Yanbu National Petrochemical Company Site Safety Procedures Manual

Yanbu Petrochemical Complex U & O Project July 2005

Fluor Arabia Limited Contract A2IT Page 1 of 9

ATTACHMENT A

WELCOME TO THE
YANSAB PROJECT

NEW HIRE ORIENTATION

My name is . I am the on this project. You are joining a

team that is Number One in the industry in safety. This is an accomplishment of which project participant and

the Owner is very proud. It is our intention to provide, maintain, and enforce a safety program that is in the

tradition of the Owner. Without your help, it is impossible to maintain such a program because the program

centers around you. Today we are going to go over a general overview of the safety, security and medical

requirements and procedures for the project. More in depth training in some categories will be provided in

future training classes and weekly safety meetings and daily Toolbox talks conducted by your supervisor.

It is imperative that you give your undivided attention as the information being given is very important to you

and a test will be given at the end.

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PROCEDURES
Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 2 of 9

EVACUATION
In the event of a fire, vapor release, or project evacuation is required, the emergency alarm will sound, signaling the type of
emergency that is being experienced: (Instructor will go over alarm signals).

FIRE

VAPOR RELEASE

EVACUATION

ALL CLEAR

TEST

YOU SHOULD IMMEDIATELY:

Extinguish all smoking material. There will be no smoking during an evacuation.

Cease all work and shut off all electrical equipment, including 8-packs, welding machines, air compressors.
Close valves on gas cylinders.
Walk! (DO NOT RUN OR JUMP FROM ELEVATED POSITIONS) to the designated assembly points. (Instructor
will cover assembly points). Remain at the assembly point until the all clear signal is sounded. Be prepared to follow
the directions of Senior l Management personnel.

FIRST AID / INJURIES

All injuries are to be reported to Medical facility immediately. DO NOT LEAVE THE SITE WITHOUT
REPORTING AN INJURY, REGARDLESS HOW MINOR YOU MAY THINK IT IS.
The employee must fill out an accident investigation form immediately or his supervisor must fill out the form to
start the investigation. Should the investigation not be completed due to the condition of the injured then it will
continue as soon as the condition has been stabilized.
The injured employees' supervisor will fill out the Supervisor's Accident Investigation Form as soon as possible but
no later than the end of the shift.
If we have an employee injured on our job we want the best medical care possible; we will spare no expense.
However, if we have an injury that we suspect is fraudulent we will spare no expense investigating and prosecuting.

PROTECTIVE EQUIPMENT

HEAD PROTECTION

A company issued hard hat (with the bill to the front) must be worn at all times once entering the work area
(Instructor will define work area) with the exception of offices, equipment with fully enclosed cabs, lunch and break
periods provided no work is going on in the immediate area.
No metal hard hats will be permitted on this project.
All hard hats must be in accordance with ANSI standards.
There will be no change in the design, surface or suspension of the hard hat.
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Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 3 of 9

Hard hats will also be worn when welding, grinding, cutting and other work requiring a hood or face shield and/or
goggles are performed.

EYE AND FACE PROTECTION

Approved safety glasses with side shields are required at all times once entering the work area with the exception of
offices, equipment with fully enclosed cab and windshield, when superior eye protection is worn and during lunch or
break periods provided, or when no work is being performed in the immediate area. Employees will be furnished
one pair of nonprescription ANSI approved Safety Glasses. If employee loses, or leaves at home his safety glasses,
the replacement pair will be payroll deducted. Replacement lenses for damaged or broken lenses will be replaced at
no charge to the employee.
Dark lens safety glasses are not allowed in buildings with inadequate lighting.
Employees working with or assisting in work handling molten materials or reactive chemicals will wear a full face
shield with monogoggles.
When grinding or buffing, a face shield with approved safety glasses.
When cutting or burning, burning goggles will be required.
When welding, a welding hood and lens equipped with no less than a Number 10 filter.
Additional eye protection will be worn when specified on permits or as conditions warrant.

RESPIRATORY AND HEARING PROTECTION

Respiratory and/or hearing protection is required in designated areas and or when performing specific tasks
(Instructor will address areas and tasks).
Employees must be clean shaven.

BARRICADES

Barricade tape is not to be used in lieu of physical barricades for floor, hole, wall openings or when permanent
handrails have been removed.
Yellow barricade tape indicates to use caution when approaching or entering the area.
Red barricade tape requires authorization to enter area. Anyone entering area without authorization is subject to
disciplinary action. Red barricade may be wrapped around hard physical barricades such as timber or scaffold tubing
to increase the visibility of the restricted area.

FALL PROTECTION/TIE-OFF

The 100% tie-off policy is in effect at all times, without exceptions. Employees will be protected against a falling
distance of 1.8 meter and greater at all times (100%) by means of fall protection device with proper secure
anchorage and/or secured flooring, railing, etc.
Full body harness will be worn with double locking shock absorbing and lanyards secured when working from
unprotected elevations 1.8 meter (6 feet) or greater and when working in powered manlifts, crane baskets, etc.
(Instructor will explain 100%tie-off )

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Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 4 of 9

ELECTRICAL TOOLS, CORDS

Tools are to be visibly inspected by the employee prior to use. Any tool or cord found to be defective is to be
returned to the tool room.
Tools and cords must have a current color code.
Check the RPM rating of grinding wheels or disc. The RPM rating must be greater than that of the driver.
Tools and guards are not to be altered.
Electrical cords and welding leads will be maintained at a 7-foot level, avoiding pinch points and creating trip
hazards.
Do not tie electric cords to metal rods or nails.
All electrical tools must be grounded and equipped with ground fault circuit interrupter (GFCI) to protect possible
electrical shock.

EXPLOSIVE ACTUATED TOOLS

Explosive Actuated Tools are sometimes referred to as powder actuated drivers, ramset tools or stud gun. It is a tool
that depends on an explosive charge to provide the driving force.
Only certified employees are permitted to use this type tool. The employee must have a certification card in his
possession when using the tool.
These explosive actuated tools are very dangerous and the use thereof must be properly controlled and locked away
when not in use. It must be inspected prior and after each use and the cartridges accounted for.

LADDERS

Ladders must be free from defects and have a current inspection color code.
Use a ladder of sufficient length for the work to be performed.
Place the ladder so that it's base is out 1/4 the distance of the height.
Ladders are to be tied or secured at the top.
No extension ladder should extend its full length; it should overlap at least four rungs or 1 meter.
Step ladders are not to be used in lieu of extension ladders.
Step ladders are to be fully extended and locked in position.
Only one employee is to work off of a step ladder.
Do not stand or sit on the top or top two rungs of a step ladder.
No work will be allowed of a ladder where both hands are needed at the same time to perform the work.

SCAFFOLDS

All scaffolds, platforms, and staging must be completely decked with decking secured and shall be built with
standard handrails and toeboards on open sides and ends.
The footing for scaffolds shall be sound and capable of carrying the maximum intended load.
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Fluor Arabia Limited Contract A2IT Page 5 of 9

No scaffold shall be erected, moved, dismantled or altered except under the supervision of a competent person. No
scaffold shall be used unless it has a valid current inspection tag indicating it is safe for use..
Scaffolds will be tagged by a competent person as to its status.

RED DO NOT USE

YELLOW SAFETY HARNESS REQUIRED - DUE TO SOME TYPE OF PHYSICAL RESTRAINT,

A COMPLETE SCAFFOLD COULD NOT BE BUILT. TIE OFF IS REQUIRED.

GREEN SAFE FOR USE

CLOTHING

Employees will work fully clothed (Instructor will cover type of material Nomex, Flame Retardant Cotton, etc.) if
applicable.
Collarless shirts, tank tops, half shirts and short sleeve shirts are not permitted.

JEWELRY

Jewelry is not prohibited but good judgment should be used.

COMPRESSED GAS CYLINDERS

Compressed gas cylinders will be capped, tied-off, (only chain, No wire or rope allowed), or otherwise properly
stored when not in use.
Cylinders must remain in the upright position at all times.
Cylinders will be kept upright and secured in a trolley when in use.
Keep protective caps in place.
No oil or grease is to be used on valves or gauges.
Gas cylinders will not be moved except in proper racks and the upright position.

UTILITY HOSES
Utilities are not to be used without permission from the CLIENT SITE SPECIFIC PROJECT Safety Management.

Utility hoses are color-coded as follows:

YELLOW - NITROGEN (PIPING IS ORANGE)

GREEN - AIR
BLUE - WATER
RED - STEAM

Each hose has a different coupling to minimize mistakes.

Each hose will have whip-lash arrestors fitted across couplings.

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Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 6 of 9

LIFT CAREFULLY
Like everything else, the right way to lift is easier and safer. If the load is too heavy, GET HELP.

All lifts of 5 ton and greater requires an approved non-engineered or engineered lifting permit. Engineered lifts also require
an approved lifting study and lifting plan. Check with your supervisor and Crane and Rigging department for the correct
lifting permit and requirements.

LOCKOUT

Lockout the power source prior to making adjustments or repairs to any equipment.
Do not tamper with energy sources that are locked and/or tagged out.
DO NOT DEPEND on the control switch on porta bands, drills, grinders etc. UNPLUG THEM.

LIFTING AND/OR SWINGING LOADS

Do not walk under a suspended load or permit others to do so.

Barricade the lift area to control access into the area.
Never pick up a load in excess of the capacity of the equipment (Instructor will give overview of non-engineered
and engineered lift procedure). All lifts of 5 tons and greater require a lift permit.
Only one person at a time will give hand signals to operator.
Tag lines will be used to control loads.
Never leave a suspended load unattended.
Never ride on a load, crane hook, headache ball or forks of a lift truck. Do not use a crane if it is not inspected
and/or without a valid color code for the month.

RIGGING

Never use hands or feet to guide cable or line onto a drum or hoist. Use a bar as a guide.
When it is necessary to stretch cables or lines across roads or walks, block the road or walk if the cable or line is
lower than 4.0 meters (14 feet) above roads or less than 2.0 meters (7 feet) above walks.
Seat chain links into a hook by hand pressure only. Never hammer a chain link onto a hook.
Never connect or repair chains by bolting links together.
Use shackles, bolts with nuts and other positive locking devices to fasten together hoisting equipment. Never use
drift pins or pin wrenches for fastening or anchoring hoisting equipment.

CHAIN BLOCKS

Before using chain blocks, inspect and check for proper operation using a test load before making a critical lift.
Make sue it has a valid inspection and color code.
Know how much you are lifting and the chain block limitations.
Avoid having more than one person at a time pull on the pull chain of a chain block.
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Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 7 of 9

Never use a load chain as a sling for lifting.

Straighten chains and make every link seat before lifting. Never jerk or put any strain on a kinked chain.
Use wire rope to suspend or anchor chain blocks. Never use manila or other rope.
Minimize exposure to the weather otherwise it can render the lowering mechanism inoperative.

PERMITS

There are various permits required on the project. The following are examples of the more common or most used:

COLD WORK - Work that does not ordinarily create enough heat to ignite flammable gas-air mixtures or
flammable materials.

HOT WORK - Any work, tool, or equipment (welding, burning, grinding, vehicles, portable welders, etc.) which
might provide a source of ignition for a flammable mixture.

OPENING/BLINDING - Exposing the interior of any process equipment such as tanks, pipes, vessels, etc., to the
atmosphere.

CONFINED SPACE - The authorization required to enter any vessel, pipe, confined space, excavation etc., for any
reason.

LOCK AND TAG - Required to prohibit operation of a valve, switch or piece of equipment when injury or property
damage could result from the operation.

EXCAVATION - To provide guidance for and protection of employees working in and around excavations and
trenches.

LIFTING – To control all lifts 5 ton and greater and could be engineered or non-engineered lifts.

CONSTRUCTION – Apart from any other work, all work requires a daily permit for all construction work.

ROAD CLOSURE – To close Roads to prevent access when hazardous work is being performed.

RADIOGRAPHY – Required for all radiography and NDT work.

Again, these are the more frequently used permits. There are some task specific permits required for certain task i.e. Hot
Tapping, etc. that will be addressed by your supervisor.

GENERAL
Drink water only from approved drinking water containers or dispensers.
Proper housekeeping is essential and will be part of every job.
Clean up all spills or leaks promptly. If you must leave the area, barricades or post someone to remain there until
your return.
Obey all posted speed limit signs.
Obey all safety signs, signals and barricades.
Pedestrians will have the right-of-way.
Yield right-of-way to emergency vehicles.
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Fluor Arabia Limited Contract A2IT Page 8 of 9

Smoking is permitted in designated areas only.

All lighters and strike anywhere matches are prohibited.
No firearms, weapons, or cameras are allowed on the job site.
Riding on equipment such as cranes, cherry pickers, forklifts, etc. is not permitted.
No riding in the back of pickups and open vehicles are allowed
Employees must obey all danger and caution signs.
Correct all unsafe conditions when possible. Report all others to your immediate supervisor or safety personnel.
No running is permitted on the job site.
Pony tails, and otherwise exceptionally long hair, is to be worn in such a manner that it will not cause danger to an
employee from fire or entanglement in tools or moving machinery.
All material raised and lowered from any height must be done by rope (No dropping or throwing).
No horseplay will be tolerated.
No fighting or any form of altercation will be tolerated. All involved will be subject to termination.
Drugs, alcohol, and any form of non-prescription medications shall be prohibited, as well as reporting to work under
the influence of same. Those involved in distributing or accepting any form of illegal drugs or alcohol on the job
site will be terminated.

EQUIPMENT OPERATIONS

Operators must be certified for the type of equipment being operated.

No riding on equipment with operators.
Equipment must be properly inspected and have a valid color code.
Equipment will be supported by flagmen equipped with red and green flags.

ACCESS

Climbing, sliding down columns or diagonal bracing is not permitted. Walking elevated beams and pipe without
being tied off is not permitted.

HAZARD COMMUNICATION

The intent of the Project and OSHA Hazard Communication Standard is to ensure that employees who must work with
hazardous chemicals are informed of the hazards as well as of safe methods of handling. Handling and storage are the two
most common causes of accidents with chemicals.

There are several ways that the information is relayed to the employee, these being:

Container labeling - labels give you immediate hazards associated with the chemical.
Material Safety Data Sheets (MSDS) give you detailed information about the chemical - physical and health
hazards, First-Aid, fire fighting, protective equipment, etc.

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Yanbu Petrochemical Complex U & O Project July 2005
Fluor Arabia Limited Contract A2IT Page 9 of 9

Know what you are handling, read the label, and if there is any doubt, consult the Material Safety Data Sheet.
All this information is available through the Safety Department (Instructor will give instructions on how to obtain
the Owner MSDS). All you have to do is ask and this information will be made available. Should you be denied this
information, contact Safety immediately.

CHEMICAL SCREENING

All employees will be subject to chemical screening (urinalysis) prior to mobilization to the project. Additional chemical
screening may be required at any time upon a showing of suspicious behavior or activity including accidents. Also, all
employees will be subject to periodic random chemical screening. The project is committed in providing and maintaining a
safe and productive job site. We also know that a worker under the influence of alcohol or drugs can be neither safe nor
productive. As always, your acceptance of employment represents consent to abide by company rules. These include:

Searches of our persons, vehicle, and personal property while on company/client property, including chemical
screening;
The prohibition of weapons, alcohol and controlled substances on company/client property;
The prohibition of any project employee being on company/Owner property while under the influence of alcohol or
controlled substances.

The result of a violation of these rules or a refusal to submit to a search or chemical screening test will be immediate
termination of employment.

If the initial chemical screen shows positive, a second test by a different method will be performed on the sample. If the
second test is below confirmation limits, the result will be negative. If the second test meets or exceeds the confirmation
limits, the result will be considered positive and the employee will be terminated.

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