cannot pull down the entire scaffold
works.

12.6.3 Tube and Coupler Shoring

Couplers (clamps) shall not be used if they are deformed, broken,

or have defective or missing threads on bolts, or other defects.

The material used for the couplers (clamps) shall be of a

structural type such as drop-forged steel, malleable iron, or
structural grade aluminum. Gray cast iron shall not be used.

When checking the erected shoring towers with the shoring

layout, the spacing between posts shall not exceed that shown
on the layout, and all interlocking of tubular members and
tightness of couplers shall be checked.

All base plates, shore heads, extension devices, or adjustment

screws shall be in firm contact with the footing sill and the form
material and shall be snug against the posts.

12.6.4 Single Post Shores

For stability, single post shores shall be horizontally braced in

both the longitudinal and transverse directions, and diagonal
bracing shall also be installed. Such bracing shall be installed as
the shores are being erected.

All base plates or shore heads of single post shores shall be in

firm contact with the footing sill and the form materials.

Whenever single post shores are used in more than one tier, the
layout shall be designed and inspected by a structural engineer.
Lay-out to be submitted to Saudi Aramco for approval.

When form work is at an angle, or sloping, or when the surface

shored is sloping, the shoring shall be designed for such loading.

Adjustment of single post shores to raise form work shall not be

made after concrete is in place

Fabricated single post shores shall not be used if heavily rusted,

bent, dented, re-welded, or having broken weldments or other
defects. If they contain timber, they shall not be used if timber is
split, cut, has sections removed, is rotted, or otherwise
structurally damaged.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 262
 All timber and adjusting devices to be used for adjustable timber
single post shores shall be inspected before erection.

Timber shall not be used if it is split, cut, has sections removed,

is rotted, or is otherwise structurally damaged.

Adjusting devices shall not be used if heavily rusted, bent,

dented, re-welded, or having broken weldments or other defects.

All nails used to secure bracing or adjustable timber single post

shores shall be driven home and the point of the nail bent over if
possible.

February 1993 - 12.0 Concrete, Concrete Forms, And Shoring Page 263
III. Mechanical Equipment And
Materials

February 1993 - Construction Safety Manual - III. Mechanical Equipment And Materials Page 264
1.0 CRANES AND LIFTING EQUIPMENT
SAUDI ARAMCO INSTRUCTIONS AND STANDARDS

ALL REFERENCED STANDARDS ARE INCORPORATED INTO THIS SECTION.

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 2.702. Electrical Safety for Boom or Derrick Type Hoisting Equipment

GI 6.029. Reporting and Recording Of Motor Vehicle Accidents

GI 7.024. Marine and Offshore Cranes and Rigging

GI 7.025. Mobile Heavy Equipment Operator Testing and Certification

GI 7.026. Cranes and Heavy Equipment Accident Reporting

GI 7.027. Personnel Work Platform Operations

GI 7.028. Crane Lifts: Types and Procedures

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

GI 7.030. Inspection and Testing of Cranes, Elevators, Powered Platforms, and

Mobile Aerial Baskets

Refinery Instruction Manual:

1.087. Precautions to be taken for Operating Cranes near Overhead Power

Lines

1.808. Operating Cranes

Heavy Equipment Operator Licensing Information, Attachment No. III.1

Schedule 'D':
Saudi Aramco Safety, Health and Environmental Requirements -
Cranes and Rigging Equipment

Saudi Aramco Crane Safety Handbook

Riggers Handbook

American Petroleum Institute:

API SPEC 2C Specification for Offshore Cranes

API SPEC 2D Operation and Maintenance of Offshore Cranes

February 1993 - Construction Safety Manual: Cranes And Lifting Equipment Page 265
Contractor Liaison Notice No. 5.

Procedure for Obtaining Crane and Heavy Equipment Operator's

Licenses for Expatriate Employees (See Appendix F)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A10.4. Safety Requirements

ANSI 30.2. Overhead and Gantry Cranes

ANSI B30.3. Hammerhead Tower Cranes

ANSI B30.4. Portal, Tower and Pillar Cranes

ANSI B30.5. Mobile and Locomotive Cranes

ASME B30.6. Derricks

ASME B30.8. Floating Cranes and Floating Derricks

ASME B30.14. Side Boom Tractors

ANSI B30.16. Overhead Hoists

ANSI B30.22. Articulating Boom Cranes

1.1 Competent Person

A competent person is a person who, by possession of a recognized

pertinent degree or certificate of professional standing, or who by
extensive knowledge, training and experience has successfully
demonstrated the ability to solve or resolve problems relating to safe
crane operations and procedures (e.g. Rigger Technician, Crane and
Rigging Specialist, etc.). A competent person shall supervise all lifts.

1.2 Saudi Aramco Crane Operations (General Requirements)

Before beginning any crane operation, the supervisor and operator

should complete the pre-operation checklist (Figure III.1). A lift plan
required as a part of this procedure must provide the following
information:

1. Crane radius
2. Boom length
3. Safe working limits of the crane (load chart)
4. Weight of the load
5. Ground and site conditions
6. Placement of the crane
7. Swing and tail clearances
8. Necessary communication to be used
9. Explanation of hand signals

February 1993 - 1.0 Cranes and Lifting Equpment Page 266

 10. Rigging hardware
11. Rigging sketch for critical or hazardous lifts
12. Rated capacity of rigging components
13. Sling angles
14. Strain calculations
15. Wind velocity
16. Load moment indicator
17. Other

One competent person shall be placed in charge of the lift with the
responsibility of explaining in detail, the duties of all involved in the lift
before the actual lift commences. The outriggers must be fully extended
prior to the lift, and the rubber tires must be off the ground (see Figure
III.2, Crane Lift Plan).

Cranes shall have a valid Crane Safety inspection sticker issued by the
Saudi Aramco Crane, Communication, and Facilities Inspection Unit.
(See GI 7.030.)

1.3 Saudi Aramco Crane Operator Qualifications

A valid SAG heavy equipment license and Saudi Aramco Crane Operator
Certificate are required for all contractor mobile crane operators.
Contact the Vehicle & Heavy Equipment Training and Testing Unit (Tel.
Nos. 875-4347/874-1857) to operate specific mobile heavy equipment.
(See GI 7.025.)

1.4 Special Crane Operating Procedures

Heavy lifts, critical lifts, and crane personnel work platform operations
require special procedures outlined in the Saudi Aramco General
Instructions. The Heavy Haul Unit, Transportation Dept., Abqaiq should
be contacted and lift plans/work permits submitted. (See GI's 7.027,
and 7.028.)

1.5 Effect of Wind Speeds on Crane Operations

When wind velocities are above 32 km/h (20 mph), the rated load and
boom lengths shall be reduced according to manufacturer specifications.
Wind forces are greater at height by as much as 35% or more. All lifts
above ground level, must account for wind force, i.e., side loads, down
drafts, etc. as applied to the load and boom. (See TABLES III.1 and III.2.)

February 1993 - 1.0 Cranes and Lifting Equpment Page 267

1.6 Overhead Power Lines

There is an area surrounding every power line that is referred to as the

absolute limit of approach. It is strictly forbidden to move any crane
boom or load line or load into this are unless the line has been de-
energized or insulated. There are no exceptions. The absolute limit
of approach varies according to the following table:

Line Voltage Absolute Limit Of

Approach
Up to 250,000 volts 20 feet (6 meters)
Over 250,000 25 feet (7.5 meters)

February 1993 - 1.0 Cranes and Lifting Equpment Page 268

FIGURE III.1: PRE-LIFT OPERATION CHECKLIST

· OPERATOR:

- CURRENT SAUDI ARAB GOVERNMENT CRANE OPERATORS' LICENSE

- CURRENT SAUDI ARAMCO OPERATORS' CERTIFICATE

· OUTRIGGERS:

- FULLY EXTENDED
- LEVEL GROUND
- COMPACT SOIL
- HEAVY PAD SUPPORTS
- LOCKING PINS/LOCKS SET
- NO HYDRAULIC LEAKS
- NO DAMAGE
- GOOD CONDITION
- WHEELS OFF THE GROUND

· OPERATION:

- CURRENT CRANE SAFETY INSPECTION STICKER

- CLEAR 360o VISIBILITY
- NO SHADES/CURTAINS IN CAB
- LOAD CHARTS IN CAB
- CLEAR VISIBILITY
- WIND, ABOVE 20 m/h (32 km/h), NO GO
- DO NOT OPERATE DURING STORMS AND AT NIGHT
- LIGHTNING, NO GO
- BARRICADE CRANE CAB SWING AREA
- TAG LINES IN USE
- CLEAR OVERHEAD POWER LINES
- CLEAR AREA OF PERSONNEL 1-1/2 x BOOM LENGTHS
- NO LIFTS OVER WORKERS OR CRITICAL PROPERTY
- TRIAL LIFT, FLOAT LOAD ONE METER OFF GROUND TO CHECK
BALANCE
- CLEAR VIEW OF SIGNAL MAN (RIGGER)
- DO NOT PULL LOADS WITH CRANE
- LOAD RADIUS INDICATOR
- MAN LIFT WORK PERMIT
- ANTI-TWO BLOCK OPERATIONAL
- LMI (LOAD MOMENT INDICATOR) OPERATIONAL

· RIGGING:

- CHECK ALL RIGGING FOR DAMAGE

- CHECK SLING LOAD CAPACITY
- CHECK BLOCK, HOOKS, etc. FOR DAMAGE
- HOOK SAFETY LATCH IN PLACE
- RECORD WEIGHT OF LOAD
- RECORD WEIGHT OF CRANE GEAR, ADD CRANE GEAR WEIGHT TO
TOTAL WEIGHT

February 1993 - 1.0 Cranes and Lifting Equpment Page 269

 - LIFT PLAN APPROVED
- USE LOAD WEIGHT MEASURING DEVICE FOR UNKNOWN LOADS

· TRAVELING:

- BLOCK SECURED
- TIRES PROPERLY INFLATED AND IN GOOD CONDITION
- BRAKE LIGHTS, SIGNALS, MIRRORS, HORN OPERATIONAL
- ROUTE PLAN CHECKED FOR FIRM GROUND, OVERHEAD AND SIDE
RESTRICTIONS
- ESCORT VEHICLES REQUIRED WITH FLASHING BEACON LIGHTS
- SPEED TO BE MAINTAINED FOR SAFE LIMITS (SLOW AS POSSIBLE)

· PARKING:
- BOOM AND HOOK BLOCK(S) LOWERED TO TRAVEL POSITION
- APPLY SWING BRAKE AND POSITIVE SWING LOCK
- TIE DOWN HOOK BLOCK(S)
- RETRACT STABILIZERS
- RETRACT OUTRIGGERS
- EXTEND STABILIZERS AND LATCH ONTO FLOAT PADS
- WEIGHT OF CHASSIS OFF THE TIRES
- LET ENGINE IDLE 3-5 MINUTES
REMOVE ALL FOREIGN MATERIAL FROM CAB(S)
- CLOSE ALL DOORS, WINDOWS, SKYLIGHTS AND COMPARTMENTS
- TURN OFF SWITCHES
- STOP ENGINE

February 1993 - 1.0 Cranes and Lifting Equpment Page 270

FIGURE III.2: LIFT PLAN FOR CRANES
1. Contractor:__________________________________________________ J.0. No.:_____________________________________________
2. Crane Inspection Sticker valid: Yes: No: Date of
expiry:________________________________________________________________
3. Operator Saudi Aramco certified: Yes: No: 4. Description of
load:___________________________________________________
5. ·Type of crane to be used Stowed Erected N/A (lbs/kgs)
______________________
·Boom length (total) Jib:    _______
_______________________ft/m
·Jib length Extension:    _______
______________________________ft/m
Hookblock (Main): ______ _____ _____ _______
Aux. Boom Head: ______   _______
Headache Ball: ______   _______
Slings, Shackles, ______ ______ ______ _______
etc.:
Others: __________________________________ _______
__________________________________ _______
Total (Gross Load _______
Weight):

6. ·Weight of load · Effective weight of jib _____ lbs/kgs (see jib

_______lbs/kgs chart)
·Effective weight of jib headache ball · Weight of load block _____ lbs/kgs
______ lbs/kgs
·Weight of hoist rope below boom tip______ · Weight of spreader bar _____ lbs/kgs
lbs/kgs
·Weight of other rigging ______
lbs/kgs
Total load weight _____ lbs/kgs
7. Hoisting clearance ________ft/m. 8. Lift quadrant zone ___________________ . 9. Operating radius ___________ft/m.
10. Crane capacity at operating radius __________ (Note: Do not make lift if total load is greater than crane capacity shown
in Item 10. Refer to GI 7.028 for appropriate derating based on type of lift.)
11. Crane capacity for jib configuration:____________ 12. Ground and site
conditions:______________________________________________
13. Wind speed:__________mph (Maximum 20 mph)
14. Work permit required: Yes No:
15. Load moment indicator: Yes: No: Type:_________________________________________

February 1993- Cranes And Lifting Equipment Page 271

16. Sketch and supplementary information for crane lift is required to be attached to this plan. (Note: The sketch of the
crane should include the following rigging information: size of each component; safe working load (SWL) capacity;
length of slings; type of component; component diameter; weight of component and sling angles).
Contractor:______________________ Date:__________________ Crane Operator:_______________________
Date:__________________________
Approved:_______________________ Date:__________________ Reviewed by:_____________________
Date:_____________________________
(Competent Person) (Saudi Aramco Site Representative)
Approved:_______________________ Date:__________________
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
Footnote: This form is to be filled out for the following lifts: 1. At all construction sites and operating plants;
2. Associated with offshore and marine sites and operations; 3. Within safety zones of power lines; 4.
Involving personnel platforms (as per GI 7.027, 7.028 and 7.030).

February 1993 - 1.0 Cranes and Lifting Equpment Page 272

TABLE III.1: WIND SPEED (MILES PER HOUR) VS. FORCE OF WIND IN POUNDS PER
SQUARE FOOT

MILES FORCE PER SQUARE

PER HOUR FOOT, POUNDS
1 .004
2 .014
3 .036
4 .064
5 .1
10 .4
15 .9
20 1.6
TABLE III.2: WIND SPEED DEFINITION

The following table lists speed, in the major units, relative to Beaufortwind Scale
Numbers, the internationally accepted reference for wind force:

Beaufort Descriptio Knots M/Sec KM/H Miles/H

Numbers n
0 Calm 0-1 0-0.51 0-1.84 0-1.15
1 Light Air 1-3 0.51-1.53 1.84-5.52 1.15-3.45
2 Light 4-6 2.04-3.07 7.36-11.04 4.6-6.9
Breeze
3 Gentle 7-10 3.58-5.11 12.88-18.4 8.05-11.5
Breeze
4 Moderate 11-16 5.62-8.18 20.24- 12.65-18.4
Breeze 29.44
5 Fresh 17-21 8.69-10.73 31.28- 19.55-24.15
Breeze 38.64
6 Strong 22-27 11.24- 40.48- 25.3-31.05
Breeze 13.80 49.68
7 Near Gale 28-33 14.31- 51.52- 32.2-37.95
16.87 60.72
8 Gale 34.40 17.38- 62.56-73.6 39.1-46
20.44
9 Strong Gale 41-47 20.96- 75.44- 47.15-54.05
24.02 86.48
10 Storm 48-55 24.53- 88.32- 55.2-63.25
28.11 101.2
11 Violent 56-63 28.62- 103.04- 64.4-72.45
Storm 32.20 115.92
12 Hurricane 64+ 32.71+ 117.76+ 73.6

Reference: GROVE COLES CRANE SPECIFICATION BULLETIN NO. 045

February 1993 - 1.0 Cranes And Lifting Equipment Page 273

2.0 SLINGS AND LIFTING GEAR (RIGGING)
Saudi Aramco General Instructions:

GI 7.027. Personnel Work Platform Operations

GI 7.029. Inspection, Testing and Maintenance of Wire Rope Slings

American National Standards:

ANSI B30.5. Mobile and Locomotive Cranes

ANSI B30.9. Slings

ANSI B30.10. Hooks

ANSI B30.20. Below the Hook Lifting Devices

ANSI B30.21. Manually Lever Operated Hoists

Saudi Aramco Crane Safety Handbook (See Appendix E)

Saudi Aramco Riggers Handbook

Saudi Aramco Inspection Procedures

07-AIP-0I-P Inspection of Steel Wire Rope Slings

2.1. Safe Working Load (SWL)

Slings and other rigging equipment must be constructed according to a

recognized standard.

The safe working load of rigging equipment is the maximum load which
the equipment should be subjected to; this load should never be
exceeded.

Before use, all new equipment should be subjected to a proof load test
by the manufacturer and certified. The safe working load and serial
number shall be clearly marked on the sling and the lifting gear, either
by tagging, stamping, engraving, or embossing. Riggers shall not use
lifting gear unless the safe working load is clearly visible (see Figures III.3
and III.6).

Slings shall not be tagged with an safe working load in the field.
Approval by the Inspection Department and subsequent review by the
Loss Prevention Department is required.

February 1993 - Construction Safety Manual: Slings And Lifting Gear Page 274
2.2. Chain Slings

2.2.1 Grades

Only alloy steel chain complying with ASTM A391 shall be used.
Other grades are subject to approval by the Saudi Aramco Crane,
Communications and Facilities Inspection Unit [CCFIU] (see
Figure III.5).

Each grade of chain should be clearly tagged by the

manufacturer, and riggers should be trained to look for the safe
working load marked on each sling. They shall be forbidden to
use any equipment unless the safe working load is clearly
visible.

All attached fittings (hooks, rings, etc.,) shall be as prescribed by

the manufacturer. Hooks, shackles, and eyebolts shall be equal
to or exceed the safe working load of the chain.

2.2.2 Repairs

Modern chains are produced under closely controlled factory

conditions using proper heat treatment and testing procedures.
On-site welding repairs cannot provide the necessary controlled
conditions to safely repair a damaged chain. Damaged chains
must be returned to the manufacturer for repair or destroyed. In
particular, watch for bent links, cracked welds, and excessive
wear.

2.2.3

Logger chains or chains used to secure truck loads shall not be

used for rigging.

2.3 Wire Rope Slings

2.3.1

Wire rope is the most common type of sling in use on

construction sites. It is essential that each wire rope sling is
properly constructed and used. All wire rope slings shall be
manufactured, inspected, and load tested by a recognized
manufacturer. Homemade wire rope slings shall not be allowed
at Saudi Aramco unless they meet all standards and pass
inspection by CCFIU.

2.3.2 Damaged slings shall be destroyed if there are:

2.3.2.1

* 10 random broken wires in one lay.

February 1993 - 2.0 Slings And Lifting Gear Page 275

 * 4 broken wires in one strand of a rope lay.
* One broken wire at the fitting.

2.3.2.2

* Severe localized abrasion or scraping.

2.3.2.3

* Kinking, crushing, birdcaging, or any other damage

causing distortion.

2.3.2.4

* Evidence of heat damage.

2.3.2.5

* End attachments are cracked, deformed, or

excessively worn.

2.3.2.6

* Bent or opened hooks.

2.3.2.7

* Severe corrosion.

2.3.3

Each sling shall bear a permanent manufacturer's identification

stating the safe working load (SWL) in tons and serial number.
Proof load test and documentation of testing is required from the
manufacturer (see Figures III.3 and III.6).

2.3.4

Wire rope clips (bulldog clips or crosby clips) shall not be used to
make slings.

2.4 Synthetic Webbing Slings

These are manufactured from woven man-made fiber. Their strength lies
in the width of their bearing surface. These slings must not be subjected
to point loading, sharp edged objects, and non-vertical lifting (see Figure
III.7). Synthetic web slings shall be marked with a stitched in label to
show:

(a) Name or trademark of manufacturer

(b) Rated capacity for each type of hitch
(c) Type of material

February 1993 - 2.0 Slings And Lifting Gear Page 276

 2.4.1 Removal from Service

Slings which have been damaged or are defective in any way

shall be immediately removed from service, cut up and
destroyed.

2.4.2 Repaired Slings

The use of repaired slings is prohibited.

2.5 Synthetic and Natural Fiber Rope Slings

2.5.1

Each synthetic and natural fiber rope sling shall be permanently

marked to show:

2.5.1.1 Name or trademark of manufacturer

2.5.1.2 Manufacturer's code or stock number

2.5.1.3 Rated loads for the types of hitches used

2.5.1.4 Type of natural or synthetic material

2.5.1.5 Date of manufacture

2.5.2

All associated rigging hardware shall equal or exceed the safe

working load rating of the rope sling.

2.5.3

Slings shall be removed from service and destroyed when:

2.5.3.1

* The fibers are cut, badly abraded or seriously worn.

2.5.3.2

* There is considerable filament or fiber breakage (a

light fuzzing is acceptable) on the surface.

2.5.3.3

* There are particles of broken filament or fibers

inside the rope between strands.

February 1993 - 2.0 Slings And Lifting Gear Page 277

 2.5.3.4

* There is other damage visible such as: melting or

charring, kinks or hackles, knots, damaged fittings.

2.6 Care of Slings

The following points must be considered in the storage and handling of

slings:

2.6.1

Slings will undergo shock loading when a load is suddenly lifted

or when the hoisting is abruptly stopped. This can be caused by
the sudden application of the crane brake, the jerking of the load
by poor operation, or the sling slipping on the load. A shock load
can increase the normal working load by as much as five times
its value.

2.6.2

As the angle between the legs of a multiple sling increases, the

safe working load decreases. The included angle should be no
more than 900 and must never exceed 120 o under any
circumstances (see Figure III.9).

2.6.3

Before storage, chain and wire rope slings should be cleaned,

lightly lubricated, and inspected. Slings must be stored in a
location where they are not liable to suffer mechanical damage,
away from extremes of heat, cold, and especially dampness.

2.6.4

Contractors shall maintain a job site log of slings containing the

following information: ID. number; date in service; safe working
load as stated in proof load certificate; full details of periodic
inspections (see Figure III.13).

2.6.5

All rigging shall be inspected at least every six months per ANSI
B30.9, and a Sling Inspection Report shall be completed and
filed for review by the Crane Inspector to comply with GI 7.029.

February 1993 - 2.0 Slings And Lifting Gear Page 278

2.7 Hooks

2.7.1

Hooks should be fitted with a safety catch on the hook opening,

or should be moused with wire and a shackle used or the hook
should be designed so that the slings cannot be displaced (Figure
III.11).

2.7.2

Loads should be applied on the hook only in the part designed to

take them (i.e. the bend [bow] of the hook). Point loading can
result in over stressing the hook causing it to open or break.
Therefore, point loading shall not be permitted.

2.7.3

Hooks should be regularly inspected for signs of damage.

2.7.4

The hook shall be removed from service for the following

reasons:

1. If there are visible cracks

2. If it is twisted 10o out of place
3. If there is a 15% throat opening beyond the
manufacturer's specification

A thorough examination shall be carried out each year by a

qualified inspector.

2.8 Spreader Bars

2.8.1

All spreader bars shall be manufactured, tested, and inspected to

ANSI B30.20.

2.8.2

Spreader bars shall be permanently identified with the safe

working load, manufacturer's name and serial number.

2.8.3

Spreader bars shall be stored away from moisture, and protected

from physical damage.

February 1993 - 2.0 Slings And Lifting Gear Page 279

2.9 Eyebolts And Safety Hoist Rings

Sometimes machinery or other equipment is delivered to the site

with eyebolts attached as lifting points. For such situations, the
design and function of each of the three basic types of eyebolts
should be known (see Figure III.10.).

2.9.1

Standard eyebolts are the weakest and are dependable only for
vertical lifts.

2.9.2

Shouldered eyebolts can be used at slight angles, but are unsafe

at less than 45 degrees with the horizontal.

2.9.3

Safety hoist rings (swivel eyes) are bolted in place with a

calibrated torque wrench and maintain maximum capacity at all
angles.

2.10 Shackles

Shackles (clevis) are used for making connections in rigging.

They should be tested by the manufacturer and marked with the
safe working load.

The pins are separate but matched parts of the shackles, so care
must be taken to use the correct pin for each shackle. Rebar,
mild steel bolts or similar items are not acceptable replacements
for shackle pins (see Figure III.12.).

2.11 Rigger

The job of rigger requires thorough training. The man assigned

must be well-acquainted with the capabilities of the crane being
used, hand signals, the different functions of lifting gear, and the
various methods of loading.

February 1993 - 2.0 Slings And Lifting Gear Page 280

FIGURE III.3: IDENTIFICATION TAGS

All slings shall carry permanent

manufacturer's
identification.

February 1993 - 2.0 Slings And Lifting Gear Page 281

FIGURE III.4: INSTALLING A WEDGE SOCKET ON A ROPE

FIGURE III.5: TWO-LEGGED CHAIN SLING: MAJOR COMPONENTS

FIGURE III.6: SLING FIXINGS

(Sling No. 123

SWL 8 Tons)

February 1993 - 2.0 Slings And Lifting Gear Page 282

FIGURE III.7: SYNTHETIC WEBBING SLINGS

February 1993 - 2.0 Slings And Lifting Gear Page 283

FIGURE III.8: SLING LOADING FIGURE III.9: EYEBOLTS

FIGURE III.10: CRANE HOOKS FIGURE III.11: SHACKLES

February 1993 - 2.0 Slings And Lifting Gear Page 284

FIGURE III.12: WIRE ROPE SLING INSPECTION LOG

Contractor:______________________________________ Location: __________________________

BI/JO Number: ___________________________________ Project Title: ______________________

Sling# Diameter Length SWL Date-In Date-Out- Inspector Signature

Service Service (Date)

February 1993 - 2.0 Slings And Lifting Gear Page

285
3.0 MECHANICAL EQUIPMENT
The widespread use of mechanical equipment in the construction industry
improves the quality and efficiency of the work but it can lead to situations which
are potentially hazardous.

This section cannot cover all the situations which could arise, but it outlines some
of the hazards likely to be encountered from specific items of equipment and their
use.

The only safe way of using mechanical equipment is to have properly trained
operators, running equipment that is well maintained and carrying out the work for
which it was designed.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 7.025 Mobile Heavy Equipment Operator Testing and Certification

GI 7.026 Cranes and Heavy Equipment Accident Reporting Procedures

GI 7.030 Inspection, and Testing Requirements Of Elevating / Lifting

Equipment

GI 8.003 Breathing Apparatus

GI 447.002 Pressure Relief Valves - New Installation, Change in Set Pressure,

Replacement or Retirement from Service

GI 447.003 Pressure Relief Valves - Routine Test, Inspection, Quality Assurance

and Regulation

Saudi Aramco Engineering Standards:

Inspection Procedures

17-SAIP-6.01 Diesel Electric Generating Set

20-SAIP-3.01 Welding Generator

31-SAIP-1.01 Pumps

31-SAIP-1.02 Compressor

31-SAIP-8.05 Vibrating Roller

31-SAIP-8.10 CAT Motor Grader

31-SAIP-8.15 Road Rollers

31-SAIP-8.16 Scraper

February 1993 - Construction Safety Manual: Mechanical Equipment Page 286

31-SAIP-10.01 Concrete Mixers

31-SAIP-12.04 Diesel Fork Lift Truck

31-SAIP-12.05 Electric Fork Lift Truck

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Mechanical Equipment

AMERICAN NATIONAL STANDARDS:

ANSI-A 10.4-81

Safety Requirements For Personnel Hoists

ANSI-B 15.1-84

Safety Code for Mechanical Power Transmission Apparatus

ANSI-B 30.1-86

Safety Code for Jacks

ANSI B30.5. Mobile and Locomotive Cranes

ANSI-B 56.1-88

Safety Standard for Low and High Lift Trucks

3.1 Operators

3.1.1 Qualifications

Only trained personnel shall operate any mechanical equipment.

Operators shall be trained in the procedures and functions
relevant to a specific piece of equipment; they must be fully
aware of the capabilities and limitations of the machine and
have a knowledge of the day-to-day maintenance that it
requires.

It is recommended that contractors train and test all equipment

operators and issue them with written authorization specifying
the equipment which they are competent to operate.

3.1.2 Licensing Requirements

Operators of mobile heavy equipment must be in possession of a

Saudi Arab Government (SAG) license for that particular class of
machinery and a Saudi Aramco certificate issued by the Saudi

February 1993 - 3.0 Mechanical Equipment Page 287

 Aramco Heavy Equipment Operator Testing and Training Unit
(see GI 7.025).

3.2 Machinery Guards

All moving parts of machinery must be shielded by guards. This is

particularly true with gears, pulleys, V-belt drives, fans, and revolving
shafts. All of these are present on most of the static equipment used on
or around construction sites. Other examples of equipment which must
be guarded include cooling fans on compressors and generators, the
main drive shafts on pumps and dumpers, and the cable drum on
winches and concrete mixers.

Guards must be installed on equipment before it arrives on site and

maintained in position at all times while the equipment is operating.
Guards removed for routine maintenance or for repair must be replaced
before the equipment is returned to service.

3.2.1 Multi-Piece Tire Rims and Locking Rings

As safety equipment like tire cages, restraining bars, racks and

clips during tire check-out cannot fully protect employees
working on or near the tire repair area, always deflate the tire
first before making repairs. Inflate tires inside a strong
restraining device (tire cage) by increasing the tire pressure very
slowly.

3.3 General Requirements

3.3.1

Before any mechanical equipment is used in a Saudi Aramco

restricted area, all required work permits must be obtained.

3.3.2

All machinery should be inspected before being placed in service

and at regular intervals thereafter.

3.3.3

Maintenance schedules should be established for each piece of

equipment and strictly followed.

3.3.4

No repair, adjustment, or replacement of parts on moving

machinery is permitted. Before making any repairs, all
equipment must be stopped and deactivated so that it cannot be
unintentionally started.

February 1993 - 3.0 Mechanical Equipment Page 288

 3.3.5

At the start of each shift, the operator must check oil, water, fuel,
and hydraulic levels, that all gauges are operating and that the
machine is functioning smoothly. Safety equipment (e.g.,
guards, limit switches, governors) must be checked daily.

3.3.6

Equipment traveling or working on the highway must have lights

and reflectors. Park equipment clear of the roadway. If this is
not possible, use flashing lights, cones, or other warning devices
to alert approaching traffic.

3.3.7

When vehicles are left unattended (even overnight), engines

must be stopped, parking brakes applied and the wheels
chocked. Blades, scraper bowls, and other hydraulic equipment
must be lowered to the ground before the operator leaves the
machine. The ignition key should be removed and/or battery
cables disconnected to avoid start-up by unauthorized
personnel.

3.3.8

Unless otherwise instructed, operators must dismount from

machines while maintenance or repair work is being carried out.

3.3.9

Cabs fitted to equipment must give 360 o visibility. Cabs must be

kept clean and clear of such items as rubbish and loose tools.
Windows must be kept clean at all times and should be replaced
if the glass becomes pitted, cracked or broken.

3.3.10

Where the operator of a mobile machine cannot see the area all
around his machine, an attendant must be in a position to direct
and assist the operator.

3.3.11

All equipment must be located so that exhaust fumes will not

affect workers in the area. Gasoline-driven equipment shall not
be used inside a building or other confined space.

3.4 Compressors

Compressors are one of the most common pieces of equipment used in

construction work. They can be used to supply air for portable power

February 1993 - 3.0 Mechanical Equipment Page 289

 tools or to supply air to sustain men working with breathing apparatus in
extremely hazardous atmospheres. There is a considerable difference in
the quality of the air used for these two functions.

3.4.1

All employees on site must know the dangers of compressed air.

Never use compressed air to dust off clothing or machinery.
Horseplay with compressed air must be strictly forbidden. When
compressed air is used in special cleaning/purging tasks, goggles
and full face shield must be worn.

3.4.2

Compressors must be properly designed, inspected, tested and

maintained. Relief valves shall be installed in accordance with
GI 447.002/3, and the air receiver must be periodically
inspected.

3.4.3

Before start up, a daily check should be made of the

compressor's pressure relief valve, fuel, oil and water levels and
the air reservoir should be drained of trapped water. The
operating manual for the particular type of compressor used
should be strictly followed.

3.4.4

When compressors supply air for breathing:

1.) The air intake must be located so that it does not draw in
exhaust gas.
2.) There must be a filter to remove oil mist.
3.) They must be equipped with an automatic high
temperature alarm.
4.) The air must be tested periodically to be certain it is safe to
breathe (see Administration, I.10., 1.3.)

3.5 Concrete Mixers and Batching Plants

A concrete mixer of some type will be used on almost every construction

site. The principles of good maintenance and properly trained operators
apply equally whether it is only a small mixer for masonry work or a full
batching plant with a large capacity cement silo, sand and aggregate
bins, and a power shovel.

3.5.1

All chains, gears, and revolving shafts must be guarded.

3.5.2

February 1993 - 3.0 Mechanical Equipment Page 290

 Safety chains and catches must be operative, and the lifting
mechanism must be in good order.

3.5.3

Men must not be allowed to work under or near the loading skip
unless it is held in position by a safety chain or catch or
positively blocked.

3.5.4

The mixer drum and the area around the machine must be
thoroughly cleaned at the end of each day's operation.

3.5.5

Cement bags must not be allowed to accumulate in the mixer

area; they should be collected and disposed of at regular
intervals during the day.

3.5.6

A hooped access ladder must be firmly attached to silos for

access to the top manhole. Men must not be allowed to work
inside the silo unless they are wearing a safety belt with a lifeline
and an attendant is posted outside ready to assist in case of
emergency.

3.5.7

The approach to the sand and aggregate bins should be

barricaded, and the barricades should only be removed to allow
access for vehicles delivering material.

3.5.8

Personal protective equipment such as respirators, ear muffs,

and goggles shall be worn. Loose fitting clothes shall not be
worn around moving machinery.

3.5.9

Lockout and tag system is required in batching plants to ensure

the safety of repair and/or maintenance personnel. This is a
means to disable process/mechanical electrical 'control'
equipment during repairs and maintenance. Lockout and tag
system rules must be posted in a conspicuous location
throughout the plant and workers must be thoroughly trained in
the lockout/tag procedures.

February 1993 - 3.0 Mechanical Equipment Page 291

3.6 Dumpers and Dump Trucks

Dumpers and dump trucks, commonly used for construction work, often
travel on the public highway. Therefore it is essential that they be
properly maintained.

3.6.1

The latch on dumper skips must be in good working order, and

the release mechanism should function smoothly.

3.6.2

Dumpers are not designed to carry passengers. It must be

strictly forbidden for employees to ride in the skip or on the
engine cover.

3.6.3

When repairs or maintenance are being carried out on a

hydraulically operated dump truck, the dump body should be
fully lowered. If it is necessary to have it in the raised position, it
must be blocked. Do not rely on the hydraulic ram to support the
raised body for an extended period.

3.6.4

All vehicles with cabs shall be equipped with windshields and

powered wipers. Cracked or broken windshields or windows shall
be replaced. All cab glass shall be safety glass or equivalent.

February 1993 - 3.0 Mechanical Equipment Page 292

3.7 Excavators

Excavations are carried out using very specialized equipment which

roughly falls into two categories: 1) fixed position machines, and 2)
moving machines.

The choice of equipment to be used is determined by the size of the

project, topography, volume of earth to be hauled out and many other
factors. Fixed position machines include, but are not limited to, face
shovels, backhoes, draglines and grabs. The "fixed" excavator loosens
the soil and loads from a stationary position. They are useful to perform
specific excavation tasks at a single location. Their loss of mobility is
compensated by the fact that greater force can be applied at the
excavation face. "Moving" machines include, but are not limited to,
bulldozers, loaders, scrapers, graders and trenching machines. They
remove, transport and deposit excavated material all in one cycle of
operation. They are used in applications where large volumes of earth
need to be moved over uneven ground. In this process, they also help to
level the ground over which they operate. (Also see General And Civil,
II.2 of this manual.)

3.7.1

The excavation work permit may require that underground

pipelines or cables be located by manual digging. The permit
must be counter-signed by the Power Distribution Department
(PDD) and the area Utilities Services Department.

3.7.2

Operators of excavators must possess a valid Saudi Arab

Government license for the machine and a valid Saudi Aramco
certificate issued by the Saudi Aramco Heavy Equipment
Operator Testing Unit.

3.7.3

Outriggers must be fully extended when operating a mechanical

excavator so fitted.

3.7.4

An attendant must be appointed and be available at all times

during excavation to assist and guide the operator.

3.7.5

Excavators with a swinging motion must have a clearance of at

least 0.6 meter (2 feet) from any fixed object.

February 1993 - 3.0 Mechanical Equipment Page 293

 3.7.6

Booms on excavators must be latched before travel.

3.7.7

Do not excavate closer than 10 feet to the nearest pipeline or

other equipment in place.

3.8 Fork Lift Trucks

Fork lift trucks are designed to operate on firm, level ground. This type
of equipment has a limited use in construction operations. They are,
however, sometimes used in materials handling yards and for placing
loads where there are firm ground conditions. Operators of fork lift
trucks must have a valid Saudi Arab Government heavy equipment
license and a valid Saudi Aramco certificate.

3.8.1

It is essential that drivers be fully trained and experienced. They

must be able to manipulate loads smoothly and efficiently.

3.8.2

A specific course of instruction should be established for fork lift

drivers. They should not be allowed to use the vehicles on site
until they have taken the course.

3.8.3

Special equipment fitted to the truck, in addition to or in place of

the forks, must be designed for the specific machine.

3.8.4

The truck shall be equipped with overhead protection.

3.8.5

When traveling with a load on the forks, the forks should be as

low as possible to maintain stability.

3.8.6

If the load being carried obstructs the operator's forward view,

he should travel in reverse.

February 1993 - 3.0 Mechanical Equipment Page 294

 3.8.7

Operators, loaders, helpers and other workers should never place

any part of their bodies between the mast uprights, cross
members, or other moving parts of the fork lift truck. Stay well
within limits of the truck body or cab.

3.9 Generators

A competent electrician shall be available to ensure that

electrical connections are properly made. The operator should
be responsible only for the mechanical function of the machine.

3.9.1

All pulleys, belts, and fans must be totally enclosed or otherwise

guarded.

3.9.2

The side panels to the engine cover are designed to give access
to the machinery for maintenance or repair. They must be
closed at all times when the engine is running.

3.9.3

The machine must be properly grounded before each use.

3.9.4 Fire Prevention Guide for Portable Generators

The following is a typical check list of the major items to look for.
There may be other potential fire hazards not listed, therefore a
thorough inspection must be made.

· Repair all fuel leaks.

· Check hose and pipe connections for wear and cracks.
· Clean up all combustible trash around the generator.
· Clean up all fuel spills and place clean sand around area
when required.
· Sheds constructed of combustible materials placed around
generators and wooden base frames are prohibited.
· Exhaust piping system shall be kept away from work areas
and combustible materials.
· Generator sets shall be located at least 50 feet from
buildings or materials that may catch fire.
· Inspect all wiring for damage or improper splices/repairs.
· Electrically ground all generator sets (system and frame
ground).
· Fire extinguishers must be readily accessible. One CO 2
extinguisher for the generator and a dry chemical
extinguisher for the engine drive is recommended.

February 1993 - 3.0 Mechanical Equipment Page 295

 · Conduct daily inspections of all generator sets using this
guide.

3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders

Heavy earth moving equipment only allows the operator a limited view
of the immediate area. It is, therefore, essential that a banksman be
appointed to warn the operator of hazards that cannot be seen from the
operator's position.

This equipment shall be equipped with rollover protection. A valid Saudi

Arab Government heavy equipment license and a valid Saudi Aramco
certificate issued by the Saudi Aramco Heavy Equipment Operator
Testing Unit are required for each operator of such equipment.

3.10.1

Before moving his machine, the driver must walk around it to see
that the area is clear.

3.10.2

Men must not be allowed to sit or lie in the area around the
machine.

3.10.3

The engine shall not be left running when the driver is not at the
controls. Before leaving his machine, a driver must shut off the
engine and remove the ignition key.

3.10.4

Blades, scraper bowls, etc. must be lowered to the ground before

the driver leaves his unit. The wheels should be properly
chocked.

3.10.5

If there is work to be done underneath such hydraulic equipment,

the equipment must be blocked in position.

3.11 Woodworking Machinery

Only fully trained operators may be allowed to use woodworking

machinery. This machinery is inherently dangerous since the hazardous
parts, knives, blades, etc., cannot be fully enclosed. Only that part of the
blade necessary to carry out the work shall be exposed at any one time.

3.11.1

February 1993 - 3.0 Mechanical Equipment Page 296

 The area around saws, planers, and routers must be barricaded
and only authorized and trained personnel allowed within the
barricaded area.

3.11.2

The ground around such machinery must be kept clear of off-cuts

and other tripping hazards.

3.11.3

Machinery should be securely anchored to prevent movement

during use. (See General And Civil, II of this manual.)

February 1993 - 3.0 Mechanical Equipment Page 297

4.0 MATERIALS HANDLING
Materials handling forms a large part of construction work. How construction
materials are handled can have a considerable effect on the efficiency of
production and on the safety record of the site. Because of the temporary nature
of site work and the frequent change of the work place, it is not possible to
mechanize material handling to the same extent as it would be in a more stable
operation. However, there are many areas in which labor intensive, inefficient,
costly, and frequently dangerous, manual material handling work can be replaced
by the use of machines.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 355.001 Identifying, Ordering, Receiving, Storing, Issuing And Disposing Of

Hazardous Materials

GI 1130.013 Vehicle Loading

GI 1131.165 Use of Trailer Brakes

GI 1131.921 Use of Trailer Safety Chains

4.1 Planning

Successful mechanization of material handling requires that the correct

machines be available and properly used. The storage and movement of
the various materials must be carefully arranged to make optimum use
of the machines so that efficient service can be provided and ensure that
all vehicle, crane and heavy equipment operators hold current Saudi
Arab Government License and Saudi Aramco Certification where
required.

Planning for materials handling operations begins as the production

schedule is being drawn. Ensure that the layout of storage areas
provides for adequate access for necessary mechanical equipment.

4.1.1

Selection of the storage area should be made with due

consideration for drainage and protection from rain and
sandstorms (see Figure III.13 Typical Construction Materials Store
Yard).

4.1.2

Open storage areas should be planned to minimize the reversing

and maneuvering of trucks especially into and out of confined
areas.

February 1993 - Construction Safety Manual: Materials Handling Page 298

 4.1.3

Access ways must be wide enough to allow for the passage of

fire trucks. Fire fighting equipment should be located throughout
the area. Contact the Fire Prevention Group of Loss Prevention
for information (see Figure III.13 Typical Construction Materials
Store Yard).

4.1.4

Cribbing timber, racks, or pallets should be used to ensure that

all materials are stored off the ground.

4.1.5

Protection should be provided for materials such as cement,

insulation, and other bulk material which could be damaged by
moisture.

4.1.6

All machinery, equipment, and valves should be maintained fully

assembled and securely closed. All machined surfaces must be
covered and fully protected from exposure to the weather.

4.1.7

The quantity of material on site at any one time must be

restricted to a minimum stock. Flammable stores shall be kept
separated. Such a policy should greatly reduce losses due to
pilferage or damage (see Figure III.13 Typical Construction
Materials Store Yard).

Once these factors have been established, the staffing of the

storage areas can then be considered.

4.1.8

On larger projects, the movement of materials could justify the

employment of a loading and unloading gang, whereas small
jobs would probably need only one man assigned to this
responsibility.

4.1.9

Routinely, on most sites, there should be a man appointed as a

materials controller responsible for materials from the planning
stage through to the final unloading, storage, and distribution
stage.

February 1993 - 4.0 Materials Handling Page 299

4.2 Machine Transport

A wide variety of mechanical equipment is available for transporting and

distributing materials on and around a job site. They range from simple
equipment such as a dumper or a tractor and trailer to more
sophisticated equipment such as a concrete pump or a large crane.

4.2.1 Dumpers

Dumpers are one of the most commonly used pieces of

construction equipment and have proved very useful in
transporting concrete and other small loads around site.
Unfortunately they are also a common source of injuries and
damage.

Dumper drivers must be properly trained and experienced and

must hold a current Saudi Arab Government license. The
equipment is designed for the movement of material only.
Passengers must not be allowed to travel in the skip or anywhere
else on the machine. Dumpers must be regularly maintained
with particular attention to brakes, steering, and skip release
mechanism. If they are to be used for towing, a proper towing
eye with a shackle or pin must be provided.

4.2.2 Tractors and Trailers

Tractors and trailers are useful for moving larger loads around
the site. In addition to the normal precaution of good
maintenance, it is essential that safety chains or wire ropes be
fitted between the tractor and trailer so that if the towing
connection should break or become separated for some reason,
the trailer can still be brought to a controlled stop by the tractor.
Trailer and its load shall not exceed the towing capacity of the
tractor and shall be fitted with an independent braking system if
it is designed to carry more than 9,072 kilograms (20,000
pounds). Trailers used for carrying pipes should be fitted with
side stops, and loads must be securely tied down before being
transported.

4.2.3 Conveyor Belts and Monorails

Conveyor belts and monorails are occasionally used for

transporting concrete, sand, or aggregate on site. They require a
complete maintenance program. Because of the many problems
associated with them, thorough consideration must be given to
their use. All pulleys, rollers, gears and pinch points shall be
guarded. On/off switches shall be clearly marked and readily
accessible.

February 1993 - 4.0 Materials Handling Page 300

 4.2.4 Concrete Pumps

Concrete pumps are used for the placement of concrete in

difficult situations. They have the advantage of being able to
move large amounts of concrete very speedily to the area where
it is required. The operation of this equipment demands
specialized knowledge of concrete technology; however, placing
concrete by this method can significantly reduce the number of
dumpers employed or the crane usage time expended on a civil
engineering contract.

4.3 Site Stores

For small or valuable materials which cannot be conveniently stored in

outside areas, it is essential that an indoor stores shed, under the control
of a responsible person, be established on site. Because of the nature of
the materials stored in such an area, the main considerations must be
security and fire prevention.

The issuing and receiving of stores must be under the control of a

responsible person. Adequate fire fighting equipment must be readily
available in the area. Materials should be stored on shelving or with
small items such as nuts and bolts, etc. in bins suitably marked with the
contents. The safe loads allowed on racks and the maximum stack
heights should be established. All hazardous material, such as paints,
fuels, chemicals, etc., should be separated and stored in an isolated
flammable storage area (see Appendix C). Notices warning of the
dangers associated with these materials should be posted in the hazard
area.

4.4 Manual Handling

There are many areas of construction work where mechanization cannot

take the place of sheer muscle, and it is in such areas that the majority
of injuries occur. The inevitable results of lifting incorrectly are strained
backs, slipped discs, sprains and strains, and a complexity of internal
injuries.

It is, therefore, essential that workers be trained in the correct methods

of manual handling. Safe lifting can only be carried out by the proper
use of the right muscles. Back and abdominal muscles are weak, while
the leg and thigh muscles are strong. The spine has a natural and
comfortable shape when a man is standing upright; however, if he
bends, the spine arches and becomes weaker. If the spine can be kept in
a straight position when lifting, the strain of the lift goes to the strong
muscles of the leg and thigh and loads can be lifted safely, with much
less physical effort. This is the basic principle of manual handling.

February 1993 - 4.0 Materials Handling Page 301

 4.4.1

There are four significant points in a proper lift:

1. Grip: A good grip makes maximum use of the palm of the

hand, the ball of the thumb, and base of the fingers.
2. Back: The back must be kept straight to maintain its most
natural and strongest position. This means that the knees
and ankles must be bent and the chin kept well into the
chest. The body must be positioned as close to the load as
possible so as to act as a counterweight.
3. Feet: The feet should be apart the width of the hips with
one foot slightly in front of the other so that a natural lead
off is obtained.
4. Arms: The arms must be kept as close as possible to the
body.

4.4.2

The important factor in manual handling is that a man should

know his capabilities and ask for assistance with loads beyond
his capabilities. In dual lifting, partners should be approximately
the same height and weight so that the load does not become
unevenly distributed.

4.4.3

Loads, even when properly lifted, can slip. The man lifting must
be prepared for such a possibility and wear the proper protective
equipment. Safety footwear is mandatory to protect feet and
gloves should be worn to protect hands from laceration or
splinters and to give some protection if the fingers are trapped
between the load and the other surfaces.

February 1993 - 4.0 Materials Handling Page 302

FIGURE III.13: TYPICAL CONSTRUCTION MATERIALS STORE YARD

Note: Maximum grid of

driveway 50 ' X
150'

February 1993 - 4.0 Materials Handling Page 303

ATTACHMENT III.1: HEAVY EQUIPMENT OPERATOR LICENSING INFORMATION

GENERAL INFORMATION

All crane and other heavy equipment operators working on Saudi Aramco projects
are required to have a valid heavy equipment operator Saudi Arab Government
(SAG) license and a Saudi Aramco Heavy Equipment Operator Certificate. This
applies to Saudi Aramco employees as well as contractor employees.

Saudi Arabs and non-Saudi citizens employed by Saudi Aramco or contractors

working on Saudi Aramco projects may obtain their SAG license by following the
established procedure.

SAUDI ARAMCO EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAVY EQUIPMENT LICENSE

Application forms for SAG Heavy Equipment License are

completed and processed at the Saudi Aramco License Unit,
Building # 510, Dhahran. (Saudi Aramco employees in all other
areas apply to local Saudi Aramco License Unit). After
completion of an eye examination and blood test, the applicant
is scheduled for an operator competency test by the Heavy
Equipment Operator Training/Testing Unit, Dhahran (Tel. 874-
1857). Upon successful completion of the test, application forms
are returned to the Saudi Aramco License Unit for processing
through the SAG Traffic Department, Dammam, for SAG License
issue.

SAUDI ARAMCO EMPLOYEES (NON-SAUDI)

WITH HOME COUNTRY HEAVY EQUIPMENT LICENSE

Employees with valid home country licenses need only apply

through the Saudi Aramco License Unit, Building # 510, Dhahran
(Saudi Aramco employees in all other areas apply to their local
Saudi Aramco License Unit). After completion of an eye
examination and blood test, application forms are forwarded by
the Saudi Aramco License Unit for processing to the SAG Traffic
Department, Dammam, for SAG License issue. A company test is
not required.

CONTRACTOR EMPLOYEES (SAUDI AND NON-SAUDI)

WITHOUT HEAVY EQUIPMENT LICENSE

Application for SAG Heavy Equipment License is made directly to

the SAG Traffic Department, Dammam.

Upon completion of the eye examination and blood test, the

contractor company representative contacts the Saudi Aramco
Heavy Equipment Operator Training/Testing Unit (Tel. 874-1857)
for scheduling of the competency test. (Application form is to
accompany contractor employee to the test site).

February 1993 - 4.0 Materials Handling Page 304

 After the successful completion of the competency test, the test
sheet is attached to the application form. The application form is
then taken to the SAG Traffic Department, Dammam, for
processing and license issue.

CONTRACTOR EMPLOYEES (NON-SAUDI)

WITH HOME COUNTRY HEAVY EQUIPMENT LICENSE

Contractor employee with a valid home country license need

only apply for SAG license to the SAG Traffic Department,
Dammam, for processing and license issue. A competency test
is not required for SAG license.

On receipt of the SAG license, the contractor company

representative contacts the Saudi Aramco Heavy Equipment
Operator Training and Testing Unit (Tel. 874-1857) for scheduling
of the Saudi Aramco certification test.

February 1993 - 4.0 Materials Handling Page 305

IV. Electrical And Radiation

February 1993 - Construction Safety Manual: IV. Electrical And Radiation Page 306
1.0 ELECTRICITY
The human senses (smell, taste, hearing, etc.) do not provide a warning of an
electrical hazard. The great majority of electrical accidents result in burns. Fire
and explosion from sparks in flammable atmospheres can and does lead to loss of
life and serious damage to property. All electrical installations, no matter what
voltages are used, should always be treated with great caution.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 6.012. Isolation, Lockout And Use of Hold Tags

Power Distribution Instruction:

No. 10.0. Power Distribution System Operations

No. 11.0. Hold Orders, Clearances and Permission to Test

No. 50.0. Safety Grounding

Saudi Aramco Engineering Standards:

Electrical Power Manual (SAES-P series)

SAES-B-064 Onshore And Near Shore Pipeline Safety

Operations Instructions Manual:

No. 1.111. Electrical Connections

NFPA 70: National Electrical Code

ANSI/IEEE C2-90

National Electrical Safety Code

ANSI B30.5. Mobile and Locomotive Cranes

29 CFR 1926 Subpart N - Cranes, Derricks, Hoists, Elevators And Conveyors

US Department of Labor, Occupational Safety And Health

Administration (OSHA)

February 1993 - Construction Safety Manual: Electricity

Page 307
1.1 Voltage

The severity of electric shock is not entirely dependent upon the voltage
of the power source. The ratio of the voltage to resistance determines
the current that will flow through the body and the resulting injury.

In terms of a formula this ratio is:

Current through the body = Voltage applied across the body

Resistance of the body + contact resistance

The hazard is greater if working conditions are wet or if the worker

perspires freely. This produces a combination of wet skin and body salt
which provides low resistance to current flow.

1.2 Temporary Installations

Distribution of electricity on a construction site is different from a

permanent installation. As construction work proceeds, the type of
equipment in use changes. From excavation to completion, there is a
constant need for convenient means of connecting equipment. This
requires a variety of voltages, phases, and current in different places at
different times. Load requirements will vary considerably. All temporary
electrical systems shall conform to the National Electrical Code.

1.2.1

The contractor is responsible for the temporary electric supply

system on a construction site and the safety measures
associated with the National Electrical Code.

1.2.2

Cables on site are subject to rough treatment. Special care

should be taken to ensure that the grounding conductor remains
intact. If the conducting wire breaks, the supply will not be
interrupted under a ground fault condition and the system will no
longer be safe. Only UL, FM or other recognized testing lab
approved extension cords bearing appropriate lab trademarks
shall be used. Damaged or spliced cords are not acceptable to
Saudi Aramco.

1.2.3

Special care shall be taken to ensure that the correct fuse or

breaker ratings are strictly enforced and that the Ground-Fault
Circuit Interrupters (GFCIs) are installed properly on all circuits.

February 1993 - 1.0 Electricity Page 308

 1.2.4

All installation work must be carried out by qualified,

experienced electricians. Before connecting temporary electrical
installations to existing installations, prior approval must be
obtained from the Saudi Aramco proponent department. This is
to ensure that no overloading of electrical devices will occur and
system protection will not be compromised.

1.2.5

A competent person must be made directly responsible for the

overall safety of the installation. Its general usage, its
maintenance, and any alterations and extensions to the system
should be under his control. He must be at the site whenever
work is being done. Before any part of a newly installed
electrical system or its equipment is energized, it must be
thoroughly tested. Safety can be ensured by regular inspection
and maintenance.

1.3 Hand Tools and Lighting

1.3.1

Many injuries, fires, and explosions have resulted when

extension lights with defective cords or fittings have been used
or when bulbs have been broken, exposing the live filament wire
to an explosive atmosphere. All electrically operated tools shall
be rated and used at a voltage not exceeding 125V. The use of
220V is prohibited.

1.3.2

Defective extension lights and electric hand tools shall be

repaired or replaced. A defective electrical tool or cord can
cause burns, falls as a result of sudden shocks, or even fatalities.

1.3.3

Portable electric tools, extension lights and cords should be

inspected each time they are issued and returned. This should
be part of a tool store procedure. Frequent random checks
should be made where those tools, lights and plugs are being
used on site.

Portable hand lamps shall comply with the following:

(1) Metal shell, paper-lined lamp holders shall not be used.

(2) Hand lamps shall be equipped with insulated handle.

February 1993 - 1.0 Electricity Page 309

 (3) Substantial lamp guard shall be attached to the handle or
holder. Metallic lamp guards shall be grounded. Three-
wire power cords with grounding conductor shall be used.

1.3.4

Failure of electrical equipment, because of misuse, is a frequent

cause of shock. Workers are prone to abuse extension cords by
pulling them over sharp metal objects, hanging them across
equipment, kicking them, or letting them be run over by
industrial equipment. They often strain the cords during use,
causing the plug and fixture to part and expose live wires.

1.3.5

Many accidents occur when lower volt equipment is plugged into

higher volt systems. Before any portable tool or extension light
is plugged in, the voltage required for the tool or light must be
the same as the power source, and the plugs must be checked
for damage.

1.3.6

The importance of grounding all portable tools and lights cannot

be emphasized too strongly. All non-current carrying metal parts
of any electrical equipment must be properly grounded. This will
reduce the electrical shock hazard.

1.3.7

In hazardous areas, more stringent rules apply as to the type of

equipment which may be used. Explosion proof light fittings for
extension lights is one example. As with all work carried out on
Saudi Aramco installations, Work Permits must be obtained and
the type of equipment to be used discussed and agreed upon
before the permit is issued.

1.3.8 General Precautions:

Only qualified electricians should make repairs and carry out

maintenance checks. All extension lights must be fitted with
protective guards, so if accidentally dropped, the lamp remains
intact. Up to a 120 volt maximum rated AC portable lighting
system may be used for illuminating inside confined spaces and
vessels, provided it is protected by an externally located ground
fault circuit interrupter and also meets the provisions of GI
520.001 Section 5.5.5.1 and 520.001-4 (Supplement 4) -
"Confined Space Entry Procedure" (Abqaiq Plants).

February 1993 - 1.0 Electricity Page 310

 1.3.9

Ground fault circuit interrupters shall be used on all electrical

circuits including portable power electrical supplies (see NFPA
Handbook of the National Electric Safety Code, Section 305-b for
GFCIs) on temporary wiring.

1.3.10

The National Electric Safety Code defines requirements for the

construction and use of portable extension and electric cords in
industrial service. This code shall be followed by construction
groups.

1.4 Work on Live Equipment

1.4.1

Whenever workmen are required to work on energized

equipment, the job must be planned thoroughly and the
workmen should proceed with caution.

Before any work on live equipment starts, there must be a

thorough knowledge of the work involved, personal protective
equipment must be available, and all necessary work permits
must be obtained.

1.4.2

Employees must never work alone on live equipment. In

addition to the man doing the job, there must be another
electrician standing by. A foreman or supervisor should also be
in attendance while this work is being carried out, and he must
know how to isolate the equipment.

1.4.3

Before starting a job, the exact voltages should be known. This

is important as it determines the type of personal protection
required for the work and the procedures established in the work
permit. If there is any doubt about voltages, a check must be
made before the work is started.

1.4.4

Work platforms and equipment used near energized equipment

shall be properly grounded.

February 1993 - 1.0 Electricity Page 311

 1.4.5

Work on live equipment can be as safe as work on isolated

equipment if the following are observed:

1 There must be a thorough knowledge of the equipment

and the job to be done.
2 If there is any doubt, the advice of the supervisor or
responsible person should be sought.
3 The work must be correctly planned before starting.
4 Protective equipment must be used correctly.

1.5 Overhead and Underground Cables

On any construction site, power supplies may have already been

installed below ground or overhead.

Contact should be made with the appropriate Saudi Aramco department

at the planning stage of the job to determine the work permit
requirements, route and depth of any underground cables and the
recommended safe clearances. If re-routing existing cables is necessary,
this should be done before the main contract starts.

1.5.1 Overhead Lines

(Figure IV.1)

High voltage or overhead lines are usually uninsulated.

Therefore, any kind of metallic object coming near or in contact
with them can cause a hazardous situation. High voltage can
easily arc across a considerable distance. (See OSHA 29 CFR
1926 Subpart N.)

1.5.2 The Contractor Should Arrange for Power Lines to be:

1 Re-routed clear of all construction work or placed

underground if possible.
2 Made "dead", grounded, and certified as such by Saudi
Aramco.
3 Protected by barriers and timber or wire "goal-posts", so
that no part of any mobile crane, earth moving equipment,
etc. can approach the live cable. Clearance distances
should be agreed upon with Saudi Aramco. Access below
the powerlines shall be restricted by barriers to where the
"goal-posts" are located (see Figure IV.1).

The need for caution in working with overhead lines cannot be

over-emphasized. High voltage overhead lines have been
mistaken for telephone cables.

It should never be assumed that there is enough clearance; it

should always be proved. It should never be assumed that a
cable or line is "dead"; it should always be checked.

February 1993 - 1.0 Electricity Page 312

 1.5.2.1 Spacing Between Powerlines and Pipelines

Special precautions are required during installation,

operation or maintenance of above grade or below
grade onshore pipelines. (See SAES-B-064.)

1.5.3 Underground Cables

Normal depth of underground cables varies between 46

centimeters (18 inches) and 0.9 meter (3 feet). (Changes in
ground level, due to the work, can mean that the "as built" depth
is no longer correct). No mechanical excavations should be
started before test trenches have been dug by hand and cable
locations established. Unless cables have been laid very deep,
heavy vehicles should not be allowed to pass over them.

Underground cables, exposed during excavation work should be

assumed to be energized and not repositioned or moved until
certified to be de-energized. Exposed buried cables in open
trenches should be properly supported and the area barricaded.

Accidental damage to any cable exposed during excavation shall

be immediately reported to Saudi Aramco. The area must be
barricaded until the damaged cable has been made safe.

1.6 Overhead Power Transmission and Distribution

The standards given in this section provide minimum requirements for

safety and health during construction.

1.6.1 Initial Inspections, Tests, or Determinations

Existing conditions shall be determined before starting work, by

an inspection or a test. Such conditions shall include, but not be
limited to, energized lines and equipment, condition of poles,
and the location of circuits and equipment, including power and
communication lines.

Electrical equipment and lines shall be considered energized

until determined to be de-energized by testing and grounding.

Operating voltage of equipment and lines shall be determined

before working on or near energized parts.

1.6.2 De-energizing Lines and Equipment

The procedures outlined in GI 2.100 and GI 6.012 shall be

followed, and all circuits will be identified, tagged, locked, and
tested.

Equipment shall be checked for potential and protective grounds

shall be applied.

February 1993 - 1.0 Electricity Page 313

 Guards or barriers shall be erected as necessary near to adjacent
energized lines.

When more than one independent crew needs to work on the

same line or equipment at the same time, a separate "clearance"
shall be given to each crew by the Saudi Aramco Power
Dispatcher, and a prominent tag and lock for each such
independent crew shall be placed on the line or equipment by
the designated crew leader.

Upon completion of work on de-energized lines or equipment,

the crew leader shall determine that all members in his crew are
clear and that protective grounds installed by his crew have been
removed. He shall release his clearance to Saudi Aramco.

1.6.3 Emergency Procedures and First Aid

The Contractor shall provide training or require that his

employees are knowledgeable and proficient in the following:

1 Procedures involving emergency situations;

2 First-aid fundamentals including cardiopulmonary
resuscitation; and
3 Remote field crews shall have an employee certified in First-
Aid.

1.6.4 Night Work

When working at night, spotlights or portable lights for

emergency lighting shall be provided as needed to perform the
work safely.

1.6.5 Work Near/Over Water

When crews are engaged in work over or near water and when
danger of drowning exists, suitable protection such as buoyant
work vests shall be worn. Life rings, ropes and at least one skiff
shall be provided.

1.6.6 Hydraulic Fluids

All hydraulic fluids used for the insulated sections of derrick

trucks, aerial lifts, and hydraulic tools which are used on or
around energized lines and equipment shall be of the insulating
type.

1.6.7 Live-Line Tools (Hot Sticks)

Only live-line tool poles having a manufacturer's certification

meeting the following requirements shall be used:

1 100,000 volts per foot of length for 5 minutes when the tool
is made of fiberglass, or

February 1993 - 1.0 Electricity Page 314

 2 75,000 volts per foot of length for 3 minutes when the tool
is made of wood; or

All live-line tools shall be visually inspected and wiped clean

before use each day. Tools with any hazardous defect shall be
removed from service.

1.6.8 Material Handling

1.6.8.1 Unloading

Prior to unloading steel, poles, cross arms, and similar

material, the load shall be thoroughly examined to
ascertain if the load has shifted, binders or stakes have
broken, or the load is otherwise hazardous to
employees.

1.6.8.2 Pole Hauling

During pole hauling operations, all loads shall be

secured to prevent displacement and a red flag shall
be displayed at the trailing end of the longest pole.

Precautions shall be exercised to prevent blocking of

roadways or endangering other traffic.

When hauling poles during the hours of darkness,

illuminated warning devices shall be attached to the
trailing end of the longest pole and haul truck brake
lights shall not be obscured.

1.6.8.3 Storage

No materials or equipment shall be stored under

energized bus, energized lines, or near energized
equipment.

1.6.8.4 Framing

During framing operations, employees shall not work

under a pole or a structure suspended by a crane, A-
frame, or similar equipment unless the pole or
structure is adequately supported.

1.6.8.5 Attaching the Load

The hoist rope shall not be wrapped around the load.

This provision shall not apply to electric construction
crews when setting or removing poles.

Non-conductive tag lines or other suitable devices shall

be used to control loads being handled by hoisting
equipment.

February 1993 - 1.0 Electricity Page 315

 1.6.9 Grounding for Protection of Workers

1.6.9.1 Isolation and Voltage Testing

Equipment to be worked on when it is deenergized

shall be isolated from the system and tested for
voltage using test equipment rated for the system, and
be grounded.

1.6.9.2 Applying and Removing Grounds

(See Figure IV.2)

Grounding cables shall be connected to ground first,

and then the equipment. Grounding cables shall be
installed and removed using hot sticks or insulating
gloves and protective apparel.

Grounding cables shall first be disconnected from the

line or equipment and then be disconnected from
ground.

Grounding cables shall be at, or as close as practicable

to, the work location.

Protective grounds shall be installed so that it is not

possible for workers to come in contact with a
grounded component and an ungrounded component
simultaneously.

1.6.9.3 Grounding Distance

If the work is to be performed at more than one

location in a line section, the line section must be
grounded and short circuited at each end of the line
section and the conductor to be worked on shall be
grounded at each work location.

1.6.9.4 Removal of Grounds for Testing Purposes

Grounds may be temporarily removed with the

permission of the Power Dispatcher. Extreme caution
shall be exercised while the equipment/line is not
grounded.

1.6.9.5 Grounding Electrode

When grounding electrodes are utilized, such

electrodes shall exhibit low resistance to ground;
thereby, rapidly diminishing the electrical hazard to
personnel. Otherwise, insulated tools (or other
operating equipment) must be used by personnel.

February 1993 - 1.0 Electricity Page 316

 1.6.9.6 Grounding Cables And Clamps

Grounding cables and clamps shall be capable of

conducting the anticipated fault current and shall have
a minimum size of No. 2 AWG standard copper.

1.6.10 Overhead Lines

Prior to climbing poles, ladders, scaffolds, or other elevated

structures, an inspection shall be made to determine that the
structures are capable of sustaining the additional or unbalanced
stresses to which they will be subjected.

Where poles or structures may be unsafe for climbing, they shall

not be climbed until made safe by guying, bracing, or other
adequate means.

Before installing or removing wire or cable, strains to which poles

and structures will be subjected shall be considered and
necessary action taken to prevent failure of supporting
structures.

When setting, moving, or removing poles using cranes, derricks,

gin poles, A-frames, or other mechanized equipment near
energized lines or equipment, precautions shall be taken to avoid
contact with energized lines or equipment.

Unless using protective equipment suitable for the voltage

involved, employees standing on the ground shall avoid
contacting equipment or machinery working adjacent to
energized lines or equipment.

Lifting equipment shall be bonded to an effective ground or it

shall be considered energized and barricaded when utilized near
energized equipment or lines.

Pole holes shall not be left unattended or unguarded. Even in

desert areas, unguarded pole holes are a hazard.

Tag lines shall be of a non-conductive type when used near

energized lines.

1.6.10.1 Metal Tower Construction

When working in unstable material, the excavation for

pad or pile-type footings in excess of 1.52 meters (5
feet) deep shall be either sloped to the angle of repose
as required or shored if entry is required. Ladders shall
be provided for access to pad or pile-type footing
excavations in excess of 1.2 meters (4 feet). (See
Section II, 2.4, Excavations, Trenching, And Shoring for
depth and slope criteria.)

February 1993 - 1.0 Electricity Page 317

 When working in unstable material, provision shall be
made for cleaning out auger-type footings without
requiring an employee to enter the footing unless
shoring is used to protect the employee.

A designated employee shall be used in directing

mobile equipment adjacent to footing excavations.

No one shall be permitted to remain in the footing

while equipment is being spotted for placement.

Where necessary to assure the stability of mobile

equipment, the location of use for such equipment
shall be graded and leveled.

Tower assembly shall be carried out with a minimum

exposure of employees to falling objects when working
at two or more levels on a tower.

Guy lines shall be used as necessary to maintain

sections or parts of sections in position and to reduce
the possibility of tipping.

Members and sections being assembled shall be

adequately supported.

No one shall be permitted under a tower which is in the

process of erection or assembly, except as may be
required to guide and secure the section being set.

When erecting towers using hoisting equipment

adjacent to energized transmission lines, the lines shall
be de-energized when practical. If the lines are not de-
energized, extraordinary caution shall be exercised to
maintain the minimum clearance distances required.

Erection shall be set on firm level foundations and

when the cranes are so equipped, outriggers shall be
used.

Tag lines shall be utilized to maintain control of tower

sections being raised and positioned, except where the
use of such lines would create a greater hazard.

The loadline shall not be detached from a tower section

until the section is adequately secured.

Except during emergency restoration procedures,

erection shall be discontinued in the event of high wind
or other adverse weather conditions which would make
the work hazardous.

February 1993 - 1.0 Electricity Page 318

 Equipment and rigging shall be regularly inspected and
maintained in safe operating condition.

Adequate traffic control shall be maintained when

crossing highways and railways with equipment.

An employee shall be utilized to determine that

required clearance is maintained in moving equipment
under or near energized lines.

1.6.10.2 Stringing/Removing De-energized Conductors

When stringing or removing de-energized conductors,

the provisions of the following paragraphs shall be
complied with.

Prior to stringing operations, a briefing shall be held

setting forth the plan of operation and specifying the
type of equipment to be used, grounding devices and
procedures to be followed, crossover methods to be
employed, and the clearance authorization required.

Where there is a possibility of the conductor

accidentally contacting an energized circuit or
receiving a dangerous induced voltage buildup, to
further protect the employee from the hazards of the
conductor, the conductor being installed or removed
shall be grounded.

When the existing line has been de-energized, proper

clearance authorization shall be secured and the line
grounded on both sides of the crossover, or the line
being strung or removed shall be worked on as if
energized.

When crossing over energized conductors in excess of

600 volts, rope nets or guard structures shall be
installed unless provision is made to isolate or insulate
the workman or the energized conductor. Where
practical the automatic re-closing feature of the circuit
interrupting device shall be made inoperative. In
addition, the line being strung shall be grounded on
either side of the crossover or and worked on as if
energized.

Conductors being strung in or removed shall be kept

under positive control by the use of adequate tension
reels, guard structures, tielines, or other means to
prevent accidental contact with energized circuits.

Guard structure members shall be sound and of

adequate dimension and strength, and adequately
supported.

February 1993 - 1.0 Electricity Page 319

 Anchors, riggings, and hoists shall be of ample
capacity to prevent loss of the lines.

The manufacturer's load rating shall not be exceeded

for stringing lines, pulling lines, sock connections, and
all load-bearing hardware and accessories.

Pulling lines and accessories shall be inspected

regularly and replaced or repaired when damaged or
when dependability is doubtful.

Conductor grips shall not be used on wire rope unless

designed for this application.

While the conductor or pulling line is being pulled (in

motion) employees shall not be permitted directly
under overhead operations, nor shall any employee be
permitted on the crossarm.

A transmission clipping crew shall have a minimum of

two structures clipped in between the crew and the
conductor being sagged. When working on bare
conductors, clipping and tying crews shall work
between grounds at all times. The grounds shall
remain intact until the conductors are clipped in,
except on dead end structures.

Except during emergency restoration procedures, work

from structures shall be discontinued when adverse
weather (such as high wind or ice on structures) makes
the work hazardous.

Stringing and clipping operations shall be discontinued

during electrical storms.

Reel handling equipment, including pulling and braking

machines, shall have ample capacity, operate
smoothly, and be leveled and aligned in accordance
with the manufacturer's operating instructions.

Reliable communications between the reel tender and

pulling rig operator shall be provided.

Each pull shall be snubbed or dead ended at both ends

before subsequent pulls.

1.6.10.3 Stringing Adjacent to Energized Lines

Prior to stringing parallel to an existing energized

transmission line, it shall be determined whether
dangerous induced voltage buildups will occur in the
system, particularly during switching and ground fault
conditions.

February 1993 - 1.0 Electricity Page 320

 When stringing adjacent to energized lines, the tension
stringing method or other methods which preclude
unintentional contact between the lines being pulled
and any employee shall be used.

All pulling and tensioning equipment shall be isolated,

insulated, or effectively grounded.

A ground shall be installed between the tensioning reel

setup and the first structure in order to ground each
bare conductor, sub-conductor, and overhead ground
conductor during stringing operations.

During stringing operations, each bare conductor, sub-

conductor, and overhead ground conductor shall be
grounded at the first tower adjacent to both the
tensioning and pulling setup and in increments so that
no point is more than 3.218 kilometers (two miles) from
a ground.

· The grounds shall be left in place until conductor

installation is completed.

· Such grounds shall be removed at the last phase of

aerial cleanup.

· Except for moving type grounds, the grounds shall

be placed and removed with a hot stick.

· Conductors, sub-conductors, and overhead ground

conductors shall be grounded at all dead-end or
catch-off points.

A ground shall be located at each side and within 3.2

meters (10 feet) of working areas where conductors, or
overhead ground conductors are being spliced at
ground level. The two ends to be spliced shall be
bonded to each other. It is recommended that splicing
be carried out on either an insulated platform or on a
conductive metallic grounding mat bonded to both
grounds. When a grounding mat is used, it is
recommended that the grounding mat be roped off and
an insulated walkway provided for access to the mat.
(See Power Distribution Instruction No. 50.)

All conductors, sub-conductors, and overhead ground

conductors shall be bonded to the tower at any
isolated tower where it may be necessary to complete
work on the transmission line.

· Work on dead-end towers shall require grounding

on all de-energized lines.

February 1993 - 1.0 Electricity Page 321

 · Grounds may be removed as soon as the work is
completed, provided that the line is not left open
circuited at the isolated tower at which work is
being completed.

When performing work from the structures, clipping

crews and all others working on conductors, sub-
conductors, or overhead ground conductors shall be
protected by individual grounds installed at every work
location.

1.6.11 Underground Lines

Warning signs shall be promptly placed when covers of

manholes, hand holes, or vaults are removed.

Before an employee enters a street opening, such as a manhole

or an unvented vault, it shall be promptly protected with a
barrier, temporary cover, or other suitable guard.

When work is to be performed in a manhole or unvented vault,

GI 2.100, Work Permit System, shall be enforced.

· No entry shall be permitted unless forced ventilation is

provided or the atmosphere is found to be safe by testing
for oxygen deficiency and the presence of explosive gases
or fumes.

· Where unsafe conditions are detected, by testing or other

means, the work shall be ventilated and otherwise made
safe before entry.

· Provisions shall be made for an adequate continuous

supply of air.

1.6.11.1 Work in Manholes

While work is being performed in manholes, an

employee shall be available in the immediate vicinity
to render emergency assistance as required. This shall
not preclude the employee in the immediate vicinity
from occasionally entering a manhole to provide
assistance, other than for emergencies. This
requirement does not preclude a qualified employee,
working alone, from entering for brief periods of time, a
manhole where energized cables or equipment are in
service, for the purpose of inspection, housekeeping,
taking readings, or similar work if such work can be
performed safely. However, someone on the surface
must be aware of this type of entry and know the
expected duration of the task.

February 1993 - 1.0 Electricity Page 322

 Before entering or using open flames in a manhole
excavation in an area where combustible gases or
liquids may be present, such as near a gasoline service
station, GOSP, refinery, etc., the atmosphere of the
manhole or excavation shall be tested and found safe
or cleared of the combustible gases or liquids (See GI
2.100).

1.6.11.2 Trenching and Excavating

During excavation or trenching, in order to prevent the

exposure of employees to the hazards created by
damage to dangerous underground facilities, efforts
shall be made to determine the location of such
facilities and work in accordance with GI 2.100, Work
Permit System.

When underground facilities are exposed (electric, gas,

water, telephone, etc.) they shall be protected as
necessary to avoid damage.

When multiple cables exist in an excavation, the cable

to be worked on shall be identified by electrical means
unless its identity is obvious by reason of distinctive
appearance.

Before cutting into a cable or opening a splice, the

cable shall be identified and verified by the proponent
department.

When working on buried cable or on cable in manholes,

metallic sheath continuity shall be maintained by
bonding across the opening or by equivalent means.

1.6.12 Construction in Energized Substations

When construction work is performed in an energized substation,

authorization shall be obtained from the local power service
dispatcher and a work permit shall be issued. (See GI 2.100)

When work is to be done in an energized substation, safety

precautions shall be detailed in the work permit (See GI 2.100).

Extreme caution shall be exercised in the handling of busbars,

tower steel, materials, and equipment in the vicinity of energized
facilities.

1.6.12.1 Barricades and Barriers

Barricades or barriers shall be installed to prevent

accidental contact with energized lines or equipment.

February 1993 - 1.0 Electricity Page 323

 Signs indicating the hazard shall be posted near the
barricade or barrier.

1.6.12.2 Control Panels

Work on or adjacent to energized control panels shall

be performed by designated employees.

Precaution shall be taken to prevent accidental

operation of relays or other protective devices due to
jarring, vibration, or improper wiring.

1.6.12.3 Mechanized Equipment

Use of vehicles, gin poles, cranes, and other equipment

in restricted or hazardous areas shall at all times be
controlled by designated employees.

All mobile cranes and derricks shall be effectively

grounded when being moved or operated in close
proximity to energized lines or equipment, or the
equipment shall be considered energized. (See OSHA
29 CFR 1926 Subpart N.)

Fenders shall not be required for low-boys used for

transporting large electrical equipment, transformers
or breakers.

1.6.12.4 Substation Fences

When a substation fence must be expanded or

removed for construction purposes, a temporary fence
affording similar protection, when the site is
unattended, shall be provided. Adequate bonding and
grounding interconnections shall be maintained
between temporary fence and permanent fence.

All gates to all unattended substations shall be locked,

except when work is in progress.

1.7 Electric Shock

Speed is essential in dealing with any electrical accident. A copy of "The

Treatment for Electric Shock" placard in Arabic and English should be
prominently displayed so that everyone knows what to do in an
emergency. Employees will be trained in First Aid and cardiopulmonary
resuscitation (CPR).

February 1993 - 1.0 Electricity Page 324

 In brief, the sequence for dealing with an electrical accident is:

1 If at all possible, switch off the power supply. If this is not instantly
possible, release the victim from contact with the conductor by using
dry gloves, dry blanket, dry wood, dry clothing, rubber sheets, or
properly insulated equipment.
2 If breathing has stopped, begin CPR and continue as necessary.
3 Call for first aid assistance, a doctor, and an ambulance. The Saudi
Aramco emergency number is 110.

February 1993 - 1.0 Electricity Page 325

FIGURE IV.1: TEMPORARY CROSSING FOR CONSTRUCTION EQUIPMENT

Overhead power lines are usually uninsulated and

any kind of metallic object coming near or in
contact with them can cause a hazardous situation.
High voltage can easily arc across considerable
distance. Overhead lines should therefore be re-
routed, "made dead" or protected by timber "goal
posts" and barriers. Clearance distances should be
agreed upon with Saudi Aramco before work starts.

February 1993 - 1.0 Electricity Page 326

FIGURE IV.2 PROPER USE OF INSULATING TOOLS AND PROTECTIVE APPAREL

Note: Grounding Cables Shall Be Isolated And Removed Using Insulating Tools And
Protective Apparel

February 1993 - 1.0 Electricity Page 327

2.0 IONIZING RADIATION
Ionizing industrial radiation, such as x-rays generated by equipment or gamma
rays emitted spontaneously by radioactive materials, are widely used in industry
for non-destructive testing, e.g., testing of welds in pipes and pressure vessels,
without damaging the material. The material tested does not retain any
radioactivity when testing is completed.

For all practical purposes, the radiation produced by x-ray equipment or emitted
by radioactive sources are the same. X-rays and gamma rays both have properties
which should be understood. Even though they penetrate the body, they cannot
be perceived by any of our five senses; they can be absorbed and scattered by
matter; they travel in straight lines at the speed of light; they ionize gases; they
affect photographic emulsions; and by far the most important, they can be harmful
to the living cells of the body.

INSTRUCTIONS AND FORMS

Saudi Aramco General Instructions:

150.003 Ionizing Radiation Protection

00-AID-08 Radiation Safety Manual

Saudi Aramco Forms:

Saudi Aramco 2654 Personal Radiation Exposure

Saudi Aramco Standard Drawings:

AB-36895 Radiation Warning Sign

2.1 Methods of Protection Against Radiation

Distance, time, and shielding are the usual methods of reducing

radiation exposure.

2.1.1 Distance

Distance is an effective method of protection because gamma

and x-rays obey the inverse square law, that is, the radiation
intensity decreases with the inverse square of the distance.
Conversely, dose rates at close distances can be extremely high,
even for low activity sources. It is essential, therefore, that
unshielded sources are kept at a sufficient distance from
personnel so as not to pose a health hazard to them.

2.1.2 Time

Time is a useful method of protection because high dose rates

can be accepted over very short periods of time. However, the

February 1993 - Construction Safety Manual: Ionizing Radiation Page 328

 cumulative dose must remain at acceptable limits given in GI
150.003-2.

2.1.3 Shielding

To lessen harmful radiation, materials of high density, such as

lead, depleted uranium, or tungsten, are used to absorb emitted
radiation.

In the use of x-ray equipment, precautions against emitted

radiation are necessary until the electric power is turned off and
locked out. On the other hand, radioactive materials constantly
emit radiation and cannot be switched off. Consequently, to
absorb unwanted radiation and facilitate handling, sealed
sources are housed in shielded containers or bunkers.

2.2 Classification of Personnel and Exposure Limits

In order to control human exposure to industrial radiation, all employees

and contractors are classified as either radiation workers or non-radiation
workers according to their training and need to use radiation sources.
Classification does not guarantee safety; safety procedures and
adequate equipment must be used at all times.

2.2.1 Radiation Workers

A radiation worker is an occupationally exposed person or

employee whose job involves routine use of ionizing radiation
and who has reasonable chance of being exposed to radiation
from a radioactive source.

Radiation workers are further categorized as Competent Persons

or Radiographers. Competent Persons do not normally use
radiation sources, but by training and experience are capable of
supervising both routine operations and emergency situations
involving radiation. Radiographers are expected to safely use
radiation sources in the course of their work and must be in
possession of a valid "Saudi Aramco Permit to Use
Material/Equipment Producing Ionizing Radiation" before they
can work with a radioactive source.

Radiographers must wear two personal dosimeters when working

with radiation, a direct-reading pocket dosimeter and an
integrating permanent dosimeter (film badge or
thermoluminiscent dosimeter [TLD]).

2.2.2 Non-Radiation Workers

Non-radiation workers should not receive more than those dose

limits given in GI 150.003-2.

February 1993 - 2.0 Ionizing Radiation Page 329

 2.2.3 Exposure Limits

Radiation doses to workers should always be kept as low as

reasonably achievable (ALARA). Under no circumstances shall
the doses exceed those limits given in GI 150.003-2 for
occupational or non-occupational people.

Special controls (see GI 150.003-2) are imposed on persons

who are, or are capable of being, pregnant. No occupational
exposure is allowed for persons less than 18 years of age.

Over exposure shall be reported to the Saudi Aramco proponent,

the Occupational Medicine Services Unit, and the Loss Prevention
Department.

2.3 Responsibilities for Safe Handling

The Radiation Protection Committee (see GI 150.003) has full

responsibility in all matters concerning the safe use, storage, and
transportation of industrial sealed sources and x-ray machines used on
Saudi Aramco property.

2.3.1 Contractor

The contractor appoints competent persons to be responsible for

the immediate supervision and the enforcement of instructions
and standards. Personnel involved in performing non-destructive
testing must be certified and hold a valid "Permit to Use
Material/Equipment Producing Ionizing Radiation".

2.3.2 Competent Person

Each radiographer will check at the beginning of each shift on

the zeroing and recharging of dosimeters and on the condition of
the equipment. A competent person familiar with all of Saudi
Aramco radiation use requirements will make field audits to
ensure compliance with Company instructions and standards.
He must report the results of these audits to the applicable
department responsible for the operation. Also he must be
familiar with all equipment and procedures so that the proper
corrective action can be taken in any emergency situation
involving radioactive equipment.

2.3.3. Radiographer

At the start of each shift, radiographers must ensure that all

equipment is in safe working order. All malfunctions must be
reported to the supervisor or Competent Person immediately.
The radiographer must also make sure that he is wearing a valid
TLD or film badge and a direct-reading pocket dosimeter which
has been charged and zeroed. One radiation monitoring
instrument must be available for each source in use. Equipment

February 1993 - 2.0 Ionizing Radiation Page 330

 must be transported to the work site with safety locks in place.
Under no circumstance is equipment to be transported in an
unassembled or open condition.

Upon arrival at the job site and prior to operating with any sealed
source, the radiographer must ensure that non-radiation workers
are not subject to radiation levels that would exceed that which
is permitted. Radiation areas must contain radiation warning
signs (see Figure IV.3) and be clearly displayed around the
circumference of the radiation area. In addition, in populated
work areas, a rope or tape barrier shall be erected around the
radiation area. The area will be monitored with approved survey
meter to ensure safe area for non-radiation workers is
maintained. Further guidance on industrial radiography is
provided in GI 150.003-4 and 00.AIP-08.

A weekly report on the condition of all equipment should be

passed to the supervisor.

2.4 Shipping and Transportation

Government Permits are required for shipping radioactive materials into

and out of Saudi Arabia. Additional information is available from
Purchasing Services Division.

Transporting radiation sources to work locations requires a locked

container located out of the passenger compartment. The vehicle shall
have radiation signs on the front and rear.

2.5 Storage Areas

Upon completion of work or at the end of each work period, every sealed
source must be returned to a storage area approved by the Saudi
Aramco Radiation Protection Committee. Storage is usually within
fenced area. All permanent or temporary storage areas (bunkers) must
be approved of by the Saudi Aramco Radiation Protection Committee.
Sources may not be stored in the back of a truck whether or not they are
under lock and key. Radiation readings must be taken at the perimeter
of the storage area and the radiation level must be within the acceptable
limits given in GI 150.003. Radiation signs must be fixed to the barriers
of all storage areas. (See Figure IV.3.)

· A log shall be maintained of radiation sources in storage, logged in

or out, by source and responsible competent person in charge of
source.

February 1993 - 2.0 Ionizing Radiation Page 331

FIGURE IV.3: STANDARD SIGN - RADIATION

February 1993 - 2.0 Ionizing Radiation Page 332

V. Chemicals And Operations

February 1993 - Construction Safety Manual: V. Chemicals And Operations Page 333
1.0 LIQUEFIED PETROLEUM GASES
Liquefied Petroleum Gases (LPG) are now being widely used in the construction
industry. The precautions covered in this section are directed to those industrial
operators who handle these gases, i.e., stores personnel and the actual operators
using the gases. LPG is a term applied to combinations of hydrocarbons known
under various trade names and also widely known as propane and butane.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 355.020 Control of Compressed Gas Cylinders

Saudi Aramco Engineering Standards:

SAES-D-5 Liquefied Petroleum Gas Equipment, Installation

SAES-B.057 Safety Requirements: Refrigerated and Pressure Storage Vessels

Saudi Aramco Bottled Gas Manual:

Part 1.7 Liquid Petroleum Gas

American National Standards:

NFPA 54-88 Fuel Gas Code

ANSI A10.10-81

Safety Requirements for Temporary and Portable Space Heating

Devices & Equipment Used in the Construction Industry

NFPA 58-89 Liquefied Petroleum Gases, Storage and Handling

1.1 General

These gases are colorless, heavier than air, and normally odorless, but
for commercial usage, an odorizing agent is added for the obvious
reason of facilitating detection in the event of accidental escape of the
gas.

At normal temperatures, they are gaseous and can be changed into a

liquid by the application of moderate pressure. In the liquid form,
relatively large quantities of LPG can be safely transported and stored in
suitably designed containers. The approximate ratios of gas volume to
liquid volume are 275:1 for propane and 240:1 for butane.

Both gases are heavier than air at normal temperatures. Any leakage
will form a gas cloud which will settle at the lowest possible level. It may
ignite if a flame or sparks are present. This could happen at some

February 1993 - Construction Safety Manual: Liquefied Petroleum Gases Page 334
 considerable distance from the source of leakage. The gases form an
explosive mixture with air, and they react vigorously with oxidizing
materials. These gases can be highly dangerous; if the container is
exposed to heat or flame, there is a high risk of explosion. To reduce the
risk of explosion, the cylinders must be equipped with relief valves or
fusible plugs.

1.2 Storage

1.2.1

Cylinders, whether empty or full, should be stored under cover

for protection against the elements. The storage place should
be detached from any other buildings and constructed of non-
combustible material. It should preferably be a well-ventilated
one-story building with all doors leading directly to the outside.

LPG cylinders must be stored at least 6.1 meters (20 feet) away
from oxygen or oxidizers or must be separated from them by a
fire wall rated at 30 minutes.

1.2.2

The building should be fenced-off and signs should be displayed

both in Arabic and English: "No Smoking".

Water and dry chemical fire extinguishers shall be available.

1.2.3

Natural ventilation points should be positioned at both high and

low levels.

1.2.4

All electrical fixtures should be of an explosion-proof type.

1.2.5

All gas valves, fittings, connections, and piping shall be made of

stainless steel, brass or copper; rubber/plastic hoses are
prohibited.

1.3 Handling of Cylinders

1.3.1

Cylinders must not be dropped or allowed to come into violent

contact with each other.

February 1993 - 1.0 Liquefied Petroleum Gases Page 335

 1.3.2

They must be stored and used in an upright position, thus

preventing the liquid from passing through the relief valve
regulator and into the equipment.

1.3.3

They must not be placed in or near excavations or any low level

area.

1.3.4

They must be placed on level ground and secured to prevent

accidental tipping over.

1.3.5

Care should be taken that the valve assemblies are not

damaged. The main valve should be closed and the valve cap in
position when the cylinder is not in use.

1.3.6

Smoking is not permitted when handling cylinders.

1.4 Leakage

1.4.1

Cylinders, valves, connections, hoses, and pipings should be

regularly inspected for damage or leakage. Detection can be
carried out by the following methods, if flammable gas meter is
unavailable:

1 Smelling
2 Touching: Leaking cylinder may be colder than those around
it.
3 Listening: Sound of escaping gas.
4 Looking: Localized condensation or frosting.

1.4.2

Small leaks may be confirmed by using soapy water.

1.4.3

A leaking cylinder must be immediately removed to an open

space, clear of all buildings and people or any potential source of
ignition.

February 1993 - 1.0 Liquefied Petroleum Gases Page 336

 1.4.4

The cylinder must be placed with the leak uppermost.

1.4.5

The supplier must be notified immediately.

1.5 Transportation

1.5.1

Full or empty cylinders which are loaded on vehicles must be

placed in an upright position, be adequately secured to prevent
movement, and have valve caps in place.

1.5.2

The vehicle should have fire fighting and first aid equipment.

1.5.3

The vehicle must also display all the necessary warning notices.

1.6 Operation

1.6.1

In permanent or semi-permanent installations, the cylinder must

be placed outside the building out of direct sunlight and the gas
piped to appliances inside.

1.6.2

The cylinder must be secured in an upright position, away from

excavation, pits, and other low lying areas.

1.6.3

The regulator and other equipment is to be connected and a test

made to ensure that all joints are gas tight.

1.6.4

The regulator capacity must be suitable for the equipment being

used.

1.6.5

Before lighting, a check is to be made to ensure that there is

sufficient ventilation for the burner and that all combustible
materials are removed from the work area.

February 1993 - 1.0 Liquefied Petroleum Gases Page 337

 1.6.6

Once the burner has been lit, it should burn with a steady blue
flame with blue-green base cones.

1.6.7

A dry chemical fire extinguisher must be readily available at the

work area.

1.6.8

Shut off valves shall be installed at the main tank supply and at
the operating source. (See Loss Prevention Booklet, "Hazards of
Gas Cylinders")

1.7 Action in Case of Fire

1.7.1

When cylinders are exposed to severe fire conditions and are

engulfed in flames, no attempt should be made to extinguish the
fire. In such condition, cylinders are likely to explode
immediately.

1.7.2

The action to be taken in such an instance is to evacuate the

area immediately and call the Fire Protection Department.

1.7.3

Cylinders which have been exposed to fire conditions must be

adequately cooled with water before any attempt is made to
remove them.

February 1993 - 1.0 Liquefied Petroleum Gases Page 338

 1.7.4

If cylinders are equipped with automatic relief valves and the fire
exposure is severe, ignited jets of gas from these valves can
extend as far as 6 meters (20 feet).

1.7.5

In the case of a small fire arising from gas leakage, it is possible

to extinguish the fire by immediately turning off the cylinder
valve. The cylinder should be approached from the opposite
direction to the source of fire.

1.7.6

If a fire does not directly involve other cylinders in the vicinity,

water hoses played on those cylinders will prevent increased
internal pressure and minimize the risk of explosion.

1.7.7

All cylinders which have been involved in a fire must be returned

immediately to the supplier, alerting the supplier that the
cylinder was involved in a fire.

1.8 Bulk Installations

Before any bulk storage installation is undertaken, the LPG supplier

should be consulted on the size of the tank required and the most
suitable fittings for that particular installation, including relief capacity.

1.8.1

Temporary tanks are to be installed above ground on a dry, hard

foundation away from drains, culverts, or hollows where it would
be possible for any leaking gas to collect.

1.8.2

Tanks should not be exposed to heat or direct rays of the sun and
they must be adequately protected against accidental or
unauthorized interference.

1.8.3

Only trained personnel are to install bulk tanks and equipment.

All items used must be of approved design and comply with the
appropriate standards.

February 1993 - 1.0 Liquefied Petroleum Gases Page 339

 1.8.4

All pipeline systems must be tested to a safe working pressure

after completion of the assembly.

1.8.5

Fire water protection shall be provided.

1.9 First Aid

If LPG has been inhaled, the affected person must be removed from the
area, kept warm and rested, and not allowed to move about. If the
affected person is not breathing, mouth-to-mouth resuscitation should be
applied. No attempt should be made to give an unconscious person
anything to drink. If the person is breathing, oxygen must be
administered by a competent person. If liquid has gone to the eyes, they
must be thoroughly washed out with water.

Medical aid must be obtained as soon as possible.

February 1993 - 1.0 Liquefied Petroleum Gases Page 340

2.0 PLANT OPERATIONS
The safe processing and movement of oil from underground to ship or
transmission pipeline is the primary Saudi Aramco objective. Any construction
operation which could affect the safety of oil processing and movement must be
planned and performed in accordance with the operating procedures of the area in
which the job is located.

Every plant area in Saudi Aramco operations has a specific set of operating
instructions and the operating supervisor for that area has full responsibility for
safety precautions. With this responsibility, he also has authority to issue work
permits and stop any work if it is not in accordance with proper procedures.

It is therefore necessary for anyone expecting to work in an area where oil or gas is
handled to know the rules and regulations and obey them.

Failure to follow the operating rules can result in not only destruction of Saudi
Aramco property but also death of construction and operating personnel. This
type of disaster must be prevented.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100 Work Permit System

GI 2.710 Mechanical Completion & Performance Acceptance of Plant/Unit

GI 441.014 Repair Procedures on Hydrocarbon Pipelines

SAES-A-005 Safety Instruction Sheet

Schedule 'D':

Saudi Aramco Safety, Health and Environmental Requirements -

Plant Operations

2.1 Additional Information On Saudi Aramco Instructions

and Standards

There are a number of additional instructions and standards which apply

to construction operations, either inside or outside Restricted Areas. The
contractor must determine which of these apply to him and ensure that
his supervisory staff is familiar with them. This can be accomplished
through discussions with operations management for the area and with
the construction engineer. A meeting of all concerned prior to starting a
job shall be conducted and a Hazard Identification Plan shall be prepared
for review by Saudi Aramco Loss Prevention Department.

Because of the large number of instructions which might be applicable to

a specific job, it is not practical to list all of them. The following,

February 1993 - Construction Safety Manual: Plant Operations Page

341
 however, will be helpful in locating applicable instructions and
standards.

2.1.1 General Instruction Manual

This manual is one which provides general instructions

applicable to all Saudi Aramco areas and operations. The
contractor will find most of the instructions applying to him in
this manual.

2.1.2 Producing Instruction Manual

This manual is designed to provide producing operating

personnel with instructions on operating practices and
procedures for specific operations. The contractor would find it
useful to know in advance what these procedures are and how
they affect him.

2.1.3 Refinery Instruction Manual

This manual is designed for use in refinery operations. Its design

and use is similar to the Producing Instruction Manual except that
it applies to refinery operations.

2.1.4 Saudi Aramco Engineering Standards

These provide detailed instructions on how to do specific jobs

and establish minimum standards to follow. The contractor must
use all applicable engineering standards in the performance of
his job. Failure to do so will result in immediate shutdown, a
delay for which the contractor will be responsible. The Saudi
Aramco construction engineer is familiar with the Engineering
Standards and will assist the contractor. Saudi Aramco Loss
Prevention personnel will advise and provide guidance on fire
and safety problems.

2.2 Work Permit System

Any contractor planning to do work in a restricted area must obtain a

work permit from the operations supervisor for the area.

To obtain this permit, the contractor must have personnel with a valid
certificate to receive work permits. GI. 2.100, Work Permit System,
provides the information needed to obtain such certificates and explains
how to use them.

The work permit is a written permission to proceed with the work in

accordance with the plans and the restrictions written on the form.
Without a proper permit, work will not be allowed in the area. (See Work
Permit System, Section II.1 of this Manual.)

February 1993 - 2.0 Plant Operations Page 342

2.3 Operation of Plant Equipment

It is expressly forbidden for any construction personnel to operate any

valves, switches, push buttons, or other devices in an operating area. If
the work dictates such action, the contractor personnel must call the
operations supervisor to perform the service.

If the job involves work on equipment which is in service, a specific set of

written procedures will have to be prepared and approved in advance by
Operating and Safety personnel. The contractor must strictly follow
these procedures. No deviations will be permitted without the prior
approval of the operation supervisor. Close contractor supervision will
be required in these types of jobs.

2.4 Shutdown and Maintenance in Plant Operations

Shutting down a plant is the sole responsibility of operating personnel.

Construction personnel should not, under any circumstances, be
involved in any operational activity.

In certain emergency situations, it may be necessary for the contractor

to shut down the job and even move his equipment to permit access for
operating and maintenance personnel. This emergency activity must be
done as requested.

2.5 Commissioning

GI 2.710, Mechanical Completion and Performance Acceptance of

Plant/Unit, outlines the procedures and requirements for accepting new
plants or additions to plants after they have been completed by the
contractor. This is to assure that the plant is safe to operate in every
respect. The contractor should familiarize himself with this instruction
before he starts work.

If there is any question on the fire and safety aspects of this instruction,
the contractor should contact the Saudi Aramco Loss Prevention
Department for clarification and assistance.

2.6 Emergency Procedures: Saudi Aramco Disaster Plan

It is necessary for all contractors to familiarize themselves with the

Disaster Control Plan for the plant and area in which the job is located.
Each person working for the contractor must know exactly what to do
when the emergency evacuation or stop work alarms are sounded and
do it without delay.

The Disaster Control Plan does not normally require the assistance of any
construction personnel. Saudi Aramco personnel are trained to handle
the emergency.

February 1993 - 2.0 Plant Operations Page 343

 If the emergency is the result of a construction operation, construction
personnel will notify operating personnel immediately. The operating
personnel will initiate alarm procedures and direct activities in controlling
the emergency.

When the emergency alarm is sounded for any reason, all contractor
personnel will immediately shut down their job, make it safe, and
proceed in an orderly manner to the designated assembly point. They
will be checked out by Security and should assemble at a point outside
the area and await further instructions from the Saudi Aramco Disaster
Commander.

Periodically, Saudi Aramco holds Disaster Drills to ensure the smooth

functioning of its Disaster Plan. The contractor is required to participate
in these drills just as if it were an actual emergency.

2.6.1 Gas Release Emergency Procedures

If there is a reason to suspect a gas release in the area through

which you are driving:

1. Immediately shut off the vehicle engine and do not try to

restart it.
2. Check the wind direction by looking at the windsock.
3. Get out of the vehicle and walk to a safe location generally
in a crosswind direction away from the point of release.
4. Inform plant operation employees of the situation.
5. Do not go and investigate, leave this to operations.

February 1993 - 2.0 Plant Operations Page 344

3.0 PRESSURE TESTING
It is essential that safe practices be observed during pressure testing, due to the
potential hazards associated with high pressure liquids and gases.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 2.100. Work Permit System

GI 2.102. Pressure Testing Safely

GI 2.710 Mechanical Completion And Performance Acceptance Of Plant/Unit

GI 432.00 Pipeline Hydrotest Water Disposal

GI 434.000 Pipeline Repair and Maintenance

GI 447.002 Pressure Relief Valves - New Installation, Change in Set Pressure, or

Retirement from Service

GI 447.003. Pressure Relief Valves - Routine Test, Inspection, Quality Assurance

And Regulation

Saudi Aramco Engineering Standards:

SAES-K-001 Refrigerant Piping

SAES-A-004 Pressure Testing

SAES-A-005 Safety Instruction Sheet

SAES-A-007 Hydrostatic Testing Fluids And Lay-Up Procedures

SAES-B-55 Plant Layout

Construction Specification Manuals:

Form Saudi Aramco 2642

Engineering (Pressure Test Report - 11/90)

Form Saudi Aramco 2642-1

Engineering (Pressure Test Information Sheet - 11/90)

February 1993 - Construction Safety Manual: Pressure Testing

Page 345
American Petroleum Institute Standards:

API-STD-600-91

Steel Gate Valves - Flanged And Butt-Welding Ends, Ninth Edition

API-STD-620-90

Design and Construction of Large, Welded, Low Pressure Storage

Tanks, Eighth Edition

American National Standards Institute:

ANSI B 16.5-88

Steel Pipe Flanges and Flange Fittings

ANSI B 31.3-90

Chemical Plant And Petroleum Refinery Piping

ANSI B 31.4-89

Liquid Transportation Systems For Hydrocarbons, Liquid Petroleum

Gas, Anhydrous Ammonia, And Alcohols

ANSI B 31.8-89

Gas Transmission and Distribution Piping System

American Society of Mechanical Engineers Standards:

Section VIII. ASME Boiler and Pressure Vessel Code

3.1 Preparation

3.1.1 SAES-A-004 (Pressure Testing)

The person in charge of hydrostatic testing should have read

SAES-A-004 and GI 2.102, 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.

3.1.2 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.

February 1993 - 3.0 Pressure Testing Page 346

 3.1.3 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 vapors 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.

3.1.4 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.

3.1.5 Pipings And Joints

Prior to testing, investigations shall be carried out to verify

whether or not temporary restraints are required to restrict the
movement of pipings and joints during testing; when necessary,
adequate restraints shall be provided.

3.1.6 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.

3.2 General Requirements

3.2.1

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, in accordance with SAES-A-004, 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.

3.2.2

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

of the equipment.

February 1993 - 3.0 Pressure Testing Page 347

 3.2.3

Any ancillary equipment not under test must be isolated by

valves (subject to part 3.1.4) or blind flanged and vented or
disconnected.

3.2.4

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.

3.2.5

The equipment / vessel shall have adequate vacuum relief

capacity to avoid damage or collapse, when draining the test
liquid.

3.2.6

Lines should be drained and dried mechanically when the test

liquid is corrosive or otherwise hazardous.

3.2.7

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, see SAES-A-004 and GI 2.102.

3.2.8

A system under test shall be depressurized (with the exception of

pressure due to a liquid head) before any work is done to stop
leaks or repair weakness, including the tightening of bolts. In
tightness tests, bolts may be tightened without depressurizing, if
specifically approved in the written test procedure.

3.2.9

A block valve is required on the line from the test pump to the
equipment under test.

3.2.11

Air shall not be used to displace test fluid from underwater

equipment unless it has been determined that the equipment
will not float.

February 1993 - 3.0 Pressure Testing Page 348

3.3 Test Liquid

3.3.1

Water is a normally the preferred test liquid. Alternatives must

be approved by a deviation from standard or they may be used if
they are specifically permitted by SAES-4-004.

3.3.2

Salt water must not be used for testing any material subject to
stress corrosion cracking in the presence of chloride ions (such
as stainless steel type 304 or 18.8 - CrNi).

3.3.3

Pneumatic (gas) testing may be required as per SAES-A-004.

Pneumatic testing other than as specified in SAES-A-004 may
be done only with the explicit permission of the Consulting
Services Department. Testing with air or other gases under
pressure can be hazardous due to the explosion potential.

3.3.4

Possible changes in pressure due to thermal expansion,

contraction or hydrostatic heads must be taken into account.

3.3.5

Written procedures approved prior to testing shall be followed for

the disposal of test mediums containing chemical additives for
control of corrosion or bacteria, as per the requirements of GI
432.000.

February 1993 - 3.0 Pressure Testing Page 349

4.0 CHEMICALS
There are thousands of chemicals in existence and hundreds of new ones are
being developed for commercial use every year. While almost all of these
chemicals are beneficial in some way, they can be dangerous too. In fact, of the
thousands of chemicals in existence, it is difficult to find any that are absolutely
harmless.

When dealing with an unfamiliar chemical, it is always wise to assume that it is

hazardous. The exposure to hazards associated with a material depends largely
on its proper identification, handling, usage, transport, storage and disposal. In
addition, materials which may be completely harmless in one application may be
deadly in another.

There are too many chemicals and too many possible combinations to deal with
them individually here. In the references listed, there are many sources of
information on the identification, storage, transportation, use, and disposal of
hundreds of chemicals. In the literature there are tables of hazardous chemical
reactions. If the name of the chemical is known, the names of others with which it
is likely to react dangerously can be found. The proper identification and labeling
of chemicals is a very important safety precaution.

When dealing with a potentially harmful chemical, precautions should be taken to

ensure that employees do not swallow it, inhale it, or allow it to contact their skin.
The chemical must not be allowed to accidentally mix with other substances in
transportation, storage, or use. It must not be subjected to undue shock, pressure,
or heat. When the chemical is no longer needed, it must be safely disposed of or
recycled.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 150.001. Asbestos Regulation

GI 330.87. Bulk Deliveries of Oil Field Treatment Chemicals from Local Vendors

GI 355.001. Identifying, Cataloging, Ordering And Tracking Of Hazardous

Materials

GI 355.002 Receiving, Storing, And Issuing Hazardous Material

GI 355.003 Disposing Of Hazardous Materials

GI 355.004 Handling And Storing Polychlorinated Biphenyls (PCBs) For disposal

GI 355.015. Requisitioning, Receiving, Storing and Issuing Explosives

GI 355.015-1 Deterioration And Disposal Of Explosives

Refinery Instruction Manual:

February 1993 - Construction Safety Manual: Chemicals

Page 350
No. 5.001. Caustic And A Dip Diluting Plant 20 - Safety Regulations

No. 10.740. LPG Plant, Salt Water Chlorination

No. 13.850. Sulfuric Acid Safety Regulations - Air And Water Unit

Operating Instruction Manual:

No. 5.244. Inhibitor, Handling Procedure

Saudi Aramco Engineering Standards:

Saudi Aramco Bottled Gas Manual

Saudi Aramco Chemical Hazard Bulletins (CHBs)

American National Standards:

ANSI 288.2. Standard Practice for Respiratory Protection

American Petroleum Institute:

API 2202-91

Dismantling And Disposing Of Steel From Tanks Which Have

Contained Leaded Gasoline

National Fire Protection Association Standards:

NFPA 321. Basic Classification of Flammable and Combustible Liquids

NFPA 325M. Fire Hazard Properties of Flammable Gases, Liquids, and Volatile
Solids

NFPA 49. Hazardous Chemical Data

NFPA 491M. Manual of Hazardous Chemical Reactions

NFPA 704. Standard System For The Identification of Fire Hazards of Materials

Threshold Limit Values for Chemical Substances and Physical Agents in the Work
Environment - American Conference of Government Industrial Hygienists (ACGIH)

Material Safety Data Sheets (MSDS) - Manufacturer's literature on chemicals

approved by US. Department of Labor

Dangerous Properties of Industrial Materials - Dr. N. Irving Sax

4.1 Hazard Identification System

The hazardous nature of a material is related to the manner in which it is

transported, stored or used; the materials with which it may come in

February 1993 - 4.0 Chemicals Page 351

 contact; and how it is disposed of or recycled. There is no single
identification system which can briefly indicate the hazards for all these
conditions. Saudi Aramco uses NFPA 704 Identification of Fire Hazard
Materials, which indicates the fire hazards associated with any chemical
and also describes the hazards which might be encountered in storage,
transportation, use or disposal of the chemical.

Many of the materials in the Chemical Section, Class 26, of the Saudi
Aramco Material System Catalog are marked by the use of hazard
identification labels. The container may not be so marked, but it is
indicated in the catalog description of the chemical. The system is
based on four different symbols or numbers arranged in a diamond
pattern (see Figure V.1).

The degree of possible injurious health effects, susceptibility of the

materials to burning and to release of energy are rated by numbers (see
Figures V.2 and V.2.A.). A zero (0) rating indicates little or no hazard and
a four (4) indicates a high degree of hazard. It should be remembered
that although a zero health hazard rating indicates that the material
offers no hazards to fire fighters beyond that of ordinary combustible
material subjected to fire, it does not mean that the material is harmless
if inhaled or swallowed.

4.2 Health Hazards

Hazards to health arise from inhaling, swallowing, or skin contact. The

severity of the hazard ranges from nuisance chemicals that produce no
injury, to chemicals that on short exposure can cause severe injury or
death. For industrial workers, the most prominent means of entry of a
hazardous chemical into the human body is through the respiratory tract
by inhalation. The next most important means of entry is through skin
absorption. The least hazardous pathway is through swallowing the
chemical, as this seldom occurs in industry. (Reference: Chemical
Hazard Bulletins.)

4.2.1 Inhalation Pathway Hazard

Chemicals may be in the form of gases, vapors, dusts, or a

mixture of these. The senses of sight or smell cannot be
depended upon to warn of chemical hazards. Some gases are
harmful in concentrations which cannot be detected by their
odor. Furthermore, some gases paralyze the sense of smell.
Hydrogen sulfide, at low concentrations, can very quickly
paralyze the olfactory nerves so that harmful concentrations
cannot be detected through smell. Ordinary automotive
gasoline, to some extent, does the same thing.

When handling a volatile liquid, the maximum allowable

concentration (MAC) of the vapor should be known and not
exceeded. Where exhaust ventilation is not available, good
mechanical ventilation must be provided or the work must be
done outdoors.

February 1993 - 4.0 Chemicals Page 352

 In the case of a chemical spill, it may not be possible to control
the maximum allowable concentration. Therefore it is necessary
to keep the worker from breathing the vapor by limiting the
amount of vapor through careful handling or through the use of
local exhaust ventilation. If the concentration of the chemical in
the air exceeds the threshold limit value (TLV) or MAC, then
respiratory protective devices are needed. It is important that
the right kind of device for the particular hazard be obtained.
(See Breathing Apparatus, Section I.10 of this Manual.)

Dust is a common hazard. Whenever dusty material is handled,

a respiratory hazard may exist. Exhaust ventilation, fans,
blowers, and proper handling procedures must be used to keep
the dust from entering the worker's breathing zone. If these
methods fail, dust masks must be provided and their use
enforced.

Fine droplets of liquid form whenever liquids are sprayed or

splashed so suitable precautions must be taken to prevent the
fine droplets of liquid from entering the worker's breathing zone.
Ventilation is also recommended. If such methods are not
adequate, suitable respiratory protection must be provided.

4.2.2 Skin Hazards

Skin contact/exposure hazard may not be as dangerous to life as

respiratory hazards, but they are far more common. Dermatitis
resulting from contact with harmful chemicals is a common work
injury. Proper handling methods are the first step in protection.
The second step, in the case of materials which act rapidly on
the human body, such as corrosive chemicals (i.e. acids and
caustics) is to provide a physical barrier in the form of goggles,
face shields, hoods, gloves, aprons, suits, etc. The third step is
to provide eyewash fountains and safety showers, which flush
the material from the eyes or skin.

The type of personal protective equipment required depends on

the hazardous characteristics of the chemical and the way it is
used. Personal cleanliness is important. Thorough washing of
the hands and face before meals, daily bathing, and a regular
change of clothing will reduce harmful contact with chemicals.

February 1993 - 4.0 Chemicals Page 353

 4.2.3 Hazards of Swallowing Chemicals

In industry, swallowing chemicals does not occur frequently. The

main precaution is to ensure that employees know that the
material is hazardous if swallowed, and that they must wash
their hands free of harmful chemicals before smoking, drinking
or eating. Never store harmful chemicals in food containers or
handle chemicals near food.

4.3 Emergency Treatment

4.3.1 Artificial Respiration

Persons overcome by harmful gases and vapors must be taken

out into the fresh air and, if they have stopped breathing, given
artificial respiration; if there is no heartbeat, commence
cardiopulmonary resuscitation (CPR). Call emergency assistance
immediately by telephoning 110.

4.3.2 First Aid

In case of accidental swallowing of chemicals, it is not wise to

induce the patient to vomit. The hospital must be informed of
the chemical injury or chemical swallowed and the person should
be moved to the hospital immediately for medical treatment. In
the case of caustics or corrosives, drinking a large amount of
water, followed by medical treatment, is recommended.
Telephone 877-8056, Saudi Aramco Emergency Medical Services,
for poison information.

4.3.3 Showers and Eyewash Fountains

For skin hazards, the best treatment is thorough water washing

under the emergency shower or eyewash fountain. Field
treatment should only consist of flushing away the chemical.
The patient should then be taken to the hospital for treatment.

These water flushing devices are required, because working

procedures and personal protective equipment may fail. In the
case of materials that are immediately harmful to the eyes or
skin, safety showers or eyewash fountains should be provided.
They should be within 6 meters (20 feet) of the exposure site and
accessible in an unobstructed straight line from the work
location. Emergency showers shall be properly identified with
signs and color background in accordance with SAES-B-55. A
person who is blinded by a chemical must immediately be taken
to the shower or eyewash fountain. Some emergency showers or
eyewash fountains are designed so that standing under or near
them activates the water supply. Others have hinged gates
which are pushed to activate the shower, but all should be easily
activated.

February 1993 - 4.0 Chemicals Page 354

 If the water piping to the shower or fountain is exposed to the
sun, the water will become so hot during summer that it could
scald the user. The piping must be buried, insulated or shaded
from the sun or the line must be only a very short branch from a
main water line that is used frequently enough to keep the water
from overheating in the sun. Emergency showers and eyewash
fountains should be checked daily.

CAUTION:

There are two important points that workers must be taught

about the correct use of emergency fountains and shower:

1 Before removing goggles, face shields, or other personal

protective equipment, the user must get under the shower
or use the eyewash fountain to wash off as much of the
chemical as possible.

2 It is a mistake to start for the hospital without first doing

everything possible to flush out the harmful chemical. The
eyes or skin must be washed for quite a long time to
remove the chemical. It is necessary to wash the eyes
holding the eyelids open with the fingers for at least fifteen
minutes to free the eyes of bases or caustics. This will be
painful, but it is absolutely necessary. In the case of acids,
water will remove the acid quickly, but it is necessary to
hold the eyelids open with the fingers, painful as this may
be, and roll the eyes around under the shower or in the eye
fountain to make sure that all acid is removed. At least
fifteen minutes of thorough washing are required in the
case of acid contact to skin or eyes.

Caustic alkalis such as sodium hydroxide and potassium

hydroxide are much more difficult to wash from the skin or eyes.
Strong alkalis of this type mixed with water feel slippery to the
touch. The skin should be washed until the slippery feeling has
gone and washing should be continued for at least 15 minutes.

February 1993 - 4.0 Chemicals Page 355

4.4 Fire Hazards

4.4.1

Only the necessary amount of hazardous materials should be

brought into the work place, usually not more than one day's
supply. Hazardous materials must not be allowed to accumulate,
and any extra amounts should be cleared from the work area.
Slop liquids or trash should be cleared away immediately. All
flammable materials should be stored according to the
specifications of their Chemical Hazard Bulletins, (CHBs) or
Material Safety Data Sheets (MSDS).

4.4.2

Smoking and the use of sparking devices near flammable liquids

or finely divided combustible solids must be prohibited.

4.4.3

Blocking off air to a burning object is often possible in acid dip

tanks or rubbish containers where a cover can be provided and
dropped down on the container to smother the flames.

4.4.4

The use of fire fighting equipment, such as fire extinguishers or

water streams, must be available in case all effective fire
prevention measures fail to prevent a fire. (See Fire Prevention,
Section I.11 of this Manual). Ordinary sand is a good
extinguishing agent for smothering small fires. The fire hazards
of most common materials can be found in the references given
in this section. The proper fire extinguisher should be at the job
site and readily available at all locations where a fire hazard is
possible.

4.5 Reactivity Hazards

The manual of Hazardous Chemical Reactions, NFPA 491M, lists many

of the chemicals which are likely to have dangerous reactions with other
chemicals. As a general precaution, rough handling and shock should be
avoided. Chemicals should not be allowed to mix with other chemicals
unless it is known that no harmful reaction will occur.

4.6 Transportation, Storage and Disposal

4.6.1 Transportation

During transportation, hazardous materials must be protected

against shock, accidental mixing with other materials, damage to
containers, undue heat from the sun or other sources, and theft,

February 1993 - 4.0 Chemicals Page 356

 which could allow the hazardous materials to come into contact
with people who are unaware of the dangers. Specific
recommendations for the particular material may be obtained
from the Area Loss Prevention Office. The Saudi Aramco
Chemical Engineering Response Team or Fire Protection
Department also handles spills which occur during
transportation. A vehicle transporting hazardous chemicals must
be suitably labeled.

4.6.2 Storage

The NFPA fire codes contain recommendations for safe storage of

flammable liquids, compressed gases, and typical highly
combustible or explosive solids. Precautions must be taken to
avoid shock, undue heat, or unplanned mixing. There are some
cases where separating walls or specified distances are required.

Specific storage recommendations for hazardous materials

contained in the Saudi Aramco Chemical Hazard Bulletins (CHBs)
and manufacturer-provided Material Safety Data Sheets (MSDS)
should be followed. Incompatible chemicals should not be stored
together.

A list of hazardous materials shall be kept by the contractor

indicating type and quantity of materials used in each case, its
hazardous classification rating and the quantity disposed of.

4.6.3 Containers

Hazardous materials must be stored in containers that are safe

for the transportation and use of the material. Containers must
be labeled with the appropriate hazardous materials label to
indicate the actual contents. All safety factors must be observed
when transferring material from one container to another and
the receiving container must be labeled to correctly describe the
contents. Empty containers previously used to hold hazardous
material must be washed free of the material or destroyed.

4.6.4 Disposal
(See GI 355.003 and 355.004)

Hazardous/toxic waste is liquid, solid and semi-solid material,

which, because of the quantity involved, the concentration,
and/or the biological, physical, chemical or infectious
characteristics, pose a hazard to human health and/or the
environment if it is improperly managed.

The following are some examples of waste materials which are

considered hazardous/toxic, and are to be disposed of in
accordance with established Saudi Aramco procedure.

· Waste paints and related products

February 1993 - 4.0 Chemicals Page 357

 · Asbestos
· Resins
· Wood preservative products
· Insecticides and pesticides
· Flushing fluids / chemicals
· Compressed gases (acetylene, oxygen, chlorine)
· Flammable / combustible liquids (gasoline, diesel oil)
· Corrosive liquids (acid)
· Cleaning fluids
· Explosives
· Flammable solids
· Poisons and infectious chemicals
· Radioactive materials
· Magnetized materials
· Polychlorinated Biphenyl (PCB (electrical transformer oil)

The disposal of hazardous material must be conducted by the

contractor/user (c/u). The latter is obligated to perform the
following:

Step 1:

The hazardous material must be identified by composition or

content. If this is not possible, prior to arranging for disposal of
the material the contractor/user should notify the AM&RD (Al
Midra and Reclamation Division). The material will be provided
to AM & RD in containers clearly marked "Hazardous Material"
only, with no other conflicting or confusing words.

Step 2:

The c/u must follow manufacturers or literature safety guidelines

(Material Safety Data Sheets, MSDS, Chemical Hazard Bulletins,
CHBs, etc.) in addition to the Saudi Aramco procedures contained
here. In cases where procedures overlap, the c/u should use the
more conservative methods of disposal. Hazard rating codes
assigned to SAMS material indicate the degree of hazard. (See
Figure V.2A.) Obtain advice as needed from the Hazardous
Materials Advisor, MHED (Materials Handling Engineering
Division) at telephone number 872-7419 or from individual
specialist units listed below:

Specialist Unit Telephone Number

Central Area Storehouse Dept. (CASD) 872-7419
Laboratories Dept. (LP) 876-6725
Loss Prevention Dept. (LPD) 873-8779
Process And Control Systems Dept. 875-3131
(P&CSD)

February 1993 - 4.0 Chemicals Page 358

 District Medical And Support Services 877-8425
(DM&SS)
Industrial And Environmental Affairs 874-1402
Dept. (I&EAD)
Fire Protection Dept. (FPD) 874-3345

Step 3:

The hazardous waste material must be adequately sealed up in

containers to prevent leakage and labeled to denote composition
or content.

Step 4:

Request a safety inspection of the material by the Hazardous

Material Advisor.

Step 5:

When a large quantity of hazardous material needs to be

disposed of, inform the:

a). Chemical Storage Segment, Material Disposal Unit,

Reclamation Operations Section, AM&RD.
b). Hazardous Materials Advisor, MHED.

Step 6:

Follow the directives of the Hazardous Materials Advisor. (See GI

355.003.)

Step 7:

Transport the hazardous material to Dhahran Reclamation Yard

using own truck or request suitable vehicle from the
Transportation Department by following their established
procedure.

Step 8:

Contact Assistant Superintendent, Reclamation Operations

Section (ROS), AM & RD before a large volume of hazardous
waste material is to be delivered. This person may request that
the material be delivered directly to Delivery Point Code (DPC),
280 Reclamation Chemicals Storage And Handling Facility
located near Abqaiq GOSP 3.

Note:

See GI 355.004 for any deviation from this established

procedure for the handling, storage and disposal of
Polychlorinated Biyphenyls (PCBs).

February 1993 - 4.0 Chemicals Page 359

4.7 Work on Equipment Which Has Contained Tetraethyl
Lead (Organic Lead Compounds)

4.7.1 Introduction

Tetraethyl lead (TEL) is an organic compound of metallic lead

which is used to improve the octane rating of gasoline. This
compound is highly poisonous. The hazard with tetraethyl lead
is that, being a liquid it gives off vapors which can come into
contact with the body by breathing or skin contact. Tetraethyl
lead is very hazardous as its vapors can be inhaled, absorbed
through the skin, or ingested through contaminated food or
cigarettes. The best protection is to avoid any contact.

To make it easier to detect spills of tetraethyl lead, it has been

dyed a bright orange color.

Tetraethyl lead, or sludges containing organic lead compounds,

are likely to be found in the following places:

1. Wherever drums of the compound are transported, stored,

or used. Leaking drums can contaminate ships' holds,
trucks, and storage areas.

2. Wherever leaded gasoline is blended, handled, or stored.

3. In controlled disposal sites designated to receive organic-

lead-containing materials. The sludge removed from
leaded gasoline tanks is decontaminated by spreading and
weathering prior to mixing with inert solids to reduce the
total lead concentration to no more than 0.5% and transfer
to a final burial site. Since tetraethyl lead is delivered
dissolved in organic solvents, it also presents a fire hazard.

4.7.2 Precautions

Tanks that have once contained leaded gasoline (TEL) are

considered dangerous thereafter even though they may have
been used in other service for years. Such tanks should be
permanently marked on the manholes with a sign warning that
the tank has contained leaded gasoline and must not be entered
without special precautions. Sludge pits where lead-bearing
sludge from the leaded gasoline tanks has been buried must be
marked with permanent warning signs.

Before entering any tank, an inquiry should be made as to the

tank's previous service and a work permit obtained. Likewise,
before marking excavations in or around refineries or gasoline
storage depots, it is wise to determine whether leaded gasoline
(TEL) sludge may be encountered. Work in cleaning, repairing,
or dismantling tanks which have contained leaded gasoline
requires special training and special precautions.

February 1993 - 4.0 Chemicals Page 360

 The workers must be medically certified and periodically
examined before and during the course of the work. Using
regular monitoring of TEL workers, any over-exposure to TEL
should be reported to the Saudi Aramco proponent department,
the Saudi Aramco Loss Prevention Department and the Industrial
Hygiene Services.

The Saudi Aramco Industrial Hygiene Services and the Loss

Prevention Department should be notified when work is to be
done in TEL tanks or in areas with TEL contaminated equipment.

February 1993 - 4.0 Chemicals Page 361

FIGURE V.1: IDENTIFICATION OF MATERIALS BY HAZARD SIGNAL DIMENSIONS AND
ARRANGEMENT

February 1993 - 4.0 Chemicals Page 362

FIGURE V.2: EXPLANATION OF HAZARD RATING CODES

February 1993 - 4.0 Chemicals Page 363

FIGURE V.3: IDENTIFICATION OF HEALTH HAZARD, FLAMMABILITY AND REACTIVITY

February 1993 - 4.0 Chemicals Page 364

VI. Marine

February 1993 - Construction Safety Manual: VI. Marine

Page 365
1.0 COFFERDAMS
A cofferdam is an enclosure constructed to exclude water from a work area during
construction. Cofferdam construction ranges from simple dikes to complicated
timber or steel structures. Cofferdams must satisfy two basic requirements:

1. They must be strong enough to withstand the forces caused by

water, soil conditions, and floating debris.

2. They should be as watertight as practicable, although some leakage,

requiring pumping, must always be expected.

The most common type of cofferdam encountered in Saudi Aramco is constructed

from steel sheet piling. The piles must be driven to design and penetration
specifications and must encounter the pre-specified driving resistance. The steel
piling is generally braced by a system of horizontal wales and struts which are
designed to resist external forces.

INSTRUCTIONS AND STANDARDS

Saudi Aramco Instructions and Standards:

Schedule 'D': Saudi Aramco Safety, Health and Environmental Requirements

Part 19 Excavations

Part 20 Work Over Water

1.1 Design

All cofferdams in excess of 1.2 meters (4 feet) in depth must be designed

by a qualified engineer. Any deviations from the design encountered in
the actual construction of the cofferdam must have the approval of a
qualified engineer.

1.2 Before Work Starts

Any cofferdam which is to be constructed in a navigable waterway or

which would constitute an obstruction or hazard to the operation of small
boats or pleasure crafts must be approved in advance by the Manager,
Saudi Aramco Marine Department. The latter will be responsible for
coordinating its approval with the approval of required Government
agencies.

1.3 Construction

All cofferdam construction work must be performed in strict compliance

with the design drawings and specifications. All work must be
accomplished by qualified craftsmen in accordance with accepted trade
practices. Any unexpected soil or hydrographic conditions encountered

February 1993 - Construction Safety Manual - Cofferdams

Page 366
 during the construction must be reported immediately to the design
engineer for evaluation and a possible modification of the structure.

1.3.1

If overtopping of the cofferdam by high waters is possible, means

shall be provided for controlled flooding of the work area.

1.3.2

Emergency evacuation warning signals shall be provided and

procedures developed. Notices shall be posted at the entrance
to the job site, and throughout the area.

1.3.3

Walkways, ramps or bridges on cofferdams shall have at least

two exit points. These shall be provided with standard
guardrails.

1.4 Potential Hazards

The construction and the use of cofferdams have three primary hazards
which merit special consideration.

1.4.1 Structural Collapse

Cofferdam structures may collapse as a result of the imposition

of unexpected structural loads or the failure of the soil inside the
cofferdam structures as evidenced by an upward heave or "blow-
out" of the bottom. Such failures often occur with little or no
warning, therefore a means of rapid exit from the enclosed
cofferdam structures must be provided for all workmen engaged
in work inside the structures.

1.4.2 Overhead Loads

Sump pumps, equipment, and machinery shall be mounted on a

cantilevered platform outside of a cofferdam. This will eliminate
overhead obstructions, which could present a hazard to the
workmen engaged in construction within the confines of the
cofferdam.

1.4.3 Dislodgment of Struts and Wales

All internal supporting structures must be secured against

accidental dislodgment. The use of locking devices on wedges
will prevent their accidental removal and the resulting collapse
of the structure.

February 1993 - 1.0 Cofferdams Page 367

1.5 Inspection

1.5.1

General inspection should be carried out daily or after any

weather condition or incident which might affect the safety of the
cofferdam.

1.5.2

The security of all wedges should be carefully checked at the

start of each shift.

1.5.3

Leaks can indicate a movement of the piles. Serious leaks

should be reported at once to the engineer in charge of
operations.

1.5.4

Pump intake fastenings and the pumping sump should be

carefully checked at the start of each shift.

1.6 Leaks

1.6.1

Small leaks can be sealed by lead caulking in the clutches from

the inside of the cofferdam. Minor leaks over a large area can be
sealed by dropping light granular material into the water
surrounding the cofferdam. The material will be sucked into the
gap between the piles where it will form a seal.

1.6.2

Where large leaks are encountered which cannot be sealed as

described above or there is an indication that the piling has
moved, the cofferdam area shall be immediately evacuated of all
personnel and the problem brought to the attention of the design
engineer for correction.

February 1993 - 1.0 Cofferdams Page 368

2.0 MARINE OPERATIONS
This section, Marine Operations, is only concerned with the transportation of
material, equipment, and personnel to off-shore job sites. This is carried out
through the Saudi Aramco Marine Department by using company-owned and/or
contractors' crafts.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions :

GI 6.020. Personal Flotation Devices for Work Over, On or Near Water

GI 1185.003. Death or Injury Aboard Seagoing Vessels

GI 1186.502. Marine Craft Fueling, Tanajib or West Pier

GI 1186.504. SAG Regulations and Practice as Applied to All Types of

Marine Craft at the Port of Ras Tanura

GI 1187.001. Collision & Damage By or To Marine Equipment or Craft

GI 1192.001. Operating Practices for Harbor Tugs, Offshore Vessels and

Launches, Including Safety Rules

GI 1192.002. Operating Procedures for Barges Including Safety Rules

GI 1192.502. Operating Procedures for Marine Oil Recovery and Storage

Barge/Vessel, Including Safety Rules

GI 1193.001. Marine Port Information and Regulations

GI 1193.002. Navigation Warnings

GI 1194.001. Requesting, Assigning and Dispatching Pollution Control

Vessels, Tugs, Launches and Barges

GI 1196.001. Whistle Signals for Use Between Tugs and Barges or Tugs and
Self-Propelled Vessels When Berthing

GI 1198.001. Rig/Barge Moving

GI 1199.001. Safe Operation of Self-Propelled Jack-Up Barges

2.1 Other Publications

US. Coast Guard - 257

International Maritime Organization - Safety of Life at Sea

February 1993 - Construction Safety Manual - Marine Operations Page 369

 International Labor Office - Accident Prevention on Board Ship, at Sea,
and in Port.

2.2 General

All safety precautions that are applicable onshore apply and must be
enforced while offshore, including the wearing of personal safety
equipment. In addition, life vests must be worn while working on, over
or near the water. Work over water may be either offshore or on a site
connected to the shore. The hazards and the precautions for both
situations are similar.

2.3 Behavior on Floating Craft

Personnel embarked on floating craft must obey the instructions of the

person in charge of the vessel. In particular they must not obstruct his
view or movements. They must travel in the passenger designated
areas. They should not enter or climb on top of the pilot house and
machinery space are similarly out of bounds. Personnel are expected to
act in a responsible manner at all times.

2.3.1

Unexpected movements of the vessel even in good weather

must be anticipated and guarded against. Personnel should
keep away from the ship's side and make use of handrails at all
times.

2.3.2

Life vests must be available for all personnel. Each person shall
wear and know how to inflate a life vest (see Figure VI.1).

2.4 Preparation for Transportation by Sea

2.4.1

Loose and movable parts of material and equipment must be

properly secured against movement. Such material and
equipment must always be prepared as if for very rough weather.
Sea conditions can change rapidly. Even with no wind, a swell
can produce violent movement. Lashing must be adequate.
Tank compartments being transported should be either empty or
completely full. Tarpaulins or plastic coverings must be of
adequate strength and well secured.

2.4.2

The Marine Department must be informed in advance so that

they may prepare for the transportation of any hazardous cargo
(acids, explosives gases, etc.) or cargoes with special

February 1993 - 2.0 Marine Operations Page 370

 characteristics (e.g., sensitive to water, delicate, or pilferage).
Information on weights and measurements must be included for
any shipment that requires a manifest (Saudi Aramco Form
9063).

2.4.3

Although the actual loading may be performed by another

department, the Marine Department carries the ultimate
responsibility for the safe loading and distribution of cargo on
the floating craft under its jurisdiction.

2.5 Tide and Sea Effects

During pile driving and general offshore work, allowance must be made
for wave action and the rise and fall of the tide, especially when erecting
stages and platforms. Tidal predictions and weather forecasts are not
completely accurate so a generous safety margin must be allowed.

2.6 Care of Tools and Equipment

2.6.1

Protective coatings reduce the corrosive effects of salt water and

salt-laden air on tools and equipment. Nuts, bolts, and threads
should be covered with grease or a similar protective coating.

2.6.2

Electrical and radio equipment must not be left exposed. When

not in use, they should be protected by being returned to their
boxes or being covered.

2.6.3

Objects that are dropped from any height can cause injury or
damage, and they may be impossible to recover. For this reason,
small hand tools should be secured by lanyards when working
over or near water.

2.7 Housekeeping

Because of the confined space frequently encountered in Marine

Operations, housekeeping is even more important offshore than onshore.

2.7.1

Tools must not be scattered around. Any spilled grease or oil

must be cleaned up. Fire hose and rope must be coiled or flaked
down clear of passageways. Doors and drawers should be kept
closed.

February 1993 - 2.0 Marine Operations Page 371

 2.7.2

Rags, papers, cigarette butts, and scrap must be properly

disposed of. Proper disposal does not mean throwing the
unwanted items overboard, thus polluting the environment.
Trash cans and ashtrays should be used.

February 1993 - 2.0 Marine Operations Page 372

FIGURE VI.1: IF YOU WORK OVER, ON OR NEAR WATER

February 1993 - 2.0 Marine Operations Page 373

3.0 DIVING OPERATIONS
Accidents involving divers and their equipment are generally serious, because
diving operations are undertaken in an element unnatural to man. What would be
considered to be a minor incident on land could cause crippling injury or even
death in a diving operation.

Due to the extreme hazards of this occupation, divers must rely on their training,
experience, and initiative to avoid accidents. For this reason, the strictest
compliance with regulations, standards, and instructions must be observed at all
times in order that everything possible is done to minimize the possibility of an
accident.

INSTRUCTIONS AND STANDARDS

Saudi Aramco General Instructions:

GI 1197.001 Procedures and Safety Rules for Diving Operations (See Appendix G)

The US. Navy Diving Manual is to be used as the standard for all Saudi Aramco
diving operations.

US. Navy Diving Manual:

NAVSHIPS 0994-001, March 1970

British Admiralty Diving Manual:

B.R. 181, 1972

United Kingdom Statutory Instruments

S.I. NO. 1229 Offshore Installations (Diving Operations) Regulations, 1981

Saudi Aramco Instructions and Standards

Saudi Aramco Bottled Gas Manual

TM 6.1 Medical Diving Emergencies (Technical Memorandum - Saudi

Aramco Medical Services Organization {SAMSO})

3.1 Employment of Qualified Divers

All divers shall be at least twenty-one (21) years old.

3.1.1

Divers must be qualified and experienced in all aspects of

underwater inspection, construction, repairs, and salvage works,
including oxy-arc cutting, thermal lancing, and the use of
pneumatic and hydraulic tools.

February 1993 - Construction Safety Manual: Diving Operations Page 374

 3.1.2

Divers shall be fully conversant with the use and operation of US.
Navy Decompression Tables, recompression chambers, and
therapeutic decompression procedures.

3.1.3

Familiarity with the use of SCUBA, Hookah, and surface supplied

helmets (Swindel, Aquadyne, Kirby-Morgan, etc.) and knowledge
of their maintenance and repair is required.

3.1.4

Divers will be required to show evidence of their training and

experience by providing certificates from a competent authority.

3.1.5

All divers must be fluent in both reading and writing the English
language and be able to depict the results of an underwater
inspection by the use of sketches.

3.1.6

Evidence of medical fitness in accordance with 3.4 must be

produced at the prescribed intervals.

3.2 Diving Equipment

All equipment used in connection with diving and submarine operations

shall be produced by a reputable manufacturer. They must be of good
quality and constructed of sound material, in accordance with
appropriate and accepted standards. Equipment should be able to
operate efficiently in the prevailing high temperatures of the Arabian
Gulf.

3.2.1 Compressors

Compressors for supplying breathing air must be fitted with

adequate filtration and purification devices. They must be able
to provide the air at a rated pressure and capacity to cover the
maximum depth required during the operation.

3.2.1.1

The air intake of compressors shall be remotely located

with reference to any exhaust system in the area to
prevent contaminants from entering the compressor
intake.

February 1993 - 3.0 Diving Operations Page 375

 3.2.1.2

All the safety devices and relief valves on high

pressure compressors must be operating properly.

3.2.1.3

Detergent lubricating oils or oils with viscosity less than

SAE 30 must not be used. Care must be taken not to
overfill.

3.2.1.4

Compressed air supplied for breathing shall be certified

Compressed Gas Association grade D or better.

3.2.2 Reserve Air Supply

A reserve supply of air must be provided, maintained, and

immediately available in the event of a primary air supply
failure, whether in the form of a standby compressor or high
pressure cylinders (or volume tanks) on the surface. If the
reserve is in the form of high pressure cylinders (or volume
tanks), it should be of sufficient capacity to enable the diver or
divers to reach the surface safely while carrying out any
necessary decompression step on the way. Reserve supply for
recompression chambers should be sufficient to allow required
surface decompression to be carried out.

3.2.3 Bail-Out Equipment

In case there might be a ruptured, cut, or irretrievably fouled

hose, each diver should be equipped with "bail-out" equipment,
either in the form of a "bail-out" cylinder, a diver's life vest, or a
pneumo hose.

3.2.4 Maintenance

All plant (including safety) and diving equipment must be

regularly maintained. Correct records must be kept of this
maintenance.

3.2.4.1

All SCUBA tanks, recompression chambers, volume

tanks, high pressure cylinders, and storage vessels
must be regularly checked and tested at the prescribed
intervals in accordance with the manufacturer's
instructions and Saudi Aramco regulations.

February 1993 - 3.0 Diving Operations Page 376

 3.2.4.2

As indicated in the Saudi Aramco Bottled Gas Manual,

air cylinders not in sea water use are to be inspected
internally and hydrostatically tested, at intervals not to
exceed five years. They should be appropriately
stamped to denote this inspection.

3.2.4.3

Each item of plant and diving equipment should be

regularly inspected by a competent person at periodic
intervals, and after the equipment has been modified.
The maximum period between inspections should be
three months.

3.2.4.4

All hoses used for carrying compressed air or other

gases must be checked for wear and abrasion and
subjected to test pressures at least once every three
months.

Hose, fittings and connections should be of the screw

thread type and properly fitted to the hoses. Hoses
used in oxygen breathing systems must be grease and
oil free.

3.2.4.5

Any pressure gauge showing an error of more than two

and one half percent (2.5%) must be adjusted or
replaced.

3.2.4.6

Communication systems must be checked for correct

operation. Every wire must be checked for continuity
and, if they are combined with the life line, for wear.

3.2.4.7

A supply of suitable protective clothing such as diving

suits, coveralls, gloves, and hoods must be available at
all times. Insulated gloves shall be provided to divers
performing welding and burning operations.

February 1993 - 3.0 Diving Operations Page 377

 3.2.4.8

Gas cylinders taken under water shall be

hydrostatically tested, inspected and stamped every
two years.

3.3 Safeguards

When divers are preparing to enter or leave the water, or are in the
water, or diving operations are underway, the International Code Flag "A"
("I have a diver down, keep well clear of area and maintain a low
speed.") must be flown. (See Figures VI.2 and VI.3.)

Communications - A two-way voice communication system shall be used

between:

1. Each surface-supplied air or mixed-gas diver and a dive team

member at the dive location.

2. Two-way communication system shall be available at the dive

location to obtain emergency assistance.

In addition, special lights and day marks for "vessels engaged in

surveying or underwater operations" should be shown in accordance
with Maritime Regulations (Figure VI.3).

3.3.1

Any person involved in an activity which could be a hazard to

divers in the vicinity, such as those in charge of submarine
blasting or masters of vessels about to move, start propulsion
engines, or operate pumps, must be forewarned.

3.3.2

Adequate arrangements must be made to provide a safe means

of access to and egress from the water. It must be kept in mind
that a diver may be unconscious as a result of an accident.

3.3.3

Proper surface support and other facilities for the safe conduct of
diving operations must be provided.

3.3.4

In all cases of emergency, the diving supervisor, the foreman

diver, or the person in charge of a diver or divers must be the
sole arbiter as to action to be taken. All personnel, whether
connected with the diving operation or not, should take
instructions from him.

February 1993 - 3.0 Diving Operations Page 378

 3.3.5 Safe Operation of Divers

3.3.5.1

Bottom time and decompression time will be controlled

by the diving supervisor or person in charge of diving.

3.3.5.2

On all work requiring four divers or more, a diving

supervisor shall be present to facilitate coordination
between divers and the surface.

3.3.5.3

All diving operations requiring more than two divers

(using air for breathing) in water of a depth greater
than 30 meters (100 feet), require the presence of a
diving supervisor.

3.3.6

At all times when a diver is in the water, a stand-by diver must

be on deck with a stand-by rig, fully dressed and ready to dive.

3.3.7

No diver working in water 9 meters (30 feet) or less shall be

required to work longer than a twelve (12) hour shift without
having a proper rest except for emergencies.

3.3.8

Repetitive diving should not be done as a routine. If the task

necessitates the use of "repeats", efforts should be made to
obtain additional divers. When this is impracticable, the tables
must be strictly adhered to in order to avoid decompression
sickness, which could require therapeutic treatment and could
endanger the health of divers and delay operations.

3.3.9

Therapeutic decompression must take precedence over all other

operational requirements.

3.3.9.1

Divers must remain in the vicinity of a recompression

chamber for a period of twelve (12) hours after the last
dive.

February 1993 - 3.0 Diving Operations Page 379

 3.3.9.2

In the case of therapeutic decompression the period in

3.3.9.1 shall be extended to twenty-four (24) hours.

3.3.9.3

In mild cases of decompression sickness which have

been treated under Tables 1, 1A, 2, 2A and 5 (US. Navy
Diving Manual), a diver can be returned to work at the
discretion of the diving supervisor.

After treatment for a case of "bends" under Tables 3, 4,

6 and 6A, a diver will not be permitted to dive again
until he has been examined and passed as fit by a
physician.

3.3.9.4

Each diver will maintain a personal logbook. Entries

shall include but are not limited to the following:

· Diver's name.
· Name and address of the employer of divers.
· Date.
· Name of the Diving Supervisor.
· Name of the vessel, barge, or installation from
which the diving operation is carried out.
· Maximum depth reached on each occasion.
· Time he spent under water on each occasion.
· Type of equipment used by the diver.
· Work carried out by him on each occasion.
· Details of decompression sickness or other
illness/injury suffered by the diver.
· Any other factor relevant to health.
· Each daily entry will be signed by the diver and also
by the diving supervisor.
· Divers must retain their logbooks for a period of not
less than two years from the date of the last entry
in the logbook.

3.3.10 Recompression Chamber

A recompression chamber must be on site during all diving

operations in excess of 18.5 meters (60 feet). Whenever a
recompression chamber is not available, only "no
decompression" dives are permitted.

3.3.10.1

The maximum rate of ascent is 18.5 meters (60 feet)

per minute in the case of air decompression and 7.6

February 1993 - 3.0 Diving Operations Page 380

 meters (25 feet) per minute in the case of oxygen
decompression.

3.3.10.2

Only necessary articles are allowed in the

recompression chamber. No tobacco or any ignition
source, including electrical shall be allowed in the
chamber. Smoking shall never be permitted in the
chamber whether under pressure or not.

3.3.10.3

The chamber shall be kept clean and dry.

3.3.10.4

Personnel in a chamber under pressure shall ensure

that both they and all loose materials are kept clear of
all atmosphere inlet and exhaust openings. The
exhaust, which is under pressure, is especially
dangerous because it subjects anything near it to a
high suction pull capable of causing extreme bodily
harm .

3.3.11 SCUBA Special Care

The use of SCUBA equipment in water over 18 meters (60 feet)

in depth should be restricted.

3.3.11.1

SCUBA equipment shall not be used to depths greater

than 45 meters (150 feet).

3.3.11.2

SCUBA equipment should never be used for dives

requiring decompression.

February 1993 - 3.0 Diving Operations Page 381

 3.3.11.3

In open water, SCUBA divers shall always be attached

to a clearly visible float by a life line. In no case shall
SCUBA divers be allowed to swim free.

3.3.11.4

In enclosed or restricted water such as beneath

structures, either a lifeline or the "buddy" system must
be used. There will be no untethered solo diving.

3.3.11.5

When using SCUBA equipment, divers will always wear

an inflatable life jacket of the approved type.

3.3.11.6

No SCUBA diving should be carried out during

darkness.

3.4 Physical Fitness

All divers must be physically fit for diving and have a certificate to this
effect issued by a qualified medical practitioner: one who has
experience and knowledge of the medical requirements for diving.

3.4.1

The medical certificate should state "Fit for Diving" and be not
more than twelve months old.

3.4.2

Doctors carrying out medicals for divers should be aware of the

importance of the condition of heart, lungs, chest, ears, nose,
throat, and teeth. An EKG and chest X-ray are mandatory on an
annual basis, while a long bone X-ray should be performed every
three years.

3.4.3

For British divers, a current British Diving Fitness Register is

acceptable and, likewise, any recognized fitness register for
other nationalities.

3.4.4

All divers should be trained in First Aid/CPR, and on all diving

operations, there should be an approved First Aid Kit suitable for

February 1993 - 3.0 Diving Operations Page 382

 use under hyperbaric conditions on site as recommended in the
US. Navy Diving Manual.

3.5 Medical Diving Emergencies: Procedures and

Responsibilities

Every incident/accident involving diving personnel shall be reported on

Saudi Aramco Form 3208 with the responsible supervisor submitting a
follow-up report on Saudi Aramco Form 681. Offshore emergency
response procedures are given in Appendix B. Specific responsibilities
are as follows:

3.5.1 Sports Divers

All divers must have an experienced person in charge with good

knowledge of decompression sickness. He has to know the
following two diving emergencies numbers to call if requiring
help: 678-1248 from 6 a.m. until 6 p.m. 7 days per week; and
378-3691 from 6 p.m. until 6 a.m. 7 days per week. He should
state his exact location and follow the instructions given to him
by the coordinator answering the number.

3.5.2 Commercial Divers

The diving supervisor will immediately arrange recompression

according to the appropriate table and report the incident to the
coordinator manning the diving emergencies numbers.

3.5.3 Coordinator, Diving Emergencies

The coordinator, on call at either of the above numbers, will

receive the information on diving medical emergencies. In the
case of sports divers, he will direct them to the nearest available
recompression chamber and alert its operator. He shall also
inform the duty diving medical consultant who can be at the
Saudi Aramco Preventive Medicine Services Division on 877-
8916 (after work hours on 878-1697 or 878-0890).

In commercial diving incidents, the coordinator may elect to

proceed with treatment using the appropriate table without
notifying the diving medical team in cases of minor
decompression sickness. In all type II bends and possible gas
embolism cases, the duty diving medical consultant shall be
notified immediately.

He shall send a monthly report of all incidents involving

therapeutic decompression to the senior Occupational Medicine
specialist.

February 1993 - 3.0 Diving Operations Page 383

 3.5.4 Diving Medical Team

This will come under the jurisdiction of the director of Preventive

Medicine Services and will be a multi-disciplinary group headed
by the senior Occupational Medicine specialist. It will be
comprised of a group of physicians with an interest and training
in hyperbaric medicine who shall rotate as duty diving medical
consultants. Nurses with special training will also be integrated
in this group which shall constantly keep abreast with current
practices. The diving medical team will provide this service to
the Marine Department.

3.5.5 Marine Department

The Marine Department is responsible for the provision,

maintenance, and manning of the recompression chambers.

3.6 Personnel Transfer at Sea

The following is to be used as guidelines for the transfer of persons at

sea from vessel to vessel or from vessel to platform (or structure).

A. Personal Flotation Devices. These references are pertinent items

from Loss Prevention Department GI 6.020 - Personal Flotation
Devices for Work Over, On or Near Water.

3. Requirements.

3.1. Wearing of personal flotation devices are

required as follows:

3.1.7

When working or riding on the deck of a marine vessel

or craft during rough seas at the discretion of the
person in charge of the vessel or craft.

3.1.11

When transferring to or from any water craft or to or

from one water craft to another.

3.1.17

At any time when deemed necessary by the boat

skipper, ship captain, supervisor, or the person in
charge of the marine vessel, installation or craft.

4.1.3

Marine craft skippers, ship captains and aircraft pilots

shall enforce the wearing of personal flotation devices

February 1993 - 3.0 Diving Operations Page 384

 in their vessels or aircraft. Failure of an employee to
heed the instructions given by the person in charge of
the marine craft or aircraft shall require the passenger
to be removed from the craft with disciplinary action to
follow by the employee's department.

4.1.4

Supervisors or persons in charge of personnel in

facilities, installations, or work activities shall be
responsible for having their personnel follow the
requirements regarding the wearing of personal
flotation devices.

4.2.

Contractors shall provide (fully functional, no defect)

personal flotation devices for each of their personnel.
They shall also provide their personnel with the
necessary instructions or training on the proper way of
wearing personal flotation devices. The proponent
Saudi Aramco organization shall be responsible for
ensuring that contractors comply with the applicable
requirements of this GI 6.020.

B. Saudi Arab and contractor vessel crews shall also be issued with
proper working uniforms and personal protective equipment such as
shoes, gloves, glasses and hard hats. The Marine Department
expects all Saudi Aramco and contractor personnel working around
marine facilities to strictly adhere to Company safety rules and
regulations.

February 1993 - 3.0 Diving Operations Page 385

FIGURE VI.2: INTERNATIONAL CODE FLAG "A"

FIGURE VI.3: SIGNALS

February 1993 - 3.0 Diving Operations Page 386

Appendix A

February 1993 - Construction Safety Manual: Appendix A

Page 387
INDEX TO APPENDIX A
This Appendix contains the following information:

* Project Management And Contractor's Safety Competition Site Registration

Form;
* Contractor Safety Competition, Rules Of Competition;
* Contractor's Competition Job Safety Evaluation;
* Saudi Aramco Safety, Health and Environmental Requirements;
* Hazard Identification Plan (H.I.P.).

February 1993 - Construction Safety Manual: Index to Appendix A Page 388

A.1 PROJECT MANAGEMENT AND CONTRACTOR'S
SAFETY COMPETITION SITE REGISTRATION
FORM
To: Saudi Aramco Loss Prevention Department Date:
____________________________

Name Of Contractor: Contractor's Address: Contractor's Phone

Number:

Job Description: Job Number: Starting Date:

Estimated Completion
Date:
B.I. Number:
Peak Number Of
Employees:

Contractor Site Saudi Aramco Site (PMT) Project Mgmt.

Representative: Engineer: Department:

Telephone Number: Telephone Number: Org. Code:

Name Of Contractor's Contractor's Site Phone Site Location:

Safety Representative: Number:

Signed:____________________________________________________(Contractor's
Representative)

Job Title:__________________________________________________

Company:__________________________________________________

Date:_______________________________________________________

Saudi Aramco Proponent

Department:____________________________________________________

This form is to be completed and sent to the local Saudi Aramco Loss Prevention
Office with a copy to the designated senior Project Engineer, who is a member of
the proponent Project Management Team (PMT).

Signed:________________________________________

February 1993 - Construction Safety Manual: Safety Competition Site Registration Form Page 389
 Saudi Aramco Project Manager

February 1993 - A.1 Safety Competition Site Registration Form Page 390
A.2 CONTRACTOR SAFETY COMPETITION, RULES OF
COMPETITION

CONTRACTOR SAFETY COMPETITION JOB SAFETY EVALUATION

RULES OF COMPETITION

1. The competition shall be run over a six-month period (January to

June and July to December) and shall be assessed according to the
requirements of Schedule 'D' of the contract documents.

2. A contractor on a Budget Item (BI) who meets the following criteria

shall be registered in the competition by the responsible Proponent
(PMT).

a. Contractor and related sub-contractor exceed 50 for the

entire six month period.
b. Estimated completion time exceeds the competition time
period.

3. An unscheduled site inspection will be carried out by the Loss

Prevention Department once before the 25th day of every even
month. A contractor shall have a minimum of three ratings within
the six month period. The Saudi Aramco Loss Prevention
representative will report to the site office before he starts his
inspection. Representatives of Project Management and the
contractor shall be invited to accompany the Loss Prevention
representative during the inspection. If it is inconvenient for a
member of the Project Management Team or contractor's personnel
to accompany the Loss Prevention representative during the
inspection, the Loss Prevention representative will conduct the
inspection alone - awarding appropriate scores. These scores shall
be final. If during the inspection there is a difference of opinion over
the points awarded, then the Loss Prevention representative will
make the final decision.

4. The Saudi Aramco Project Management Team shall receive a copy of

the inspection sheet, and they should distribute it to the appropriate
contractor. Remedial steps shall be taken to rectify faults and
improve the score rating. At the end of the competition, a copy of
the six-month summary sheet will be provided to any contractor.

5.
a. A contractor working on one BI at one location shall be
evaluated, scored and ranked separately.
b. A contractor working on more than one BI shall have an
entry in the competition for each BI.
c. A contractor working on the same BI at separate sites shall
be evaluated by site but the final score will be averaged.
d. Multiple contractors working on the same BI shall be
entered, evaluated, scored and ranked separately. (This

February 1993 - Construction Safety Manual: Contractor Safety Competition Rules Page 391
 also applies to consortium partners - provided they meet
requirements in 2 above.)

e. For those rare cases where there are multiple sites and
multiple contractors on a BI, each site under the BI will be
scored separately but averaged with all sites for that BI by
contractor.

Exceptions to the above guidelines shall be reviewed by Project

Management Team and Loss Prevention during initial registrations.

6. Following each inspection by the Loss Prevention representative, the

original copy of the form SA-6710 shall be submitted to the
superintendent, Central Area Loss Prevention Division, Building
3121, Room 113, Dhahran, not later than the 25th day of each even
month. In cases of holidays or rescheduled days off, the first work
day after the 25th is acceptable.

7. Any contractor who experiences a job related fatality, or serious

incident that results in the hospitalization of five or more employees,
and fire resulting in SR 10,000 worth of damage on any one of their
sites within the competition period, will cease to be eligible for an
award.

8. Should a registered contractor not retain an average of 50 or more

employees for the entire competition period, they will be dropped
from the competition.

9. Any item of concern not specifically covered on the Evaluation Form

A-6710, shall be reflected in column #18 under Special Items.

10. Should any contractor find he has completed the project before the
end of the competition period due to meritorious performance or
reasons beyond his control, then he will still be eligible to compete
in the final assessment.

11. Should it be found that the contractor has not entered into the
required logs details which at a later date are determined to have
occurred, e.g. restricted duty, lost work day cases, accidents, fires,
etc., then he would be deemed to have broken the rules and forfeit
the right to be included in the awards for the duration of that
competition for which he was eligible.

12. Every hazard report Saudi Aramco Form 3744 issued and not
corrected within 24 hours, a penalty of 500 points shall be deducted
from the total score.

13. Should a contractor incur a second hazard report, disqualification for

the rest of the competition period shall result.

February 1993 - A.2 Contractor Safety Competition Rules Page 392

 14. Violations noted during an initial inspection which have not been
corrected by the next general and/or follow-up inspection shall be
deemed a repeat violation and a "0" score will be given for the entire
section under consideration.

SCORING:

Where a section is inapplicable to a particular site, e.g. no scaffolding,

cranes, etc., then that section will OK from the possible percentage
score.

POINT ASSESSMENT:

Points will be assessed based on the gravity/severity of violations

encountered and will range from 0 to 100. Points can be given from 0 to
100, depending on the judgment of the Loss Prevention Department
representative.

OVERALL PERFORMANCE RATING:

Unsatisfactory= 0 - 65
Fair= 66 - 80
Good= 81 - 95
Excellent= 96 - 100

Overall percentage performance will be calculated as follows:

Points Scored x 100 = Contractor Rating:
___________
Points Possible

Every endeavor will be made to provide an accurate assessment

at each inspection. Any questions that may arise concerning this
job safety evaluation may be submitted to the proponent
department for resolution. Any contractor who persistently
returns poor scores or violates the competition rules may be
subject to corrective action by the proponent department.

Please Note:
For more information on the Contractor Safety
Competition, and for the current competition rules,
please contact your Area Loss Prevention Office.

February 1993 - A.2 Contractor Safety Competition Rules Page 393

FIGURE A.1: CONTRACTOR'S COMPETITION JOB SAFETY EVALUATION

February 1993 - A.2 Contractor Safety Competition Rules Page 394

FIGURE A.1: CONTRACTOR'S COMPETITION JOB SAFETY EVALUATION CONTINUED.

February 1993 - A.2 Contractor Safety Competition Rules Page 395

A.3 SAUDI ARAMCO SAFETY, HEALTH AND
ENVIRONMENTAL REQUIREMENTS

1. Compliance With Safety Rules - Schedule 'D'

CONTRACTOR shall at all times comply with, and ensure that its
employees, agents and subcontractors comply with, applicable Saudi
Arab Government Safety Regulations and all SAUDI ARAMCO Safety and
Loss Prevention rules and regulations. Specifically, CONTRACTOR shall
comply with the provisions of the SAUDI ARAMCO Construction Safety
Manual and SAUDI ARAMCO's publication entitled "Loss Prevention
Requirements for Contractors", Paragraphs 5 through 27 of this
Schedule (which supplement but do not limit the requirements of the
Construction Safety Manual), and such other related requirements;
specifications and standards as are made known to CONTRACTOR by
SAUDI ARAMCO. CONTRACTOR may request copies of all applicable rules
and regulations from SAUDI ARAMCO's Loss Prevention Department.
CONTRACTOR shall also take, or cause to be taken, any additional
measures which Company Representative may direct to protect against
injury to or death of any person or damage to or loss of any property
during CONTRACTOR's performance of the work. CONTRACTOR shall
maintain the SAUDI ARAMCO Construction Safety Manual and applicable
SAUDI ARAMCO GIs at the WORK Site.

2. Deviations From Safety Rules

Any deviation by CONTRACTOR from SAUDI ARAMCO's Loss Prevention

rules and regulations must be approved in writing in advance by
Company Representative.

3. Failure To Comply

Should CONTRACTOR fail to comply with the requirements of this

Schedule 'D', SAUDI ARAMCO shall notify CONTRACTOR in writing.
CONTRACTOR shall, upon being advised of its noncompliance,
immediately take all corrective action required to comply. Such
corrective action shall, unless provided otherwise in this Contract, be
taken at CONTRACTOR's expense. If CONTRACTOR fails to take such
corrective action promptly, Company Representative may direct
CONTRACTOR to suspend all or part of the WORK pursuant to Schedule
"A" until satisfactory corrective action has been taken. Costs incurred by
CONTRACTOR as a result of such WORK suspension shall be for
CONTRACTOR's account and any resultant CONTRACTOR performance
delays shall not be deemed excusable here-under.

4. Saudi Aramco Assistance

CONTRACTOR may request assistance from SAUDI ARAMCO with respect

to the implementation of its Loss Prevention requirements. Company
Representative, or such party or parties designated by him, will assist

February 1993 - Construction Safety Manual: Contractor Safety And Loss Prevention Requirements Page
396
 CONTRACTOR by explaining good safety practices, pointing out unsafe
WORK Site conditions, and by applying his/their experience and
judgment in order to assist CONTRACTOR in improving WORK safety. It
is understood, however, that rendition of such assistance by SAUDI
ARAMCO will in no way relieve CONTRACTOR of its responsibilities as set
forth in this Schedule 'D'.

5. Loss Prevention Program

CONTRACTOR shall prepare and submit a Loss PREVENTION Program to

Company Representative, for SAUDI ARAMCO's approval, not later than
fifteen (15) working days following the execution of this Contract.
CONTRACTOR shall ensure full implementation of the Program.
CONTRACTOR shall appoint a qualified full-time Safety Supervisor
approved by SAUDI ARAMCO, to coordinate the Program. The name and
address of the Safety Supervisor shall be submitted to Company
Representative no later than the Program's submission:

The Program shall outline specific essential measures to be taken by

CONTRACTOR to prevent injuries to persons and damage to property and
to ensure compliance with this Schedule 'D'. The Program shall be
organized and implemented by each craft or crew supervisor. It shall
include a specific plan to hold a ten minute safety discussion organized
and implemented by each craft or crew supervisor on at least one day in
each working week.

6. Work Permits

CONTRACTOR shall obtain a work permit (SAUDI ARAMCO Form 924)

each shift for any WORK to be carried out during such shift in any SAUDI
ARAMCO specified "Restricted Area". It shall be the CONTRACTOR's
responsibility to ascertain, in advance, whether the WORK area is
designated a Restricted Area. Company Representative shall give
guidance on Restricted Area locations. All work permit procedures shall
be carried out by CONTRACTOR in accordance with SAUDI ARAMCO GI
2.100 (Work Permits) and GI 6.012 (Isolation, Lockout and Use of Hold
Tags), which by this reference is made part of this Contract.

7. Welding And Cutting Equipment

All welding and cutting equipment shall be of a SAUDI ARAMCO approved

type and maintained in good condition.

8. Personal Protective Equipment

CONTRACTOR shall, as a minimum, provide, maintain and enforce the

use of the items of personal protective equipment listed in SAUDI
ARAMCO's Construction Safety Manual, other applicable GIs and
Operator Instruction Manuals (OIMs).

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 397
9. Tools And Portable Power Tools

CONTRACTOR shall ensure that all tools provided by CONTRACTOR are of

the best quality with proper safeguards and are suitable for the use
intended. Electrical hand tools shall be properly grounded or be of the
double insulated type. All tools shall be free from defects and
maintained in good condition. Saudi Aramco will reject tools which are
found to be defective.

10. Cartridge Operated Tools

Cartridge operated tools shall be used only with the prior written
approval of Company Representative. Furthermore, CONTRACTOR shall
ensure that only SAUDI ARAMCO approved tools shall be used and that
they shall be maintained in good condition in compliance with the SAUDI
ARAMCO Construction Safety Manual.

11. Ladders

CONTRACTOR shall ensure that only metal or timber ladders of SAUDI

ARAMCO approved type are provided and used for ingress to and egress
from WORK places where other means of ingress and egress are not
available.

12. Scaffolding

CONTRACTOR shall provide and cause to be used scaffolding, platforms

or temporary floors for all WORK which cannot be done safely from the
ground, from a ladder or from a boatswain's chair. All scaffolding shall
be constructed of SAUDI ARAMCO approved metal components and
erected to comply with the requirements of the SAUDI ARAMCO
Construction Safety Manual.

13. Electrical Installations And Equipment

All material and equipment used in temporary electrical installations

shall be of SAUDI ARAMCO approved type and maintained in good
condition.

CONTRACTOR shall ensure that all 120 volt single phase 15 and 20
ampere receptacle outlets which are not a part of the permanent wiring
of any building or structure shall have ground fault circuit interrupters for
personal protection.

14. Cranes And Rigging Equipment

CONTRACTOR shall ensure that all lifting appliances and every part
thereof, including all working gear, and all other plant or equipment for
anchoring or fixing such appliances shall be of good mechanical
construction, sound material, adequate strength and free from defect

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 398
 and are properly inspected and maintained. All chains, hooks, slings,
shackles and other equipment used for raising or lowering on a lifting
appliance shall be of a SAUDI ARAMCO approved type and maintained in
good condition. All mobile heavy equipment and crane operators must
possess a valid Kingdom of Saudi Arabia heavy equipment operator's
license and be certified by SAUDI ARAMCO to operate such equipment
(GI 7.025). All cranes and lifting equipment must be inspected and
certified by SAUDI ARAMCO before being permitted to operate on SAUDI
ARAMCO property (GI. 7.030). Certified riggers shall be provided (GI.
7.030).

15. Mechanical Equipment

CONTRACTOR shall ensure that all mechanical equipment provided is of

a SAUDI ARAMCO approved type and maintained in good condition.

All moving parts of any equipment shall be securely guarded so as to

prevent access to the moving parts by persons working on or passing
through the WORK Site.

16. Saudi Aramco Plant Operations

CONTRACTOR shall ensure that CONTRACTOR's personnel and the

personnel of its subcontractors do not open or close any valves or
electrical switches, or operate any other piece of SAUDI ARAMCO plant
without the prior approval of SAUDI ARAMCO and then only under the
direct supervision of the supervising operator or plant foreman.

17. Transportation

CONTRACTOR shall ensure that passengers shall travel only in vehicles

that are provided with SAUDI ARAMCO approved passenger seats. This
requirement shall apply while traveling to and from the WORK Site and
during travel on the WORK Site. Seat belts shall be installed and used in
all vehicles carrying personnel (except in the case of buses where seat
belts are mandatory only for the driver).

18. Injury And Damage Reporting

CONTRACTOR shall ensure that an immediate oral report is made to

Company Representative in the case of all:

· Fatal injuries;
· Injuries requiring medical attention which result in lost time;
· Damage over SR 10,000 to CONTRACTOR's plant or equipment;
· Damage, in any amount, to SAUDI ARAMCO's equipment or property;
· Fire;
· Damage and near misses to cranes and heavy equipment (GI.
7.026).

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 399
 For accidents involving CONTRACTOR employee fatalities, serious injury
to five or more CONTRACTOR employees, or damage to SAUDI ARAMCO
equipment or property, a written report shall be submitted promptly to
Company Representative. In addition, SAUDI ARAMCO may convene an
engineering review or investigation committee in accordance with the
requirements of GI 6.001 and GI 6.003..

CONTRACTOR shall maintain, in a format approved by Company

Representative, a current record showing all:

· WORK injuries
· Fires
· Incidents of property damage over SR10,000
· Motor vehicle collisions
· Incidents involving damage to SAUDI ARAMCO equipment and
property
· Damage and near misses to cranes and heavy equipment (GI
7.026)

This record shall be available for inspection at all reasonable times and
shall be submitted to SAUDI ARAMCO on request.

19. Excavations

CONTRACTOR shall ensure that any excavation work carried out during
the course of the WORK is done according to the requirements of SAUDI
ARAMCO GI 1021.010 and OIM. 1.108 which are by this reference
made part of this Contract.

20. Work Over Or Adjacent To Water

Adequate lifesaving and rescue equipment shall be provided by

CONTRACTOR on every seagoing vessel, and at every work station where
WORK is being carried out over or adjacent to water. Life vests shall be
worn by CONTRACTOR's personnel when working over water as
prescribed in SAUDI ARAMCO GI 6.020, which by this reference is made
part of this Contract.

21. Fire Prevention

CONTRACTOR shall provide and maintain in good working order

adequate fire fighting equipment. All CONTRACTOR's personnel shall be
properly trained in the use of such equipment. Store yards shall be laid
out in accordance with SAUDI ARAMCO Standards (SAES-B-7A, SAES-B-
7C) and NFPA 231 A with respect to spacing of rows, fire lanes and
compatibility of materials.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 400
22. Formwork

CONTRACTOR shall ensure that all formwork supports are constructed to

SAUDI ARAMCO approved standards. As far as practicable, steel units
shall be used.

Where the WORK requires a timber supporting structure, the timber shall
be of suitable quality and of adequate strength. CONTRACTOR shall
obtain prior written approval from Company Representative before any
timber supporting structure is erected.

CONTRACTOR shall ensure that prior to any concrete being poured into
any supported formwork structure, approval is obtained from Company
Representative.

23. Ionizing Radiation

CONTRACTOR shall ensure that radioactive sources shall be used in

compliance with the "General Rules and Regulations for the Use and
Handling of Radioactivity and Radioisotopes" as promulgated by the
Saudi Arabian Atomic Energy Department and with prior written approval
of SAUDI ARAMCO. Where the WORK requires the use of ionizing
radiation either by the CONTRACTOR or by some other organization
approved by SAUDI ARAMCO, CONTRACTOR shall ensure that all
employees are made aware of the precautions to be taken.

24. First-Aid Facilities

The CONTRACTOR shall provide and maintain first-aid facilities at the

WORK Site in accordance with Articles 134 and 135 of the Saudi Labor
Laws. When a CONTRACTOR employs 50 or more workmen at a WORK
Site the CONTRACTOR shall provide a qualified nurse and a dedicated
emergency vehicle (ambulance), properly supplied and marked, to
transport injured personnel to the nearest health care facility.

25. Handling, Transportation And Disposal Of Hazardous Materials

And Waste

25.1

When a CONTRACTOR, in the course of performing his

obligations under the Contract, handles hazardous materials, the
CONTRACTOR shall ensure that the handling of such materials is
performed in accordance with currently accepted industry
practices for the handling of such material. CONTRACTOR shall
ensure that in handling of hazardous materials, especially
liquids, such material is properly containerized and labeled in
accordance with SAUDI ARAMCO GI 355.001.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 401
 25.2

Subject to any specific requirements in Schedule "B",

CONTRACTOR shall include in its Loss Prevention Program its
procedure for the disposal of solid and liquid wastes. The
procedure shall detail specific locations for the disposal of each
type of waste (construction, chemical, sludge, sanitary, scrap
and sewage) and shall also identify the steps to be taken to treat
the wastes or otherwise prevent them from polluting the ground
water or the sea or from becoming a public nuisance. SAUDI
ARAMCO shall approve such procedure before disposal of any
waste by CONTRACTOR.

25.3

In addition to the requirements of sub-paragraph 25.2 above,

where the CONTRACTOR is required to dispose of wastes
determined to be hazardous, the CONTRACTOR shall:

25.3.1

Follow Saudi Arab Government regulations in disposing

of hazardous waste materials. CONTRACTOR must
provide SAUDI ARAMCO proof that the hazardous
wastes have been properly disposed of at a licensed
hazardous waste disposal facility.

25.3.2

CONTRACTOR shall also provide SAUDI ARAMCO proof

of an established land treatment/disposal program
which is designed to ensure that hazardous
constituents placed in or on the treatment/disposal
zone are degraded, transformed or immobilized within
the treatment zone to prevent migration to ground
and/or surface waters. The CONTRACTOR shall submit
this program to SAUDI ARAMCO for approval prior to
the disposal of any hazardous material by the
CONTRACTOR.

26. Explosives

CONTRACTOR shall promptly advise Company Representative of any

requirements for explosives and only use such explosives after the
written approval of Company Representative. Contractor shall comply
with the general rules and requirements for the handling and use of
explosives issued by the Ministry of the Interior and all Saudi Aramco
requirements per the Saudi Aramco Construction Safety Manual for the
storage, transportation and use of explosives.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 402
27. Sandblasting

CONTRACTOR shall comply with SAUDI ARAMCO GI 6.021 and

Construction Safety Manual requirements on sandblasting.

February 1993 - A.3 Contractor Safety And Loss Prevention Requirements Page 403
A.4 HAZARD IDENTIFICATION PLAN (HIP)
INTRODUCTION

In reviewing the safety requirements for our design and construction

activities (i.e. new, modified or rebuilt plants or facilities), it is difficult
for even the most experienced engineer and/or contractor to identify all
the potential safety hazards that may be encountered unless a
systematic potential-hazard review is conducted as a part of a Hazard
Identification Plan (HIP).

The attached Hazard Identification Plan (HIP) provides the method for
conducting such a review. The hazards identified are classified as A, B or
C according to their degree of potential human impact considering
severity and probability (i.e. from most severe and probable to least
severe and probable) during the initial design phase. This allows for a
change in the methodology or operating procedure in the direction of
reducing the risk associated with the hazard to an acceptable level, or
eliminating it altogether.

February 1993 - Construction Safety Manual: Hazard Identification Plan Page 404
HAZARD IDENTIFICATION PLAN:

Brief description of work to be accomplished.

I. Conduct Hazards Identification Review.

(To include on-site tour)

Record hazards identified on location map.

II. List Potential Hazards

· Each hazard will be classified A, B, or C.

· Statement of corrective action to be taken.
· Hazard areas identified on a location map and color coded.
· Contractor will submit this list to Saudi Aramco
representative.

Consideration will be given to the following potential hazards:

· Potential hazards to P.M.T. and contractor personnel.

· Potential hazards to the general public.
· Incompatible interface with existing plants, facilities,
procedures, regulations, engineering specifications, ground
condition, etc.
· Potential hazards that may be encountered from outside
sources.
· Hazardous materials identification/handling/storage.
· Potential fire / electrical hazards.

III. Hazard Classification

Once the hazards are identified, they are classified as Class A, B,

or C.

· Class "A" Hazards:

A condition or practice likely to cause permanent

disability, loss of life or body part and/or extensive loss
of structure, equipment or material.

· Class "B" Hazards:

A condition or practice likely to cause serious injury or

illness (resulting in temporary disability) or property
damage that is disruptive, but less severe than Class
"A".

February 1993 - A.4 Hazard Identification Plan Page 405

 · Class "C" Hazards:

A condition or practice likely to cause minor (non-

disabling) injury or illness or non-disruptive property
damage.

February 1993 - A.4 Hazard Identification Plan Page 406

 IV. Corrective Action

List all hazards identified in the HIP outline, and determine what
corrective action should be taken.

Example: "A" Hazards

Overhead electrical power lines over building site

· Electrical power rating, (KV)

· Show power lines on location map.

Corrective Action

Example: "A" Hazard. "Overhead Power Lines"

Corrective Action:

· Obtain work permit before starting any work under

or near electrical power lines.
· No activity in area under power line until power
lines have been disconnected and/or relocated.

Following are examples of typical hazards that can be

encountered:

1) Above Ground Potential Hazards

· Overhead power lines, list KV rating

· Bridges, by-passes
· Micro wave / communication towers
· Houses
· Traffic flow
· Facilities close-by
· Aircraft flight path
· Trees, poles
· High cliffs / dangerous overhangs
· Fuel / chemical / pressure vessels and systems

2) Ground Level Potential Hazards

· Electrical wires
· Roadways
· Ditches
· High water table
· Tie-downs
· Obstruction
· Unstable soil
· Fences/walls
· Traffic flow
· Guide wires

February 1993 - A.4 Hazard Identification Plan Page 407

 · Nearby buildings, schools, houses
· Possible flood or wash out areas
· Adverse weather conditions
· Hazards from nearby plants or operations, etc.

3) Underground Potential Hazards

· Buried utilities
· High water table
· Building foundations
· Underground water waste
· Unstable soil
· Chemical / trash dump area
· Voids in the earth (caves)
· Underground fuel / chemical / pressure systems and
vessels

4) Interface Potential Hazards

· Existing emergency evacuation plans

· Emergency communication system
· Traffic flow
· Special personnel
· Protective equipment requirements
· Hazardous waste disposal
· Hazards from other outside operations
· Escape routes
· Evacuation alarms
· Access control
· Flammable liquid / chemical / pressure vessel
storage
· Gas release into proposed area

5) Off-Shore Potential Hazards

· High wind / sea conditions

· Night time operations
· Inclement weather conditions
· Fog
· Rain
· Lightning
· Marine vessels and materials adrift
· Electrical hazards

February 1993 - A.4 Hazard Identification Plan Page 408

Appendix B:
Emergency/Disast
er Planning And
Response

February 1993 - Construction Safety Manual - Appendix B: Emergency/Disaster Planning And Response
Page 409
B.1 SEARCH AND RESCUE PROCEDURES
This Appendix outlines Saudi Aramco search and rescue procedures for on- and
off-shore facilities. Included in this appendix are the following:

· Control of Remote Area Travel And Search And Rescue Procedures (GI
6.025);

· Offshore Emergency Response;

· Fire and Other Serious Emergency Response Procedures (Supplement No. 1-

503-1).

Any further questions on search and rescue procedures should be forwarded to

your area Loss Prevention Department office or the Saudi Aramco contract
proponent.

Effective emergency planning requires that employees be familiar with emergency

procedures before a crisis. It is the responsibility of management to ensure that all
employees are familiar with the proper response to fire and other serious
emergencies.

February 1993 - Construction Safety Manual: Search And Resuce Procedures Page 410
B.2 EMERGENCY/DISASTER PLANNING AND
RESPONSE
It is the responsibility of every contractor employee to become familiar with
emergency response procedures for both offshore and onshore operating facilities.

The following Operating Instructions Manuals (OIMs) give facility-specific

emergency response guidance/procedures:

Saudi Aramco Operating Instruction Manual (OIM):

OI 1.501 Overall Disaster Control Procedure - Safaniya/Tanajib Area

OI 1.501-1 Tanajib Disaster Control Center Commander

OI 1.501-2 Safaniya Support Personnel Assignment

OI 1.501-3 Disaster Control Command Center - Tanajib Personnel Assignment

OI 1.502 Onshore Control Unit - Safaniya Producing

OI 1.503 Offshore Disaster Control Plan - Safaniya Producing

OI 1.503-1 Offshore Emergency Response

OI 1.503-2 Offshore Emergencies Only

OI 1.503-3 Safaniya Offshore Jack-Up Test Barge/Well Platform Disaster Control

Plan

OI 1.503-4 Safaniya Offshore - Offshore Casualty Evacuation

OI 1.503-5 Personnel Accountability Offshore Facilities

OI 1.527 Safety Zones and Safety of Navigation Around Offshore Installation

OI 10.011 Work Around Offshore Producing Facilities

General guidelines for preparing emergency response plans can be found in the
following Saudi Aramco Loss Prevention Department publication:

GI 70.500 Disaster Contingency Plan, Dhahran Area

Guidelines for Preparing Emergency Response Plans, October 1989

Other references include:

Saudi Aramco Corporate Loss Prevention Manual (CLPM)

Mobil Oil Corporation - Guidelines for Emergency Response and Disaster

Contingency Planning for Saudi Aramco, May 1991

February 1993 - Construction Safety Manual - B.3: Emergency/Disaster Planning And Response Page 411
The potential for emergencies and disasters exists at all construction sites and
facilities and their associated costs can be devastating in terms of employee
casualties, business interruption, loss of capital investment, etc. These events
cannot be avoided but the contractor can reduce their frequency of occurrence
and severity of damage with effective preparation/planning. This can be
accomplished by developing emergency response plans that address immediate
concerns within the contractor's operations and which also interface, as required,
with emergency response procedures developed by Saudi Aramco organizations.

The following guidelines (B 3.1 and B 3.3 and Figures) are extracted from the
publication "Guidelines For Preparing Emergency Response Plans". These are
generally used by Saudi Aramco operations as a framework for plan development.
Contractors should refer to these guidelines for developing their own plans as
appropriate, paying particular attention to the need for interfacing with local Saudi
Aramco emergency planning procedures. Contractor's plans will need to be
tailored to their specific operations and resources and the nature of their work with
Saudi Aramco.

B.2.1General Provisions

1. The purpose of the emergency plan is to provide guidance on the

following:

· A facility/site emergency response organization's structure and

responsibilities
· Development of credible emergency/disaster scenarios and
their consequences
· Establishment of emergency control resources (human,
equipment, etc.) and procedures
· Emergency response training and drills

2. Ensure that the emergency plan with the latest issue date is being
used and it incorporates all amendments to date. It must have
provision for any future amendments as addendum or reissues.
3. The emergency reporting instructions must be provided in the front
of the plan.
4. The emergency telephone numbers must be provided in the front of
the plan.
5. The disaster preparedness policy must be provided in the front of
the plan.

B.2.2Definitions

1. Emergency:

An emergency is an abnormal incident posing a threat to the

safety of workers, residents, the environment or property at a
facility or site and which can be brought under control using the
resources and procedures for emergency response in place for
the facility or site.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 412

 2. Disaster:

A disaster is an emergency which poses a more serious threat to

the safety of workers, residents, the environment or property at a
facility or site and which cannot be brought under control using
the resources and procedures for emergency response in place
for the facility or site. Whether an emergency becomes a
disaster depends on the following:

· the type of facility;

· the hazards of the facility operations;
· the proximity of neighboring communities or other
facilities;
· the capabilities of emergency personnel; and
· mutual aid capabilities of outside agencies.

3. Emergency Planning:

This involves the development of a specific plan which details

actions to be taken by trained personnel during an emergency in
an effort to efficiently control it and minimize its net negative
impact on workers, residents, the environment or property at a
facility or site. This type of planning also extends to developing
emergency control strategies and instituting training and drills
for all facility personnel.

4. Disaster Command Center (DCC):

The location where the Emergency Manager and support staff

assemble to respond to an emergency. It is a centralized
location for monitoring the facility response and also serves as a
command center for coordinating all communications, including
the allocation and distribution of information. (This will also
remain an onshore centralized location for an offshore
emergency response episode.) During an offshore search and
rescue (SAR) operation, this will become the SAR control center.
A designated helicopter pilot will report to SAR control center to
act as a search coordinator. Staffing from pertinent technical
and support groups assures accessibility to all required resources
for an overall effective emergency response.

5. Disaster Command Post (DCP):

A designated safe location near the emergency site from which

the Incident Commander directs emergency control efforts. He
directs operations and coordinates fire fighting, rescue and
medical treatment activities during the emergency episode.

At some onshore facilities, the DCP is a specially equipped

vehicle outfitted with facility maps, communication equipment
and support information similar to a DCC. This equipment
provides the means for contact with the DCC and for field

February 1993 - B.3 Emergency/Disaster Planning And Response Page 413

 coordination. At offshore facilities, the DCP would be a safe
location designated by the Incident Commander which should be
equipped with a telephone, radio communication and personal
protective/identification equipment, at a minimum.

6. Table Top Exercise:

This is a disaster management simulation where key personnel

face a hypothetical disaster situation developed by a skilled
moderator. Weaknesses are identified by evaluating the results
of the exercise and corrected by revising the plan.

7. Planning Committee:

A planning committee is a body comprising of members from key

functional groups within the organization. This is set up to
develop an emergency plan using the broad expertise of its
members.

8. Planning Coordinator:

An individual who is qualified to develop an emergency plan to

direct its development through a planning committee. This
individual is required to process great depth of knowledge of
emergency response and disaster control practices and
procedures, and manpower organizational capabilities for his
facility or site. He can review and use Saudi Aramco approved
emergency plans from other similar facilities or sites in the
development or modification of his facility/site plan.

9. Emergency/Disaster Response Organization:

The Emergency/Disaster Response Organization is a structured

working group whose function is to control an emergency or
disaster. The structure of this group is typified in Figure B.1. The
organization is basically comprised of the following positions
with their delegated responsibilities.

A. Key Positions

(a) Emergency Manager

The Emergency Manager is responsible for the overall

organization and strategy of the emergency response,
coordinates logistical efforts and has the authority for
the final decision in any emergency action. He is
usually, but not always, the senior management person
at the facility. His specific responsibilities are to:

(1) assume control of the DCC

(2) implement the Emergency Plan
(3) receive updates on control measures taken by
the Incident Commander

February 1993 - B.3 Emergency/Disaster Planning And Response Page 414

 (4) assess the situation and direct actions to
minimize damage and loss of life
(5) maintain contact with upper management
(6) declare the emergency "under control" and
authorize the "all clear" signal

(b) Incident Commander

The Incident Commander is responsible for suppression

and control tactics at the site. The Shift
Superintendent usually fills this position and provides
direction to all personnel at the scene, including the
senior fire officer. His specific responsibilities are to:

(1.) establish the Disaster Control Post (DCP) at a

safe location near the emergency site
(2) develop and implement control tactics
(3) approve use of all emergency related resources
(4) keep the Emergency Manager informed
(5) evaluate mutual aid needs, and request
assistance through the Emergency Manager
(6) coordinate mutual aid personnel and
equipment
(7) determine the need for evacuation

All normal plant functions and emergency support

services report directly to one of the above positions
according to their reporting relationships given in
Figure B.1.

B. Emergency/Disaster Support Staff/Teams

(a) Fire Protection/Rescue

This function is usually performed by a combined team

of facility/site fire protection personnel. They take
directions from the Incident Commander through the
appointed senior fire officer at the DCP. The
responsibilities of the senior fire officer are as follows:

· Fire-Fighting

(1) provide initial evaluation to the Incident

Commander
(2) deploy fire fighting personnel and equipment
(3) advise Incident Commander of the need for
outside resources
(4) keep Incident Commander current on fire
control status
(5) direct outside fire fighting organizations
(6) clean-up and restore fire protection equipment
and supplies

February 1993 - B.3 Emergency/Disaster Planning And Response Page 415

 · Rescue

(1) locate and rescue missing persons

(2) render essential first aid and life support
(3) remove victims to designated safe locations for
medical treatment

(b) Process

This function is usually performed by an operations

representative who is responsible for advising the
Emergency Manager in the following areas:

(1) operations, hydrocarbon movement, unit

isolation and emergency shutdown activities
(2) special fire protection needs
(3) materials or process in the affected area
(4) actions taken affecting the process
(5) process equipment involved in the control of
the incident

(c) Maintenance

This function is usually performed by a maintenance

representative who is responsible to:

(1) assemble maintenance manpower in the

maintenance shops
(2) assist operators in isolating and shutting down
units as directed
(3) repair of emergency equipment
(4) assist utilities personnel in bypassing or
repairing critical utility components
(5) provide fuel for emergency vehicles and
firewater pump engines
(6) transport foam and other emergency supplies

(d) Engineering

This function is usually performed by an operations

engineering representative whose responsibilities are
as follows:

(1) provide mechanical and process related

information
(2) keep the Emergency Manager, Incident
Commander, and Process Coordinator advised
of factors influencing emergency activities.
(3) assign an engineer to serve as an emergency
events recorder
(4) prepare damage assessment reports
(5) collect and preserve evidence for the incident
investigators

February 1993 - B.3 Emergency/Disaster Planning And Response Page 416

 (6) perform post-incident engineering for repair
work

(e) Security

This function is usually performed by the facility

Security Supervisor whose responsibilities are as
follows:

(1) ensure integrity of the plant perimeter

(2) provide necessary staffing to control use of
emergency gates
(3) prevent entry of unauthorized personnel
(4) direct the flow of traffic away from the disaster
scene
(5) direct emergency resources to the appropriate
staging area
(6) provide escorts for emergency vehicles when
requested
(7) advise Incident Commander on security
matters
(8) act as liaison between the Frontier Force, the
Incident Commander and Government Affairs

(f) Loss Prevention

This function is usually performed by the Loss

Prevention Advisor/Engineer whose responsibilities are
as follows:

(1) help evaluate hazardous situations and

materials
(2) recommend actions and equipment necessary
to protect personnel
(3) direct Loss Prevention staff to perform gas
testing or other emergency/disaster services
and interface as needed with Industrial
Hygiene
(4) assign Loss Prevention staff to record or log
emergency/disaster activities for future use
(5) coordinate with services as necessary
regarding safety equipment

(g) Services

This function is usually performed by a staff engineer

who coordinates support services and obtains a cost
code from the area Finance representative to account
for all financial, purchasing, and cost analysis aspects
of the incident. His responsibilities are as follows:

(1) contact the on-call Area Representative who

will provide safe and sanitary food, potable

February 1993 - B.3 Emergency/Disaster Planning And Response Page 417

 water, and field sanitation facilities on request
of the Incident Commander
(2) purchasing and contracting requirements
(3) coordinating claims actions
(4) providing necessary accommodations for
emergency response personnel

(h) Medical

This function is usually performed by district medical

personnel whose responsibilities are as follows:

(1) establish a triage area at the scene

(2) provide on-site emergency medical care
(3) advise the Emergency Manager of the number
of injured and any need for additional medical
assistance
(4) notify appropriate hospitals and clinics of the
anticipated number of casualties
(5) advise the Emergency Manager of special
medical transportation needs
(6) keep records of victims and their treatment

(i) External Relations

This function is usually performed by the area

Government Affairs representative whose
responsibilities are as follows:

(1) establish and maintain communications with

civil authorities
(2) communicate the incident status to
government organizations as appropriate
(3) request approval from the Emergency Manager
for any government inspections and/or
investigations during the emergency
(4) inform community leaders of incident status,
potential dangers which might require
evacuation and recovery efforts

(j) Operations/Utilities

This function is usually filled by plant/site foremen who

direct the activities of plant operators. Their
responsibilities are as follows:

(1) account for personnel by head count

procedures
(2) report missing persons
(3) implement the facility emergency operating
plan for a specific situation (i.e. isolation and
shutdown unit(s) as instructed and stabilize
units not involved)

February 1993 - B.3 Emergency/Disaster Planning And Response Page 418

 (4) await further orders after the units have been
shutdown and secured
(5) assign an operator to check firewater mains
pressure and start fire pumps
(6) control the plant air systems, steam systems,
and other utilities and advise the Incident
Commander on their status
(7) inform the Incident Commander and
Maintenance of system failures
(8) evacuate personnel if instructed by the
Incident Commander

(k) Communications

This function is usually performed by an operations

employee who reports to the DCC to manage radio
transmissions, telephone lines, operate special
equipment such as DVD, EARS, etc., and record all
message traffic.

(l) Environmental

This function is usually performed by an assigned

environmental specialist whose responsibilities include
providing environmental monitoring services and spill
containment/recovery advice to the Emergency
Manager and Incident Commander.

B.2.3Plan Development Action Items

Task 1:Assign (or Establish) Planning Coordinator (or Team)

1. A planning coordinator must be assigned; or

2. A planning committee/coordinator team must be

established.

Task 2:Establish Scope and Objectives

3. A scope and written objectives must be developed for the

site.

Task 3:Identify Emergency/Disaster Scenarios

4. Develop emergency/disaster scenarios specific to the

facility or site as follows. (Use Figure B.2 for scenario
development):

· Planning Coordinator/team to identify

emergency/disaster situations.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 419

 · Group these situations into generic scenarios (e.g.
tank fires, pump fires, liquid releases, vapor releases,
explosions, natural disasters, etc.)
· For each generic scenario, select the credible worst
case emergency/disaster situation to represent that
scenario (e.g. the largest tank fire) and fill out Part A
(Description) and Part B (Possible Causes) of the
Scenario Analysis Sheet (Figure B.2). Similarly,
describe all scenarios on separate sheets and assign a
rank order to each in Part E (Evaluation) based on
likelihood of occurrence. (The "consequences" of Part
E will be developed as part of Task 4, "Assess the
Consequences of Scenarios".)

The following information is useful in identifying

emergency/disaster situations (initiated on-site or off-site) within
each generic scenario:

· Fire

Fires are generally caused as a result of ignition of a gas (or

liquid) hydrocarbon leak under pressure. Unburned liquid
hydrocarbon pools in the ground and fuel the fire to increase
its intensity and spread. All situations within this scenario
can lead to disasters if fire spreads beyond the capabilities
of the fire fighting systems/personnel in place. Generally,
this occurs if the response is not quick to contain the fire to
a manageable limit before it approaches a disaster level.
Some examples of potential emergency/disaster situations
for the fire scenario are:

· congested multiple process unit area fire

· flammable liquid tank storage area fire
· wharf loading and unloading area fire

· Explosion

Flammable vapor releases are one of the most significant

sources of explosions and the potential for casualties and
property damage is high. Some examples of potential
emergency/disaster situations for the explosion scenario
are:

· boiling liquid expanding vapor explosion (BLEVE) of

storage, sphere, bullet or process vessel
· runaway (exothermic) process chemical reaction
· gas explosion from a large volume release of
refrigerated LPG
· unconfined vapor cloud explosion (UVCE) from a
flammable vapor release

· Flammable Vapor Release (FVR)

February 1993 - B.3 Emergency/Disaster Planning And Response Page 420

 In the petroleum industry, the possibility of release of
flammable vapor poses a great risk. Some examples of
potential emergency/disaster situations for the FVR scenario
are:

· failure of piping connection to pressurized storage

sphere (or bullet), or refrigerated tank
· tank overfill
· LPG tanker accident resulting in containment failure
· high pressure gas pipeline rupture

· Toxic Vapor Release (TVR)

Toxic materials may or may not be flammable but could be

in a high enough concentration to pose a health risk when
released as a vapor. Some examples of potential
emergency/disaster situations for the TVR scenario are:

· rupture of pipeline or well blowout releasing H 2S

vapor
· rupture of storage container releasing
chlorine/ammonia vapor
· rupture or leak of amine regenerator overhead
accumulator piping/flange to release H 2S vapor
· failure of H2S compressor seal releasing the vapor

· Hazardous Materials Spill

Hazardous materials are used as solvents, reagents, and

catalysts in various processes. A likely situation for a
hazardous material spill is from the tanker vehicle
transporting it to the facility or during its transfer from the
tanker vehicle to its process usage or storage point. Other
examples of potential emergency/disaster situations for the
Hazardous Materials Release/spill scenario are:

· TEL/TML gasoline antiknock compound liquid release

· rupture of storage container or associated piping
releasing chlorine/ammonia liquid
· rupture of storage container or associated piping
releasing sulfuric acid liquid

· Natural Disaster

Each facility or site is susceptible to natural disasters (e.g.

high winds, flooding, etc.). The impact of natural disasters
to cause other related process disasters should be
recognized in the planning stage. Historical data on
disasters at similar facilities or sites coupled with weather
data can help in predicting the frequency of natural

February 1993 - B.3 Emergency/Disaster Planning And Response Page 421

 disasters for the area. Another source of such information is
the Saudi Aramco Risk Analysis Manual.

Task 4:Assess the Consequences

5. Complete each scenario analysis sheet started in Task 3 by

describing the incident size, duration and effect on
operations.

6. Enter an estimate of the magnitude of potential

consequences in Part E (Evacuation) of the Scenario
Analysis Sheet (Figure B.2) after considering the following
factors for each scenario:

· Size (including explosive potential, maximum fire

areas, maximum spill volume and area, maximum
vapor cloud volume).
· Growth spread of impact area resulting from the
spread of a fire, toxic vapor cloud, or other
undesirable product of the emergency/disaster
episode.
· Amount of advance warning.
· Impact (including severity of potential damage,
potential casualties, effect on surrounding population,
domino effect of sequential explosions, and total
duration).
· Controllability of incident based on level of
emergency/disaster training of personnel and
adequacy of equipment available within a facility or
site.
· Reaction (or response) time and effectiveness of
facility resources to control incident.

After the Scenario Analysis sheets have been completed

for each scenario, assign a rank order in Part E based on
consequences. The plan coordinator selects the scenario
which represents the most likely event with the severest
consequence(s) as the basis for developing the emergency
response plan. This choice should be approved by
Contractor management.

Task 5:Review Emergency Control Needs

7. Use the Disaster Control Tasks Checklist to determine all

tasks required (see Figure B.3).

8. Assign a team member to develop the facility's response.

9. Develop and document the assigned response.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 422

 Task 6:Available/Needed Resources

10. The methods to identify, estimate, and establish available

needed resources are as follows:

(a) Develop an inventory list of critical supplies and

equipment needed to control the emergency disaster
scenarios in Tasks 3 and 4.

(b) Ensure that these critical items are stored together at

one easily accessible location (or the critical items
store itself if accessible).

(c) Display the list of critical items on the entrance to the

critical items store.

11. Identify and list the entities responsible for supplying food,
water, shelter, transportation, emergency equipment,
additional manpower, external mutual aid, medical support
and cost accounting.

12. Determine that the resource needs in item number 10.

(above) have been met List contingencies to cover failure
of any of those entities indicated in item 11. to supply the
needed items.

13. Survey alternate outside sources to determine their ability

to supply resources which may be in short supply.

14. If a mutual aid agreement has been established, develop

an inventory of equipment and supplies that any mutual
aid entity is expected to bring with them when they
respond.

15. Establish a telephone and personnel list of 24-hour

contacts at all mutual aid entities.

16. Determine and document that the equipment and supplies

provided through mutual aid are compatible with
emergency/fire protection equipment at the site.

17. Measure the response/travel time needed by all mutual aid

entities to respond to an emergency/disaster at the site.
Establish the needed time range for all outside resources
to reach the site.

18. List and detail all high cost items and their corresponding
authorization levels.

19. List emergency response skills required to control all

scenarios selected in Tasks 3 and 4.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 423

 20. Compare required skills with available skills of
construction/site personnel.

21. Establish a Disaster Command Center (DCC).

22. Consider the need to provide an alternate location for the

DCC in case the original location is rendered unusable.

23. Supply the DCC (and alternate) with:

· telephone, fax, and other radio communication/alarm

equipment
· emergency power and lighting
· reference materials (e.g. emergency response
manuals, call out lists, Material Safety Data Sheets
(MSDSs), drawings, photographs, maps, etc.) and
emergency equipment (e.g. flashlights, spare
batteries, camera, battery powered megaphones, etc.
· office equipment (e.g. dictating machines, tapes, flip
charts, stationery items, etc.)

24. Establish a Disaster Command Post (DCP) vehicle/safe

location near the emergency site..

25. Ensure that the DCP is set up with supplies similar to the
DCC (except on offshore facilities where the DCP may only
have a telephone, radio communication and personal
protective/identification equipment).

26. Additionally, ensure that the DCP also has the following:

· self-contained breathing air

· megaphone
· binoculars
· safety/environmental monitoring equipment
· means of identification (vest, hat)

Task 7:Emergency Response Organization

27. Establish an emergency/disaster response organization.

28. Ensure there are sufficient personnel to fill all assigned

positions and alternates/substitutes identified and on
standby to fill critical positions should it become
necessary.

29. Ensure that each assigned position has a documented

detailed description of its responsibilities. Such a
description must include:

· duties of the position

· reporting relationship

February 1993 - B.3 Emergency/Disaster Planning And Response Page 424

 · reporting location

30. Verify and document that all assigned individuals are

aware of their responsibilities.

31. Develop a physical method to identify each individual in

the organization chart by position (ID. badges, vests).

Task 8:Develop Emergency Response Procedures

32. Ensure that the planned facility/site emergency response

procedures are structured according to the logical
progression of action items given in Figure B.4.

(a) Reporting Emergencies:

(1.) Report to senior operations person in control room

using radios, telephones, manual pull box alarms,
or public address systems. (Emergency telephone
numbers or local 110 instructions should be posted
near or on all telephones.)

(2.) Determine how significant does an incident have

to be to be reportable.

(3.) Suggested wording for reporting emergencies (or

drills) is shown in Figure B.5 (Emergency Reporting
Instructions). Also see section VII.A (Reporting
Emergencies) of the plan (see Task 9: Write the
Plan).

(4.) Details of the telephone and radio systems (i.e.

different dialing and radio frequencies) should be
in the appendix of the plan.

(b.) Initiate The Alarm:

All emergency related signals (i.e. "stop-work",

"evacuation", and "all clear") and expected actions
relating to each signal alarm must be established and
followed.

Authority and criteria for sounding the different alarms

must be clearly stated in the plan.

(c.) Assess The Situation:

The Incident Commander must follow-up on every

emergency declared by reporting to the incident site to
assess:

· the emergency response actions taken or being

taken

February 1993 - B.3 Emergency/Disaster Planning And Response Page 425

 · additional actions and resources required to
control the situation
· extent of damage to property and harm or
negative impact to life.
· existing hazardous conditions and their likelihood
to escalate.

(d.) Mobilization Of Resources:

1. Actions are taken by facility/site personnel to

mobilize the facility's internal resources (human,
equipment, etc.) and, if needed, contact external
groups to mobilize their resources to the scene as
developed in Task 6 (Available/Needed Resources).

2. Plant personnel assigned to the emergency

response organization are to proceed to their
preassigned locations and await instructions from
the Emergency Manager or Incident Commander,
as applicable.

3. Non-essential plant personnel are to be evacuated

to preassigned assembly areas at a safe distance
from the incident scene. Supervisory or assigned
personnel are to take head count and DCC is to
organize search and rescue for any missing
personnel.

4. Support groups such as Security, Medical and Fire

Protection are to report to their preassigned
locations and must commence any preauthorized
emergency response related actions.

5. At least two methods of in-plant communication

should be available (e.g. radio and telephone).
One in-plant radio channel is reserved as the main
communication link between the Emergency
Manager and Incident Commander. At least two
methods of communication are necessary for
external contacts (e.g. telephone, radio, Direct
Voice Dispatch - DVD, Emergency Alert and
Response System - EARS, etc.).

A telephone number with a pre-recorded message

providing essential up-to-date information on the
incident (e.g. 113 in Dhahran) will be established.

(e) Suppression/Control Of Incident:

A separate control procedure must be written for

each generic incident scenario developed in Task 3
(Identify Emergency Scenarios). This procedure is
based on facility operating instructions detailing

February 1993 - B.3 Emergency/Disaster Planning And Response Page 426

 the rapid and safe sequential shut down of process
units/equipment involved or affected by the
particular incident scenarios.

(f) Post Incident Actions:

There are follow-up actions needed once an

emergency is declared under control by the
Emergency Manager. These actions are:

1. Stand Down And Fire Watch

The Emergency Manager gives the "stand down"

order to emergency response personnel. At this
time, some personnel are released from duty,
some are assigned to gather evidence, on the
emergency episode and others are to maintain a
fire watch if there is danger of reignition. The fire
watch is set up by Fire Protection following
consultation with the Emergency Manager.

2. Investigate And Report

Incident investigation of causes and reporting can

be made according to prescribed procedures. GI.
6.001 (Notification Requirements For Incidents)
and GI 6.003 (Guide For Committees Investigating
Major Incidents) are two sources which provide
guidance for developing such procedures.

3. Restore Operations

This covers all post-emergency control actions

which must be followed to restore normal
operations at the facility. This includes, but is not
limited to:

· demands of caring for injured and homeless

· repairing damaged equipment to bring process
equipment on-line
· collecting evidence for the reporting
requirement
· determining secondary hazards that may have
developed

February 1993 - B.3 Emergency/Disaster Planning And Response Page 427

 4. Revise The Plan

All new information gained as a result of the

incident should be analyzed to determine what
improvements could be made to the facility's
Emergency Response Plan. These improvements
should be integrated into the Plan and all
emergency response personnel should be
retrained and drilled to ensure that they are
familiar with and proficient in following upgraded
procedures.

33. Develop procedures for the following

emergencies/disasters (onshore/offshore as applicable):

· emergency unit shutdown

· individual equipment isolation
· process unit fire
· tank farm fire
· marine dock fire
· off-site pipeline leak
· personnel rescue
· medical emergencies
· toxic/flammable/corrosive gas leak
· evacuation from units and buildings
· process upsets
· breaches of security (including terrorism or sabotage)
· For more information refer to the Saudi Aramco Loss
Prevention Department "Guidelines for Preparing
Emergency Response Plans" manual.

34. Complete the emergency reporting form given in Figure

B.5 and follow the instructions contained therein to report
such event(s).

Task 9 - Write the Plan

35. Ensure that the plan has a Corporate Policy Statement on

emergency/disaster preparedness, and is prepared in
conformance with the format and instructions presented in
the Saudi Aramco Loss Prevention Department "Guidelines
for Preparing Emergency Response Plans" manual.

A typical Emergency Response Plan will follow the outline

given in Figure B.6.

36. The plan manual must be reviewed and signed off by all
outside mutual aid entities expected to respond to an
emergency at this site.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 428

 Task 10 - Emergency Response Training and Drills

37. Develop, document and follow the emergency response

training/drill items given below to ensure that all personnel
expected to participate in emergency response are
proficient in its theory and practice.

· table top exercise

· classroom training of personnel
· simulation of DCC operations during an emergency
· field simulations/drills of credible scenarios

38. Ensure that alternates (or standby) personnel are also

trained and drilled on emergency response

39. Train and familiarize all personnel with the provisions of

your emergency response manual.

40. (a) develop a document and drill schedule in your manual

(b) ensure that these include full scale disaster

simulations

41. Hold and document critique sessions following all drills,

simulations and/or actual incidents.

42. Establish a procedure to ensure that all suggestions from

the critique sessions are incorporated into your manual.

Task 11 - Review and Revise the Plan

43. Provide for regular reviews (e.g. documented tickler date)

and update the plan at least once a year through the plan
coordinator.

44. Keep a record of all amendments and maintain it in the

front of the plan document manual.

45. Keep a current list of all document manual holders and

periodically forward them copies of any amendments.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 429

FIGURE B.1: TYPICAL EMERGENCY ORGANIZATION CHART

EMERGENCY MANAGER
(DCC)

LOSS
PROCESS ENGINEERING MEDICAL
PREVENTION

EXTERNAL
MAINTENANCE SERVICES COMMUNICATIONS
RELATIONS

INCIDENT COMMANDER
(DCP)

OPERATIONS/
FIRE PROTECTION SECURITY MEDICAL ADVISOR
UTILITIES

LOSS PREVENTION
ENVIRONMENTAL
ENGINEER

February 1993 - B.3 Emergency/Disaster Planning And Response Page

430
FIGURE B.2: SCENARIO ANALYSIS SHEET FOR (LOCATION)

Unit/Equipment: ____________________________________ Scenario No.: _________

Type of Emergency:
· ______Fire
· ______Explosion
· ______Flammable Gas
· ______Toxic Gas
· ______Hazardous Materials Spill
· ______Natural Disaster

A. Description of the Scenario:

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________

B. Possible Causes:
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________

C. Expected Size or Duration:

__________________________________________________________________
__________________________________________________________________

D. Effect on Operations:
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________

E. Evaluation and Ranking:

__________________________________________________________________
__________________________________________________________________

· Likelihood: (1 = most likely)

· No.____of____scenarios

· Consequences: (1 = most severe)

· No.____of____scenarios

F. Location/equipment-specific notes:
__________________________________________________________________
__________________________________________________________________

Reviewed by: _________________________________ Date: ____________

February 1993 - B.3 Emergency/Disaster Planning And Response Page

431
FIGURE B.3: EMERGENCY/DISASTER CONTROL TASKS CHECKLIST

1. Warning

· Alarm/communication systems to alert employees and local

community of an emergency/disaster.

· "Alert", "Evacuation" and "All-Clear" signals must be recognized by all

affected population, and they must know how to proceed in each
case.

2. Pre-impact Preparation

If time permits, facility personnel must do the following to minimize

negative impact of an emergency/disaster:

· Notify emergency response organization.

· Call for all available material reserves and resources.

· Contact appropriate resource for weather data and other

emergency/disaster information

· Evacuate all affected areas.

3. Evacuation

· Evacuation of persons from affected areas and non-essential workers

from adjacent areas lowers the risk of casualties.

· Evacuation system testing and training.

· Control of access and exit points.

· Dead count requirements.

4. Mobilization and Utilization of Human and Material Resources

The effectiveness of an emergency response depends on the quality and

supply of human and material resources. These resources must be:

· Known in advance.

· Available on demand.

· Compatible with each other.

· Used in an organized and controlled manner.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 432

5. Incident Suppression/Control

· Selective use of assembled resources.

· Training and experience of emergency response team (especially

Incident Commander).

6. Search and Rescue

· Identify likely search and rescue situations from generic scenarios.

· Establish resources (qualified personnel and equipment) and

procedures to locate victims - and transport them to safety.

7. Care for Casualties

Factors to be addressed in the care, treatment and relocation of

casualties are:

· Access of medical personnel to site.

· Temporary hospital facilities and equipment.

· Transportation to move casualties to such facilities.

8. Communications

Efficient and accurate communications are a necessary part of effective

emergency response actions.

· Communication equipment/system in place.

· Back-up communications equipment/system.

· Compatibility of facility communication equipment with that used by

mutual aid organizations.

9. Continuing Assessment

· Continuing assessment of the situation by knowledgeable observers

to redirect emergency/disaster response actions as needed.

10. Coordination

· Coordination of call-out personnel and staging of resources to ensure

proper level of support is available where needed.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 433

11. Control and Authority

· System of overall control and distribution of authority by chain of

command.

· Call-out list for management personnel.

· Personnel responsible to contact outside agencies and/or mutual aid

organizations.

12. Security

Adequate security personnel/system be in place to:

· Control traffic.

· Control access to scene of emergency/disaster.

13. Continuity of Operations

· Plan to continue operations unaffected by emergency/disaster by

manpower reassignment.

· Ensure that sufficient manpower/equipment is on standby to handle

escalation of emergency/disaster to other units.

14. Outside Community Order

Request Government Affairs representative to contact appropriate law

enforcement authorities and community leaders to address the
following:

· Evacuation, traffic and crowd control, guarding property and

patrolling dangerous areas.

15. Secondary Hazards

· The plan should identify hazards created as a result of the

emergency/disaster (e.g. structural damage to buildings, isolated
fires from explosions, downed electrical lines, etc.)

· Determine and plan to provide additional resources needed to control

these hazards.

16. Restore Normal Operations

· Maintenance personnel should maintain a current status list of plant

utilities and services lost during the emergency/disaster and the
estimated time to restore them.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 434

17. Emergency Teams and Equipment Recovery

· System to check and replace emergency equipment damaged during

or immediately after the emergency/disaster.

· System to provide shift relief to emergency/fire fighting crews and

replenishment of fire fighting materials and other consumables.

18. Personnel Needs

· Plan to provide emergency/disaster workers and other affected

personnel with sanitary food, water, clothing, shelter and financial
assistance as needed.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 435

FIGURE B.4: FLOW DIAGRAM OF TYPICAL OFFSHORE EMERGENCY RESPONSE

EMERGENCY INCIDENT

1. INITIATE THE ALARM

2. REPORT THE EMERGENCY

3. ASSESS THE SITUATION

4. MOBILIZE RESOURCES

5. CONTROL THE INCIDENT

6. POST-INCIDENT ACTIONS

February 1993 - B.3 Emergency/Disaster Planning And Response Page 436

FIGURE B.5: EMERGENCY REPORTING INSTRUCTIONS

TELEPHONE: XXX-XXXX (if busy see below)

I have an emergency to report:

I am calling from _____________________________________________________

My name is _________________________ My badge number is _______________

I see a _____________________________________at ________________________

(fire, gas leak, etc.) (north/south/east/west)

There are ___________(no.) of people hurt and requiring medical assistance.

DO NOT HANG UP. ENSURE THAT YOU HAVE A RESPONSE THEN

IF NECESSARY REPEAT THE ABOVE INFORMATION AND ANSWER
QUESTIONS.

1. If the number is busy or unavailable, try the following in the order

listed:

2. telephone xxx-zzzz

3. radio frequency xxx.xx

4. (other for the facility)

After the message has been given successfully, the reporting individual, if an
operator, should return immediately to the emergency site to do whatever he can
safely do to improve the emergency situation.

February 1993 - B.3 Emergency/Disaster Planning And Response Page 437

FIGURE B.6: EMERGENCY PLAN - SAMPLE TABLE OF CONTENTS

Suggested headings are shown below. Sections should be separated by dividers

with extended tabs naming each section.

I. Title Page
II. Reporting Emergencies
II. Emergency Response Personnel Roster
IV. Table Of Contents
V. Introduction
A. Scope
B. When To Implement
C. Definitions
VI. Emergency Response Organization
A. Chain Of Command
B. Functional Responsibilities
VII. Emergency Response Actions
A. Reporting Emergencies
B. Initiating The Alarm
C. Assess The Situation
D. Mobilization Of Resources
1. Internal Resources
a. Plant Personnel
b. Support Groups
c. Contractors
2. External Resources
a. Saudi Aramco
b. Non-Saudi Aramco
E. Suppression/Control of Incident
1. Vapor Release
2. Toxic Vapor Release
3. Fire
4. Explosion
5. Hazardous Materials Release
6. Natural Disaster
7. Other Site Specific Incidents
VIII. Post-Incident Actions
A. Stand Down And Fire Watch
B. Investigate And Report
C. Restore Operations
D. Revise The Plan
IX. Appendices
A. Materials And Equipment Inventory
1. Emergency Equipment
2. Fire Fighting Supplies
3. Facility Maps, Plans, Drawings
4. Communication Equipment
5. Mutual Aid
a. Saudi Aramco

February 1993 - B.3 Emergency/Disaster Planning And Response Page 438

 b. Non-Saudi Aramco
B. Exceptions To Generic Scenarios
C. Operating Instruction Manuals (OIMs) And Other References

February 1993 - B.3 Emergency/Disaster Planning And Response Page 439

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

February 1993 - Construction Safety Manual - Appendix C: Fire Safety Checklist Page 440
C.1 FIRE SAFETY CHECKLIST FOR EVALUATING
CONSTRUCTION MATERIALS STORE YARD
(Based on NFPA 231-APPENDIX C)
PROTECTION OF OUTDOOR STORAGE

I. SELECTION OF A SITE

A. Adequate fire department protection.

1. Travel time to site, primary factor.

B. All-weather roads adequate to carry fire department apparatus.

1. Kept clear at all times.

C. Available water supply of sufficient pressure and quantity.

D. Sufficient clear space from combustible structures or other storage

which could be an exposure hazard.

E. No danger of flooding.

1. Run-off from fire fighting water should be considered.

2. Drainage from fuel spills should travel away from all

storage.

F. Enough clearance from storage site to highways or major roads.

II. FENCING SITE

A. Entire site should be fenced to control access.

B. Two 15' gates, directly opposite each other (180 o) are required to
permit ready access of fire apparatus to any part of the storage area
regardless of wind direction and location of fire.

III. PILING OF MATERIALS

A. LOW HEIGHT and SMALL AREA are the ideal conditions.

1. Reasons for this are -

(a) stability of the pile under normal and fire conditions

(containers maximum: 2 high).

(b) access to the seat of the fire with hose streams

from the ground.

February 1993 - C.1 Fire Safety Checklist Page 441

 B. AISLES must be maintained between individual piles; between piles
and buildings, and between piles and the boundary line fence for
the storage site, to allow access to all sides of the piles.

1. Aisles minimum of 10 feet wide.

C. DRIVEWAYS of minimum 15 feet width are required to permit travel

of fire apparatus to all parts of the storage area.

1. Driveway and aisle widths should be increased to at least

equal the height of piles of goods, since they also act as
firebreaks to limit the spread of fire.

D. ARRANGEMENT OF MATERIALS is important to reduce the speed of

the spread of fire.

1. Generally less hazardous materials should be stored

upwind and more hazardous materials downwind.

2. Piles or "blocks" of small piles are arranged with

combustibles and non-combustibles in alternate locations -

(a) This technique tends to isolate a fire, allowing

greater chance to contain it within the pile or
"block" of origin.

(b) This checker board pattern of materials also helps

reduce reliance on wind direction to control the
spread of a fire.

IV. BUILDINGS

A. Buildings within storage yards should be at least 50 feet from the

nearest storage pile.

1. This space should remain clear and free of combustible

materials, at all times.

B. ARRANGEMENT OF BUILDINGS should also consider the effects of

wind on the spread of fire.

1. One approach is to have less hazardous shops and

sheltered activities upwind, more hazardous ones
downwind.

2. In addition to the above, leave plenty of clear fire- break

space between buildings (50 feet minimum), and alternate
hazardous shops or stored goods with those structures
housing less hazardous goods or activities. Again, this will
help counteract unfavorable winds.

V. FIRE PROTECTION

February 1993 - C1 Fire Safety Checklist Page 442

 A. Communications -- a reliable means of communication with the
Saudi Aramco Fire Protection Department shall be provided.
Normally this will be a Saudi Aramco system telephone.

WARNING: Prompt NOTIFICATION of the Fire Protection Department

is mandatory and absolutely necessary to prevent out-of-control
fires.

B. Portable fire extinguishers shall be provided throughout the storage

area and the buildings located as to be quickly available for use at
any point.

C. Standard Live Hose Reels shall be provided throughout the storage

areas to allow fast application of firewater onto any location within
the store yard. These hoses are easily handled by one man and can
deliver significant quantities of water. Full coverage of the interiors
of all buildings must also be provided.

WARNING:

1. The need to notify the Fire Protection Department and man

these live hose reels as fast as possible cannot be over-
emphasized.

(a) Fire areas increase as an increasing multiple of time,

not at a constant rate. The longer you wait to apply
water on a small fire, the more you will be surprised at
the size the fire has attained.

(b) These 1-1/4" diameter hoses allow one person to apply

about 100 gallons/minute without difficulty.

2. Two inch steel (galvanized) lines shall be used to feed these

hoses. Each hose reel will have a valve at the tie-in to the
6" loop.

D. Standard Fire Hydrants - Saudi Aramco Engineering Standard B-7C

requires type 509-G hydrants for protection of outdoor storage.
Depending on system pressure, the 2-1/2" hoses used by the Fire
Protection Department can require 4 to 5 trained men to handle. It
is for this reason that fire hydrants are not normally provided with
hose or used by construction yard personnel.

1. In areas where there is no Fire Protection Department

within reasonable distance, sufficient 2-1/2" hose, and
other equipment such as nozzles, hydrant wrenches, etc.
shall be kept on the site, suitably located, housed, and
maintained ready for use.

2. Hydrants and all fire fighting equipment shall be

accessible for use at all times. No temporary storage will
be allowed to obstruct access for fire fighting.

February 1993 - C1 Fire Safety Checklist Page 443

 E. Details of Water Supply

Connect to main with gate valve.

Provide a looped system valved to feed hydrants from either

direction.

(Block valve(s) to isolate either 50% of the piping and hydrants.)

Materials - carbon steel pipe, okay for temporary yards.

(Good mechanical strength, repairable.)

Size of loop piping, 6" diameter minimum.

VI. GUARD SERVICE

A. Guards trained in the use of live fire hose reels, fire extinguishers
and the fire warning system shall be on site at all times when the
yard is otherwise unoccupied.

1. Supervised rounds are suggested to verify the entire

property is periodically observed.
2. Means of communication necessary to summon assistance
during emergency situations shall be provided.

VII. YARD MAINTENANCE AND OPERATIONS

A. The site shall be kept free from accumulation of unnecessary

combustible materials such as empty cartons or other packing or
packaging materials.

B. All electrical equipment and installations to comply with National

Electrical Code.

C. Employees' smoking areas shall be clearly designated and no

smoking strictly enforced outside these "safe" areas.

D. Motor vehicles shall be garaged and repaired outside the yard area,
in a non-combustible structure or unsheltered. Fuel handling shall
comply with NFPA 30, Flammable and Combustible Liquids Code, at
a safe distance from the storage yard.

A site layout plan of the materials storage yards shall be submitted to

the Loss Prevention Department Area Fire Prevention Engineer for review.
All essential features of this "Checklist" shall be clearly illustrated on a
site drawing of the proposed yard. Two copies of this drawing (done
accurately to scale) will be submitted and once approved, one signed
copy shall be kept at the site for periodic review. Changes to the original
storage yard layout must be reviewed and concurred by Loss Prevention
Department.

February 1993 - C1 Fire Safety Checklist Page 444

Appendix D: Saudi Aramco
Crane Safety
Handbook

February 1993 - Construction Safety Manual - Appendix D: Crane Safety Handbook Page 445
D.1 CRANE SAFETY HANDBOOK
Notice:

For utility, the crane safety handbook is bound under separate cover.
One copy will be distributed to each holder of the Construction Safety
Manual. Additional copies may be acquired by contacting the Support
Services Unit, Loss Prevention Department, E-1660, Dhahran.

February 1993 - Construction Safety Manual - Appendix D: Crane Safety Handbook Page 446
Appendix E: Suggestion Form

February 1993 - Construction Safety Manual - Appendix E: Suggestion Form Page 447
 SUGGESTIONS FOR THE SAUDI ARAMCO
CONSTRUCTION SAFETY MANUAL

MANAGER, Loss Prevention Department

Saudi Arabian American Oil Company
E-1770
Dhahran, Saudi Arabia

Please consider the following suggestion(s) relative to the Saudi Aramco

Construction Safety Manual:
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________

_______________________________________
(Signature)

________________________________________
(Date)

________________________________________
(Address)

________________________________________
Contact Telephone Number

________________________________________
Contact FAX Number

February 1993 - Appendix E: Suggestion Form Page 448

Appendix F: Distribution Form

February 1993 - Construction Safety Manual - Appendix F: Distribution Form Page 449
 Address For Distribution
Construction Safety Manual

MANAGER
Loss Prevention Department
Saudi Arabian Oil Company
E-1770
Dhahran, Saudi Arabia

Please continue to send me changes or additions to the Saudi Aramco

Construction Safety Manual.

My present address is:

Name:__________________________________________________________________________

Company:_______________________________________________________________________

Address:________________________________________________________________________

_____________________________________
(Signature)

____________________________________
(Date)

________________________________________
Contact Telephone Number

________________________________________
Contact FAX Number

February 1993 - Appendix F: Distribution Form Page 450

Appendix G: Sanitary Code

February 1993 - Construction Safety Manual: Appendix G: Sanitary Code Page 451
IMPLEMENTING THE SAUDI ARAMCO SANITARY CODE
- GI 151.006

SASC-A-010 INDOOR AND OUTDOOR RECREATION AREAS

AND FACILITIES, INCLUDING BEACHES,
CAMPGROUNDS AND MARINAS

SASC-C-010 CAMPS AND COMMUNAL LIVING FACILITIES

SASC-F-010 FOOD ESTABLISHMENTS

SASC-P-010 SWIMMING POOLS, WADING POOLS AND SPAS

SASC-R-010 SOLID WASTE MANAGEMENT

SASC-S-010 WASTE WATER AND SEWERAGE SYSTEMS

SASC-W-010 WATER

February 1993 - Appendix G: Sanitary Code Page 452

Appendix H: General
Instructions Master
Index

February 1993 - Construction Safety Manual: Appendix H: GI Master Index Page 453
GENERAL INSTRUCTIONS (GI) MASTER INDEX

GI Number Title

2.100 Work Permit System

2.102 Pressure Testing Safely

2.702 Electrical Safety for Boom or Derrick Type Hoisting Equipment

2.708 Gas Testing Procedures

2.710 Mechanical Completion & Performance Acceptance of Plant/Unit

2.711 Fire and Safety Watch

2.718 Contractor Sites Allotment Procedure

5.002 Loss Prevention Policy Implementation

6.001 Notification Requirements for Incidents (Including Fires)

6.003 Guide for Committees Investigating Major Incidents or

Engineering Reviews of Other Incidents

6.012 Isolation, Lockout and Use of Hold Tags

6.020 Personal Flotation Devices for Work Over, On or Near Water

6.021 Safety Requirements for Abrasive Blast Cleaning

6.025 Control of Remote Area Travel and Search/Rescue Procedures

6.029 Reporting and Recording of Motor Vehicle Accidents

6.030 Traffic and Vehicle Safety

7.025 Mobile Heavy Equipment Operator Testing and Certification

7.026 Lifting/Elevating and Mobile Equipment Accident Reporting

Procedures

7.027 Personnel Work Platform Operations

7.028 Heavy Crane Lift, Multiple/Tandem, Critical Crane Lifts

7.029 Inspection, Testing and Maintenance of Wire Rope Slings

7.030 Inspection and Testing of Cranes, Elevators, Powered Platforms,

and Mobile Aerial Baskets

February 1993 - Construction Safety Manual - Appendix H: GI Master Index Page 454
 8.001 Safety Requirements for Scaffolding

8.002 Prescription Safety Glasses

8.003 Air-Supplied Breathing Apparatus

8.005 Protective (Safety) Footwear

70.500 Disaster Contingency Plan - Dhahran Area

80.500 Disaster Control - Refinery and Terminal - Ras Tanura

150.001 Asbestos Regulations

150.002 First Aid/CPR Training and First Aid Kits - Remote Areas

150.003 Ionizing Radiation

151.006 Implementing the Saudi Aramco Sanitation Code

330.87 Bulk Deliveries of Oil Field Treatment Chemicals from Local

Vendors

355.001 Identifying, Cataloging, Ordering and Tracking Hazardous

Materials

355.002 Receiving, Storing and Issuing Hazardous Material

355.003 Disposing of Hazardous Material

355.004 Handling and Disposing of Polychlorinated Biphenyls (PCBs)

355.015 Requisitioning, Receiving, Storing and Issuing Explosives

355.015-01 Deterioration and Disposal of Explosives

355.020 Control of Compressed Gas Cylinders

401.081 Performance Qualifications For Welders and Welding Operators

402.001 Operational Chemical Cleaning of Boilers

432.00 Pipeline Hydrotest Water Disposal

434.00 Pipeline Repair and Maintenance

441.014 Repair Procedures on Hydrocarbon Pipelines

447.002 Pressure Relief Valves - New Installation, Change in Set Pressure,

Replacement or Retirement from Service

February 1993 - Appendix H: GI Master Index Page 455

 447.003 Pressure Relief Valves - Routine Tests, Inspection, Quality
Assurance and Regulation

475.001 Blasting Near Existing Facilities

475.002 Use of Explosives in Construction

520.001 Confined Space Entry Procedure

618.001 Special Regulations for the Use of Explosives in Seismic

Operations

1021.000 Street and Road Closure, Excavation, Reinstatement and Traffic

Controls

1127.700 Transportation Engineering Procedures for Heavy-Lift/Over-Sized

Equipment

1130.013 Vehicle Loading

1131.165 Use of Trailer Brakes

1131.921 Use of Trailer Safety Chains

1183.215 Transporting Explosives in Company Owned/Leased/Rented Motor

Transport Vehicles

1185.003 Death or Injury Aboard Seagoing Vessels

1186.502 Marine Craft Fueling, Tanajib or West Pier

1186.504 SAG Regulations and Practice as Applied to All Types of Marine

Craft at the Port of Ras Tanura

1187.001 Collision & Damage By or To Marine Equipment or Craft

1192.001 Operating Practices for Harbor Tugs, Offshore Vessels and

Launches, Including Safety Rules

1192.002 Operating Procedures for Barges Including Safety Rules

1192.502 Operating Procedures for Marine Oil Recovery and Storage

Barge/Vessel, Including Safety Rules

1193.001 Marine Port Information and Regulations

1193.002 Navigation Warnings

1194.001 Requesting, Assigning and Dispatching Pollution Control Vessels,

Tugs, Launches and Barges

February 1993 - Appendix H: GI Master Index Page 456

 1196.001 Whistle Signals for Use Between Tugs and Barges or Tugs and
Self-Propelled Vessels When Berthing

1197.001 Procedures and Safety Rules for Diving Operations

1198.001 Rig/Barge Moving

1199.001 Safe Operation of Self-Propelled Jack-Up Barges

1310.000 Transportation of Dangerous Articles Onboard Saudi Aramco

Aircraft

1321.015 Request for Air Medical Evacuation

1600.003 Destruction of Obsolete/Damaged, Unneeded Communication

Equipment

1601.002 Radio Asset Control And Accountability Program (RACAP)

1602.001 Residential Telephone Service

1602.002 Business Telephone Service Inside Aramco Communities and

Facilities

1602.003 Business Telephone Service Outside Aramco Communities and

Facilities

1603.001 Data Circuits, Message Switch And Facsimile Terminals

1781.001-1 Inspection/Maintenance - Fire Protection Equipment

1787.00-1 Fire Reports

February 1993 - Appendix H: GI Master Index Page 457

Appendix I: List Of Figures

February 1993 - Construction Safety Manual - Appendix I: List Of Figures Page 458
LIST OF FIGURES
I. Administration:

Figure I.1 Preliminary Accident Report 14

Figure I.2 Contractor Monthly Safety Report 15
Figure I.3 Injury Summary 41
Figure I.4 Protective Goggle, Spectacles, Face Shields 48
And Helmets
Figure I.4A Protection Against Radiant Energy 49
Figure I.5 Specialized Hand Protectors 50
Figure I.6 Typical Self-Powered Platform For Building 51
Maintenance
Figure I.7 Respiratory Protection 58
Figure I.8 Clearance Considerations For Safety 59
Equipment
Figure I.9 Know Your Fire Extinguisher 66

II. General And Civil:

Figure II.1 Hold Tag 94

Figure II.2 Lockout Clip (Typical) 95
Figure II.3 Excavations Made In Type A Soil 106
Figure II.3A Simple/Multiple Bench 107
Figure II.3B Unsupported Vertically Sided l08
Figure II.4 Excavations Made In Type B Soil 109
Figure II.4A Single/Multiple Bench 110
Figure II.5 Excavations Made In Type C Soils 111
Figure II.6 Excavations Made In Layered Soils 112
Figure II.6A Excavations Made In Layered Soils 113
Figure II.7 Examples Of Trench Shields 114
Figure II.8 Guide To Safe Distance Back From Top Of Slope 115
For Storage Of Materials Or Placing Equipment
Figure II.9 Examples Of Screw Trench Jacks 116
Figure II.10 Aluminum Hydraulic Shoring Typical 117
Installations
Figure II.11 Aluminum Hydraulic Shoring 118
Figure II.12 Aluminum Hydraulic Shoring Waler Systems 119
For Soil Type B
Figure II.13 Example Of Timber Shoring Protective Systems 120
Figure II.14 Timber Trench Shoring - Minimum Timber 121
Requirements
Figure II.15 Timber Trench Shoring - Minimum Timber 122
Requirements
Figure II.16 Timber Trench Shoring - Minimum Timber 123
Requirements
Figure II.17 Standard Coupler 167
Figure II.18 Adjustable Coupler 167
Figure II.19 Typical End To End Coupler 167
Figure II.20 Screwjack 167
Figure II.21 Typical Reveal Pin 167
Figure II.22 Typical Base Plate 167

February 1993 - Appendix I: List Of Figures Page 459

 Figure II.23 A Typical Independent Tied Scaffold 185
Constructed Using Tube And Coupler
Scaffolding
Figure II.24 A Typical Tube And Coupler Scaffold 186
Figure II.25 Plan View Of Two-Way Tie 187
Figure II.26 Plan View Of Column Box Tie 187
Figure II.27 Plan View Of Reveal Tie 187
Figure II.28 A Typical System Scaffold 188
Figure II.29 A Typical System Scaffold Being Assembled 189
Figure II.30 A Typical System Scaffold Base In The Process 189
Of Being Assembled And Leveled
Figure II.31 A Typical Fabricated Tubular Frame Manually 190
Propelled Mobile Scaffold
Figure II.32 A Typical Tube And Coupler Mobile Access 191
Tower
Figure II.33 Cross Tube Anchor 192
Figure II.34 Outriggers In Use 192
Figure II.35 Driven Tube Anchor 192
Figure II.36 Abrasive/Grinding Wheel 200
Figure II.37 Grinder Guards 201
Figure II.38 Bench Grinder - Machine Guarding 202
Figure II.39 Ring Test 211
Figure II.40 Correctly Mounted Wheel 212
Figure II.41 Wire Conversion Chart 213
Figure II.42 Self Adjusted Guard 214
Figure II.43 Table Saws 215
Figure II.44 Table Saw - Machine Guarding 216
Figure II.45 Radial Saws 217
Figure II.46 The Woodworking Machine Regulations 218
Figure II.47 Cartridge/Tool Issuance Control 219

III. Mechanical Equipment And Materials:

Figure III.1 Pre-Lift Operation Checklist 241-242

Figure III.2 Lift Plan For Cranes 243
Figure III.3 Identification Tags 252
Figure III.4 Installing A Wedge Socket On A Rope 253
Figure III.5 Two-Legged Chain Sling: Major Components 253
Figure III.6 Sling Fixings 253
Figure III.7 Synthetic Webbing Slings 254
Figure III.8 Sling Loading 255
Figure III.9 Eyebolts 255
Figure III.10 Crane Hooks 255
Figure III.11 Shackles 255
Figure III.12 Wire Rope Sling Inspection Log 256
Figure III.13 Typical Construction Materials Store Yard 272

IV. Electrical And Radiation:

Figure IV.1 Temporary Crossing For Construction 293

Equipment
Figure IV.2 Proper Use Of Insulating Tools And Protective 294
Apparel

February 1993 - Appendix I: List Of Figures Page 460

 Figure IV.3 Standard Sign - Radiation 299

V. Chemicals And Operations:

Figure V.1 Identification Of Materials By Hazard Signal 326

Dimensions And Arrangement
Figure V.2 Explanation Of Hazard Rating Codes 327
Figure V.3 Identification Of Health Hazard, Flammability 328
And Reactivity

VI. Marine:

Figure VI.1 If You Work Over, On Or Near Water 336

Figure VI.2 International Code Flag "A" 348
Figure VI.3 Signals 348

Appendix A:

Figure A.1 Contractor's Competition Job 355-356

Safety Evaluation

Appendix B:

Figure B.1 Typical Emergency Organization Chart 387

Figure B.2 Scenario Analysis Sheet For (Location) 388
Figure B.3 Emergency/Disaster Control Tasks Checklist 389
Figure B.4 Flow Diagram Of Typical Offshore Emergency 393
Response
Figure B.5 Emergency Reporting Instructions 394
Figure B.6 Emergency Plan - Sample Table Of Contents 395-396

February 1993 - Appendix I: List Of Figures Page 461

Appendix J: List Of Tables

February 1993 - Construction Safety Manual: Appendix J: List Of Tables Page 462
LIST OF TABLES
I. Administration:

Table I.1 Basic Personal Protective Equipment 48

II. General And Civil:

Table II.1 Maximum Allowable Slopes 105

Table II.2 Wood Scaffold Plank Loading 166
Table II.3 Tube And Coupler Scaffolds - Light Duty 176
Table II.4 Tube And Coupler Scaffolds - Medium Duty 177
Table II.5 Tube And Coupler Scaffolds - Heavy Duty 178
Table II.6 Ventilation Requirements For Confined 223
Spaces
Table II.7 Personal Protective Equipment To Be Worn 227
Or Used During Surface Preparation And
Paint Application

III. Mechanical Equipment And Materials

Table III.1 Wind Speed (Miles Per Hour) vs. Force Of 244
Wind In Pounds Per Square Foot
Table III.2 Wind Speed Definition 244

February 1993 - Construction Safety Manual: Appendix J: List Of Tables Page 463
Appendix K: Forms

February 1993 - Construction Safety Manual: Appendix K: Forms Page 464

· Appendix K contains originals of many of the forms which have appeared
as figures throughout the Manual. Please copy these for use in your
safety program.

February 1993 - Construction Safety Manual: Appendix K: Forms Page 465

PRELIMINARY ACCIDENT REPORT:

Detailed Report Required Within 3 Days Control No_________________

Accident Location: Date Of Accident: Time Of Accident:

Company: Personnel Injured: Badge Number:

Type Of Injuries: Property Damage And Estimated Cost

Damage:

Description Of Accident:

Witness Statement(s)

What Caused The Accident:

What Corrective Action Has Been Taken

Signed:_______________________________________________________________Badge
No:________________________

Date Of Report:________________________________________________

Name (Printed):_____________________________________________________________________

Company:___________________________________________________ Job
Title:_________________________________
CONTRACTOR MONTHLY SAFETY REPORT
PROJECT TITLE:___________________________________ LOCATION:_________________________________

CONTRACTOR:_______________________________________________________________________________________

BUDGET ITEM No:._______________________________________ CONTRACT No.:________________JOB No:_______

1. Work Injuries:

2. Fires:

3. Incidents Or Property Damage (Over SR 10,000):

4. Motor Vehicle Accidents:

5. Incidents Involving Damage To Saudi Aramco Equipment:

6. Crane, Heavy Equipment & Manlift Accidents:

7. Safety Meeting:

(A) Topics Discussed:

1.
2.
3.
4.
5.
(B) Attendance:

(C) Instructor(s):

Prepared By:_____________________________ Contractor Safety Officer:_____________________________________

Signed By:____________________________________ Saudi Aramco Representative:____________________________

Date:___________________________
INJURY SUMMARY (PAGE ___OF___)
Project:__________________________________Project No.:________________________Month & Year:____________________
Contractor:__________________________________File No.:_________________________

Injur Name Of Badge Craft Date Of Carry Days Nature Of Injury And Brief Description Of Accident State
y No. Injured Numb Acciden Over Lost Part Of Body Affected What, Where, How, Why
er t Yes/No This
Mont
h

Total Lost Time Total Total Man-hours Worked

Injuries This Month: Days This Month:
Lost:

Report Prepared By:________________________________

Signature:_________________________________

Title And Telephone:_______________

LIFT PLAN FOR CRANES
1. Contractor:__________________________________________________ J.0. No.:_____________________________________________
2. Crane Inspection Sticker valid: Yes: No: Date of
expiry:________________________________________________________________
3. Operator Saudi Aramco certified: Yes: No: 4. Description of
load:___________________________________________________
5. ·Type of crane to be used Stowed Erected N/A (lbs/kgs)
______________________
·Boom length (total) Jib:    _______
_______________________ft/m
·Jib length Extension:    _______
______________________________ft/m
Hookblock (Main): ______ _____ _____ _______
Aux. Boom Head: ______   _______
Headache Ball: ______   _______
Slings, Shackles, ______ ______ ______ _______
etc.:
Others: __________________________________ _______
__________________________________ _______
Total (Gross Load _______
Weight):

6. ·Weight of load · Effective weight of jib _____ lbs/kgs (see jib

_______lbs/kgs chart)
·Effective weight of jib headache ball · Weight of load block _____ lbs/kgs
______ lbs/kgs
·Weight of hoist rope below boom tip______ · Weight of spreader bar _____ lbs/kgs
lbs/kgs
·Weight of other rigging ______
lbs/kgs
Total load weight _____ lbs/kgs
7. Hoisting clearance ________ft/m. 8. Lift quadrant zone ___________________ . 9. Operating radius ___________ft/m.
10. Crane capacity at operating radius __________ (Note: Do not make lift if total load is greater than crane capacity shown in
Item 10. Refer to GI 7.028 for appropriate derating based on type of lift.)
11. Crane capacity for jib configuration:____________ 12. Ground and site
conditions:______________________________________________
13. Wind speed:__________mph (Maximum 20 mph)
14. Work permit required: Yes No:
15. Load moment indicator: Yes: No: Type:_________________________________________
16. Sketch and supplementary information for crane lift is required to be attached to this plan. (Note: The sketch of the
crane should include the following rigging information: size of each component; safe working load (SWL) capacity; length
of slings; type of component; component diameter; weight of component and sling angles).
Contractor:______________________ Date:__________________ Crane Operator:_______________________
Date:__________________________
Approved:_______________________ Date:__________________ Reviewed by:_____________________
Date:_____________________________
(Competent Person) (Saudi Aramco Site Representative)
Approved:_______________________ Date:__________________
(Heavy Haul/Rig Move Unit, Transportation Dept., Abqaiq)
Footnote: This form is to be filled out for the following lifts: 1. At all construction sites and operating plants; 2.
Associated with offshore and marine sites and operations; 3. Within safety zones of power lines; 4.
Involving personnel platforms (as per GI 7.027, 7.028 and 7.030).
WIRE ROPE SLING INSPECTION LOG
Contractor:______________________________________ Location: __________________________

BI/JO Number: ___________________________________ Project Title: ______________________

Sling# Diameter Length SWL Date-In Date-Out- Inspector Signature

Service Service (Date)
CARTRIDGE/TOOL ISSUANCE CONTROL

Cartridge Quantity Received By

Dat Issue Return Return Returne Tool Cert Name/ Issued By Remarks
e d ed ed d Un- Issued No. Signatu
Used Unused explode (Type/MD re
d L)

Warning: Above items can only be issued to workers with valid training certificate Storekeeper:
Safety Officer:
EMERGENCY REPORTING INSTRUCTIONS
TELEPHONE: XXX-XXXX (if busy see below)

I have an emergency to report:

I am calling from _____________________________________________________

My name is _________________________ My badge number is _______________

I see a _____________________________________at ________________________

(fire, gas leak, etc.) (north/south/east/west)

There are ___________(no.) of people hurt and requiring medical assistance.

DO NOT HANG UP. ENSURE THAT YOU HAVE A RESPONSE THEN IF

NECESSARY REPEAT THE ABOVE INFORMATION AND ANSWER QUESTIONS.

1. If the number is busy or unavailable, try the following in the order listed:

2. telephone xxx-zzzz

3. radio frequency xxx.xx

4. (other for the facility)

After the message has been given successfully, the reporting individual, if an operator,
should return immediately to the emergency site to do whatever he can safely do to improve
the emergency situation.
PROJECT MANAGEMENT AND CONTRACTOR'S SAFETY
COMPETITION SITE REGISTRATION FORM
To: Saudi Aramco Loss Prevention Department Date:
____________________________

Name Of Contractor: Contractor's Address: Contractor's Phone

Number:

Job Description: Job Number: Starting Date:

Estimated Completion
Date:
B.I. Number:
Peak Number Of
Employees:

Contractor Site Saudi Aramco Site Project Mgmt.

Representative: (PMT) Engineer: Department:

Telephone Number: Telephone Number: Org. Code:

Name Of Contractor's Contractor's Site Site Location:

Safety Representative: Phone Number:

Signed:____________________________________________________(Contractor's
Representative)

Job Title:__________________________________________________

Company:__________________________________________________

Date:_______________________________________________________

Saudi Aramco Proponent

Department:____________________________________________________

This form is to be completed and sent to the local Saudi Aramco Loss Prevention
Office with a copy to the designated senior Project Engineer, who is a member of
the proponent Project Management Team (PMT).

Signed:________________________________________
Saudi Aramco Project Manager