Practical Safety guide

Engineering Department
Large Industry Europe
 TABLE OF CONTENTS

Our safety commitments 1

Work clothes 2
Personal safety equipment 3
Vehicular traffic 4
Pedestrian traffic 5

Gases :
The hazards of gases 6,7
The fire triangle 8
Inflammability 9
Oxygen-rich atmosphere 10
Oxygen-poor atmosphere 11
Toxicity 12
Identification colors 13

The work permit 14

Hazards specific to our techniques :
Cold / hot 15
Pressure 16
Confined spaces 17
Cold boxes, perlite 18
Dangerous substances and products 19

Electricity 20
Noise 21
Working at high levels 22
Lifting 23
Work that poses a fire hazard 24
NOTICE Radioactive sources 25
This practical guide is intended to provide general safety information for the Digging 26
employees working in AIR LIQUIDE's Engineering and Large Industry Europe Manual handling 27
Departments. It lists the principal hazards they may encounter and presents the Housekeeping 28
safety rules which must be respected in plants and during construction, start-up and
industrial operations. In case of accident 29
These safety rules are not exhaustive and do not replace the rules specific to each In case of burns/When the alarm sounds 30
business group or entity. In case of fire 31

© AIR LIQUIDE - PRÉVENTION ACTIVE

 OUR SAFETY COMMITMENTS

«Safety is and will remain our first priority»

Chairman of the Management Board

The 10 golden rules :

1 Think before you act.
2 Always be aware of latent and potential dangers.
3 Ensure cleanliness and order.
4 Use tools, fittings and machines in perfect working condition.
5 Have written, clear and precise work procedures
and safety.
6 Adhere to work procedures and safety rules at all times.
7 Wear the recommended personal protective equipment.
8 Never resort to makeshift solutions.
9 For all non routine jobs, use the safe work permit procedure.
10 When you are faced with an unfamiliar situation,
consult a qualified person.
« ALL ACCIDENTS CAN BE AVOIDED »

This practical safety guide contains information which will help you better
understand the hazards and precautions specific to our business.
Please read it carefully.

1
WORK To work at our construction
sites or facilities,
Depending on the hazards,
you may have to wear PERSONAL SAFETY
CLOTHES you must wear : other types of personal
safety equipment : EQUIPMENT

A hard hat
which protects
your head
against blows
and falling objects.

Hearing
Tight goggles protection Appropriate gloves
Goggles
or eyeshade
(integrated into
OL / %
the hard hat). O2 / V
% CO
% EX

Portable analysis
Clean work and detection devices
clothes which To be tested frequently
are appropriate and to be kept with you
at all times over clothing.
for the work
to be done. Safety harness
with double lanyard
Working clothes are
in fire-retardant textile.

Safety boots
which protect
your feet against
falling objects,
perforations, Chemical-proof
slips. clothing
Evacuation mask

2 Other types of personal safety equipment

are also discussed in this booklet. 3
VEHICULAR Each site has its
own specific
Do not rush ;
do not run. PEDESTRIAN
TRAFFIC traffic rules :
TRAFFIC

WELCOME TO OUR SITE

RESPECT THE SAFETY RULES
TRAINS
ARE GIVEN
30 PRIORITY

Always hold the handrail Read all safety signs.

when using a stairway.

Park your car

in starting position.
Familiarize yourself
Respect signs.
with the traffic map
Vehicular, equipment
if you have Follow the signs installed Stay out of restricted-access zones
and pedestrian traffic must for your safety. where a special authorisation
respect the Highway Code. to operate or qualification is mandatory.
a mobile unit.
Keep the walkways free.
As a general rule, do not enter work areas
where you have no assignment.

4 5
GASES All the gases produced
or used at our sites may
You must be familiar
with the hazards of each gas. GASES
BE DANGEROUS.
The hazards of gases The hazards of gases

Combustible HYDROGEN
NEUTRAL, INERT GAS
or NATURAL GAS
COMBUSTIBLE GAS, inflammable BUTANE
OXIDIZING SUBSTANCE gases PROPANE
BURN, CO
EXPLODE (carbon monoxide)

Oxidizing
ASPHYXIATION= ANOXIA gases
OXYGEN
TOXIC GAS support and
AIR
ACCELERATE
COMBUSTION

Neutral or
inert gases NITROGEN
FIRE, do not support life ARGON
POISONING EXPLOSION and can cause CO2
(carbon dioxide)
death by
INSTRUMENT AIR **
THE HAZARDS OF GASES ASPHYXIATION

Toxic gases
CO
WARNING poison
the organism
(carbon monoxide)
AMMONIA
Most of the gases used or produced and can cause
at AIR LIQUIDE sites cannot be directly CHLORINE*
death by PHOSGENE*
detected by people :
POISONING
- they are colorless, invisible,
- they are odorless and thus cannot be smelled, * Gases which are not produced or used at AIR LIQUIDE sites, but which may be used or produced near our plants.
- they are tasteless. ** Instrument air may be replaced automatically by nitrogen,thus it is absolutely forbidden to use it for
breathing purpose.

6 7
GASES You must be familiar
with the principle behind
In all zones
where fire GASES
The fire triangle the fire triangle in order
to prevent fires and explosions.
and explosion
are hazards : INFLAMMABILITY

In order for a fire or an explosion to occur,

the three elements of the fire triangle must be complete :

COMBUSTIBLE OXIDIZING SUBSTANCE

solid, Ex.:
liquid, oxygen
gas. in air.
No leaks of Be careful with sources
combustible gases. of energy, heat.

SOURCE OF ENERGY ATEX area = area where a risk of EX

EXplosible ATmosphere
AT is present
Ex.: spark, flame,
heat, electrical discharge. Work in ATEX area requires :

To prevent combustion, Follow up the level of explosivity.

one of the three elements must be eliminated : Use of ATEX certified tools
(including talky-walky, lamps…)
A fire permit
COMBUSTIBLE OXIDIZING SUBSTANCE
(in case of work with hot point)

Since it is difficult to completely eliminate the oxidizing substance In case of alarm produced
(air contains 21 % oxygen, which is an excellent oxidizing substance), by the explosivity detector :
priority must be given to eliminate the other Stop working.
two components of the triangle. Stop the machines.
Leave the area.
SOURCE OF ENERGY

8 9
GASES Oxygen is a very
effective oxidizing gas.
Neutral or inert gases
such as nitrogen, argon, GASES
High concentrations and CO2 do not support life
Oxygen-rich atmosphere of oxygen in the air and replace the oxygen (O2) oxygen-poor atmosphere
are hazardous. in the air.

Any leak of a neutral or inert gas is hazardous.

21% normal
combustion
1 liter
1 of liquid
oxygen
25% accelerated
combustion

30% vigorous
combustion
produces
800 liters
instantaneous of gaseous oxygen
50% combustion,
explosion less than 18%
21% oxygen less than 12%
= dizziness,
= normal respiration lightheadedness = ASPHYXIA
In any oxygen-rich atmosphere the possibility
of fire and explosion is significant Be careful in areas where low concentrations
and special safety precautions are required. of oxygen are likely to be found :

no combustible
no grease, no oil
no particles
clean floor OXYGEN-RICH
compatible materials ATMOSPHERE
fire-retardant
work clothes. Cold boxes Retention pits Storage tanks

no flame, no spark
slow operation of equipment and controlled flow of fluids Detection with alarm
OL / % OL / %
if the concentration of oxygen in the air
O2 / V O2 / V
Detection with alarm is less than 19.5 %.
if the air contains In hazardous zones, oxygen levels
more than 23 % oxygen. must be measured constantly.
GASES Certain gases which are found
at or near Air Liquide sites
Gas identification colours
in accordance with
GASES
may cause death
Toxicity within a few minutes. Air Liquide standards : Identification colors

CO THE OTHER GASES Background colors Gas identification

carbon monoxide such as PHOSGENE, CHLORINE, AMMONIA,
This gas is odorless and painless, are intolerable and irritating.
colors
but it causes lightheadedness, You cough, spit, the mucous membranes
fainting and may cause death. of airways and the lungs are attacked.
It requires immediate treatment. The injuries caused by these gases
(resuscitation and serious oxygen therapy) are very serious, often fatal.
GAS OXYGEN
Values expressed in Part Per Million
TIME WEIGHTED SHORT TERM MORTAL RISK
TYPE OF GAS AVERAGE EXPOSURE EXPOSURE LIMIT STEL VALUE AIR HYDROGEN
for 8 hours of work for 15 minutes

CARBON MONOXIDE 25 ppm 50 ppm 1500 ppm

(CO)

PHOSGENE * 0,02 ppm 0,1 ppm 50 ppm

WATER ARGON
(CO CL2)

CHLORINE *
(CL2) 1 ppm 1 ppm 50 ppm
STEAM NITROGEN
AMMONIA 20 ppm 50 ppm 5000 ppm
(NH3)

HYDROGEN SULFUR 5 ppm 10 ppm 440 ppm COMBUSTIBLE LIQUIDS CARBON

(H2S) DIOXIDE
CARBON DIOXYDE(CO2) 5000 ppm 30000 ppm > 10 %
= 0,5 % =3%
* Gas not used at AIR LIQUIDE sites but at our neighbors' eventually. ACIDS and BASES CARBON
MONOXIDE
Detection required in all
hazardous areas.
FIRE EXTINCTION SYSTEM AMMONIA
A self-contained breathing apparatus
must be worn in case of danger.
At sites with other colours, refer to the local colour code.
12 13
 A work permit is obligatory for any work
THE WORK which is not covered by permanent instructions
Air Liquide's
processes require gas
HAZARDS SPECIFIC TO OUR TECHNIQUES

PERMIT and poses a specific threat

(for work done by our personnel
cooling and liquefaction.
COLD / HOT
or an external firm).
IND :
KEEP IN M
Before any intervention, COLD HOT
passage in control room is MANDATORY.
Oxygen liquefies at - 183ºC Some processes imply very high
Nitrogen liquefies at - 196ºC temperatures or use of vapour.
Hydrogen liquefies at - 253ºC
1 Specific description
of the work and COLD = important risks of burns HOT= risks of burns by contact,
the work location. by contact. by radiation or by gas jets.

2 Potential dangers
related to products,
and activities.

3 Risk of interference
with other external firms.

4 Protection means
to be implemented.
The main safety precautions to be taken :
5 Preliminary lock-out/
tag-out to be done.

6 Hazards caused
by the external firm
and corresponding
precautions.
Wear appropriate
safety equipment. Wear the appropriate
safety equipments
and don't cross a jet
of vapour.
GREEN AREAS : PINK AREAS : YELLOW AREAS :
to be completed for to be completed for to be completed for
works in confined spaces. the use of tools causing the digging of trench
a risk of fire. or sump.
Never walk through a cryogenic fog :
risks of falls, burns, and risk of an oxygen-rich
atmosphere or asphyxiation.
14 15
HAZARDS SPECIFIC TO OUR TECHNIQUES On our equipment, All zones where ventilation HAZARDS SPECIFIC TO OUR TECHNIQUES
the hazards associated is insufficient are hazardous.
PRESSURE with pressure are very real : CONFINED SPACES

Gases are very Air Liquide's techniques require Asphyxiation Poisoning Explosion
compressible fluids. the use of high pressures.
The principal safety precautions to be taken :
The main safety precautions to be respected : Works in confined spaces (pit, tank, cold box, etc.) or near a vent,
all those in charge and those doing the work must hold a preparatory
meeting.
CONSTRUCTION CODES
PERIODIC INSPECTIONS The precautions always involve:
TESTS
1 An obligatory confined space 4 If possible, air circulation.
Piping and containers Always check the pressure access permit.
must respect gauge before starting work.
2 Locking out / tagging out 5 Wear of an individual
the regulations in effect. oxygenmeter and outside
the work zone.
monitoring of the work.
3 Analyzing the atmosphere.

DO NOT
OPERATE

Make sure the safety Apply lock-out/tag-out

devices work properly. procedures rigorously.

Report any defect noted on a piece of equipment,

a pipe or a safety device immediately.

16 17
HAZARDS SPECIFIC TO OUR TECHNIQUES : Cold boxes contain Our processes require the use HAZARDS SPECIFIC TO OUR TECHNIQUES :
the equipment needed of products and substances,
COLD BOXES, to separate gases. which can be dangerous. DANGEROUS SUBSTANCES
PERLITE AND PRODUCTS
Cold boxes present two lethal hazards :
Be able to identify them : Use the appropriate PPE :

ASPHYXIATION DROWNING IRRITANT PRODUCT

that stings For example :
CORROSIVE PRODUCT - gloves,
that eats away - goggles,
- eyeshade,
HARMFUL PRODUCT
that poisons - chemical-proof
Because cold boxes Because cold boxes are filled clothing,
are constantly ventilated with a very fluid material : TOXIC PRODUCT - mask,
with nitrogen. perlite. that causes death - self-contained
HIGHLY FLAMMABLE breathing
PRODUCT apparatus.
Three precautions apply to any work done in cold boxes : that flames

OXIDIZING PRODUCT
1 The nitrogen supply circuit must be locked out / tagged out. that activates fire

2 The oxygen level in the work area must be measured. EXPLOSIVE PRODUCT
that explodes
3 The area must be ventilated with fresh air, if necessary.
DANGEROUS FOR
ENVIRONMENT

Be careful with the risk Be careful with the risk

of ceramic fibers inhalation. of presence of Legionellas.
Special safety equipment
must be worn for filling Wearing specific PPE In water chiller towers,
and emptying perlite. is MANDATORY for any intervention and in fog zones
or inspection around the towers,
inside a reformer casing. wear a specific mask.

18 19
 A source of energy so commonly used, In certain areas permanent
ELECTRICITY we forget how dangerous it is. or occasional noise levels are
dangerous for the human ear.
NOISE

Fatigue

Electrification Nervousness
Burns caused
or
by electrical
electrocution Auditory lesions
flashes
(death)
Permanent deafness
The principal safety precautions to be taken :
There is only one way to reduce the effects of noise :
Employees must be aware Only train, qualified wear hearing protection
of the hazards involved in working and authorized employees
with electricity. may work on electrical installations.

The appropriate
equipment Ear plugs
must be used Hard hat
or with
and it must be in moulded ear muffs
good condition hearing
(grounded or equipped protection
with double insulation). Work procedures must
be respected and special
safety equipment must be used.
Equipment is to be locked out / Wearing hearing protection is :
The electrical lock-out / tagged out under the supervision
tag-out of equipment of an
is an essential, obligatory representative responsible for OBLIGATORY RECOMMENDED
this function. FOR NOISE FOR NOISE
safety procedure. LOCKED OUT LEVELS LEVELS
- TAGGED OUT
It consists in separating DO NOT OPERATE OF 85 dB(A) OF 80 dB(A)
It is to be indicated in the AND UP
any equipment from any source lock-out / tag-out log and, AND UP
of electric energy… as the case may be, on the work permit.

20 21
 Any fall, Although accidents with lifting
WORKING even from a small height, and handling equipment are rare,
LIFTING
can have serious consequences.
AT HIGH LEVELS the consequences are always
very serious.

The main rules to be respected : The principal safety rules to be respected :

Each driver
must have followed
a specific training Each mobile unit
and have must be in good condition
a driving and comply with
authorization. CAUTION regulations
Ladder is a mean for access.
IND : A harness
It is not a work station. KEEP IN M must be worn for any Some plant pipes carry (log of obligatory
Ladders must be in good condition and hazardous work dangerous products. examinations
installed in accordance with specific rules. (see local regulations). and inspections).

Anchor points,
A signalman
if needed
must be present.
Rail at 1m
Mid rail at 0,45 m
Any mobile or fixed
Toeboard
scaffolding must comply For lifting
measuring 0,15 m with regulations.
Interior access operations in excess
ladder
Plank in good
of 5 tons,
condition supervisors special studies
ÉCHAFAUDAGE
At least one CONFORME must make sure that
brace between
two planks this equipment
are required.
Effective
support points
complies with regulations

22
before it is used.
23
WORK THAT GENERATES Given the hazards
associated with our gases,
Radioactive sources give off radiation
which can penetrate the organism and cause RADIOACTIVE
A FIRE HAZARD any hot work may result
in serious accidents.
very serious injuries : skin diseases,
bone diseases, eye diseases, leukemia, SOURCES
cancerous tumors.

A "CONTROLLED ZONE"
is always cordoned off
and identified around each
source of radioactivity.

The principal safety rules to be respected :

CURTAINS

TESTING FOR
EXPLOSIVITY
BEFORE AND
DURING WORK

Entering
a controlled area
is strictly prohibited.

PROTECTIVE
SCREEN
CORDONING OFF
WATCHMAN WITH
FIRE EXTINGUISHER Even if the hazard
is not obvious,
In certain units in operation, never enter a cordoned off area.
any work that generates a fire hazard is prohibited.

24 25
DIGGING
Particular hazards
are inherent in digging
Repetitive poor posture,
rounded back, legs straight, MANUAL
and ground work : can cause serious damage :
- lumbago HANDLING
- herniated discs

There is a method
for lifting which does not
cause damage
to your back.

Pipelines
may be
Electrical instrumentation
conduits may be damaged punctured
1 2
Position yourself
above the object Bend your legs,
The principal safety rules to be respected : to be lifted. keeping your
back straight.
Concerted effort by representatives of 3
Air Liquide and the external firm
to determine the type of terrain and the Use your
location of pipelines and networks. leg muscles
Issue a digging permit. to lift.
The area must be cordoned off.
Location and mapping
of pipelines and networks.
Constant supervision of equipment
at work.
For any trench with verticals walls
Within 50 cm of the supposed location of 1,30 m depth or more, or if required When you follow this procedure, your back remains straight.
of a pipeline or electrical conduit… by the nature of the ground…

Whenever possible,
use the mechanical
lifting devices
available.

…install shoring according

…digging must be done by hand. to the local regulations.

26 27
 - To prevent falls, slips.
HOUSEKEEPING - To eliminate all fire hazards in oxygen zones
If you witness
an accident :
IN CASE
where cleanness and the absence of
combustible materials are essential. OF ACCIDENT
- To maintain the quality image
of the Group : 1 Inform and protect. CAUTI
Keep your work ON
areas clean
and tidy If the individual is unconscious,
at all times. he/she may have been
"He can't
asphyxiated or poisoned.
be moved. In this case, you must wear
Quick !
Call for help."
a self-contained
breathing apparatus.

Cordon off
hazardous areas.
Never block
passageways.

Remove the victim

Once you have completed your work, from the danger zone.
you are responsible for removing all
of your materials and waste and
cleaning up the area. 2 Notify or have someone notify
first aid personnel.

3 Direct emergency personnel

Comply with the rules to the scene of the accident
of selective sorting of waste.
and remain at their disposal.

28 29
 For chemical,
IN CASE thermal and cryogenic
If you see a fire start :
IN CASE
OF BURNS (caused by the cold) burns :
OF FIRE
Flush thoroughly 1 Stop what you are doing.
Use with cold water
any means for at least 5 minutes
available
nearby
2 Call for help :

Use the telephone,

sound the alarm,
or notify the control
room directly.
Indicate :
For chemical burns : remove clothing.
For thermal burns : do not remove clothing. the place,
For cryogenic burns : it is preferable to remove the clothing, the nature of the fire,
unless the skin tears. the size of the fire.

3 Try putting the fire out.

WHEN THE
ALARM SOUNDS CO2
POWDER
fires of electric origins
hydrocarbons
Stop what WATER wood, paper,
1 you are doing.
2 Go to your meeting point . cardboard, tissue…

Don't take any chances.

Internal and external
fire fighters
will arrive soon.

Wait for instructions

from site supervisors.

30 31
 Creation : PRÉVENTION ACTIVE - 03 23 69 32 33
ENGINEERING DEPARTMENT
LARGE INDUSTRY EUROPE

Edition 2006