(SHEMS-SABIC)

Safety, Health & Environment Management System

Prepared by: Muhammad Usman Rafique

Email: usman.jalint@outlook.com
Cell#: +966-502674382
SHEM 8.0-Safe Work Practices:
SHEM-SP-08.01: General EHSS Rules
SHEM-SP-08.02: Laboratory SHE Rules
SHEM-SP-08.03: Material Handling and Storage
SHEM-SP-08.04: Prevention of Fires and Explosions from
Combustible Dust
SHEM-SP-08.05: Electrical Safety
SHEM-SP-08.06: Lifting Equipment
SHEM-SP-08.07: Tools Handling
SHEM-SP-08.08: Personal Protective Equipment
SHEM-SP-08.09: Working at Height
SHEM-SP-08.10: Work Permits
SHEM-SP-08.11: Control Isolation of Hazardous Energy
including LOTO
 “Work Permit SHEM.08.10”

SOPs: Any work performed by operating personnel outside the scope of their normal operating responsibilities
as defined in their Standard Operating Procedures (SOPs).
Battery Limit: A battery limit is a defined boundary between two areas of responsibility, which may be
physical (e.g. a flange on a pipe); or represented by a map coordinate; or some other means (for example a
point in time)
Conditions shall cancel the Work Permit:
-If work is not started within two hours after issuance of permit.
-Change of work environment conditions in the unit or area.
-Injury or accident during execution of work.
-When emergency alarm is sounded / activated in effected unit.
Note: Emergency drill / fault alarms shall not cancel the issued work permits.
Ensure after closure of Work Permit:
-All persons have withdrawn from the work site.
-All tools and equipment have been removed.
-All openings / enclosures have been closed, secured and/or barricade to prevent unauthorized access.
d) The work area is left clean and tidy.
LMRA (Last Minute Risk Assessment)
A method which is used to help executers to think and implement safety precautions before any job is started.
The permit hard paper copy is available at the worksite or preferably is displayed at a visible location near the
worksite, until the job is completed.
Endorsement:
When both or either one of issuer or receiver leave the field before the time of the permit duration.
Types of Permits in SABIC (Unified System):
a) General Work Permit b) Hot Work Permit c) Confined Space Entry Perm
d) Electrical Work Permit e) Radiation Permit f) Lifting Work Permit
g) High pressure jetting work permit h) Excavation work permit
Validity of permits and certificates:

General, Hot, Confined Space entry, Electrical, 12 hours

Radiation, Lifting, HPW Jetting & Excavation
Work permit
 Lifting Plan Technical Confirmation, Excavation Until completion of the Work Scope
Clearance Technical Confirmation & LOTO
Certificate

Permit Process:
1- Work Order
2- Work plan (Lifting plan, Excavation clearance Certificate, LOTO certificate)
3- Work permit
4- LMRA
5- Execution of work
6- Close out of work

Hazardous Assessment Control form:

A Hazardous Assessment/Preparation is the master document for all work permit types except Confined Space
Entry Permit that is required Formal JSA.

Hot Tapping:
A procedure used in the repair, maintenance and services activities, which involves welding on a piece of
equipment (pipelines, vessels or tanks) under pressure.

Chromatography analysis:
Chromatography is an analytical technique commonly used for separating a mixture of chemical substances
into its individual components.

Safe Working Load (SWL)

The maximum load, determined by an approved certified rigger that an item of Lifting Equipment might raise,
lower or suspend under particular service conditions also in line with Manufacturer specifications.

Working Load Limit (WLL)

The maximum load that the lifting equipment is designed to raise, lower or suspend under ideal conditions (the
Safe Working Load will usually be the same as the Working Load Limit — but can be less).
SABIC Manufacturing Standard (SMS)

High Voltage
Line voltage: higher than 1000VAC, phase ground higher than 1500VDC.
VAC (Volts Alternating Current) and VDC (Volt Direct Current
Procedure of Electrical Isolation:
Confirmation of the details of the work to be carried out.
Confirmation of the exact equipment which has been made dead and its precise location.
Confirmation that the equipment is isolated from all sources of electrical energy.
Confirmation of the points of electrical isolation/disconnection.
Confirmation that all points of electrical isolation have been secured by the use of locks and tags.
Confirmation that the electrical equipment has been proved dead with an approved voltage indicator at the
point of work.
Positive Pressure Respirators:
A positive pressure respirator in which the supply of air is carried by the wearer In Line through portable
pressurized cylinder

Documents required for the confined space entry permit:

- Only one Confined space entry permit shall be issued for entry to specific confined space and shall governor
the other groups entering the confined space to execute their activities.

- Blind list with process equipment to be attached to the LOTO.\

- Rescue Plan

- Ventilation plan

- JSA

- Confined Space entry Permit

- Hot Work Permit

- Confined space entry Compliance Checklist (SAFCO SABIC)

Sight Glass:

A sight glass comprises of two flanges, bolted together, surrounding a glass disc
sealed with gaskets and provides a means of viewing the inside of a process
vessel or tank.

Entanglement:
Employees working near powered machinery with exposed moving parts can be at high risk of entanglement.

Engulfment:
Confined spaces that contain liquids or flow able solids like grain, corn, or coal pose an engulfment hazard.
Engulfment occurs when a person is pulled under the surface of a liquid or flow able solid, and can result in
death from strangulation, constriction, or crushing.

In which conditions lifeline cannot attached to personnel working within a confined space?
a) Where the concentration of structural members piping, equipment and other obstructions to free travel
within the confined space is such as to render a lifeline useless for rescue purposes.
b) Where the concentration of workers within the confined space is such that the use of lifelines is likely to
cause line entanglement, there-by impeding the rescue effort.

Why we should conduct the gas test in the confined space?

To check the flammable conditions, Toxic and flammable gases, Oxygen enrichment and oxygen deficiency.

What are the equipment’s must be maintained ready for emergency use at the point of entry in confined
space?

a) Appropriate length of lifeline.

b) Self-contained, 60 minutes’ positive pressure breathing air apparatus (Air Pak).
c) Fire Extinguisher.
d) Radio/Air horn or other adequate communication device(s) to summon additional help in case of an
emergency.

If one person is missing in case of emergency, what will you do?

Inform to ERT (Emergency Response Team)
TLD Badges:
Thermo Luminescent Dosimeter
Lightweight personal radiation monitor that responds accurately to beta, gamma, X-ray and neutron radiation
CONTROLLED AREA:
Shall be established in locations where worker may be exposed to dose limit greater than 3/10 of the
occupational exposure limit (3μSv/h).
RADIATION SAFETY OFFICER (RSO):
A person who has been selected to be responsible for overseeing radiation safety in organization.

RADIOACTIVE SOURCE:
Any source of radiation where the radiation is produced by the decay of radioactive materials rather than
electrically, as in an X-Ray machine.

RADIOACTIVE WASTE:
The radioactive substances resulting from a source within a practice, which was retained in order to limit
emission rates into the ambient environment regardless of the physical state of such substances.

RADIOGRAPHY:
The examination of the materials by non-destructive methods utilizing radioactive isotopes or X-Ray generating
equipment.

SEALED SOURCE:
Sealed capsule containing radioactive material.

Radiation hazard due to the work shall be announced using Paging system before starting the work.

It is not allowed to proceed with any practices involving exposure to ionizing radiation without notifying the
RSO one week ahead.

Safe distance shall be calculated according to NDT source strength and redistricted area shall be barricaded
with suitable warning signs.

NDT (non-destructive test) shall be done when a minimum number of employees are in the plant.

Lifting Permit:

Lifting Permit control any lifting operations which are essentially non-routine activities.

Lifting Operations:
Lifting operations are the lifting of any load/object using a Crane (Fixed/Mobile) and chain block.
What are the documents required for the lifting?
Lifting Equipment inspection checklist
The Hazardous Assessment/Preparation Work Activity Form, Formal JSA.
Lifting plan
Lifting Permit
Third party certificates

Catastrophic failure:
Catastrophic failure is a complete, sudden, often unexpected breakdown in a machine, electronic system,

Hydro jetting:
Anti-Withdrawal Device (Back Out Preventer)
A device installed on the pipe entrance to prevent the nozzle on the end of the hose from being pulled out of
the pipe under pressure.

Dry Shutoff Control Valve:

A valve that is normally manually controlled by the Lance or Nozzle Operator to start and stop the flow of water
to the nozzle. Although closing this valve stops the water flow to the nozzle, it keeps the pressure in the supply
line at the system’s working pressure.

Jetting Gun (Shotgun):

A hand-operated device that is used in manual water jetting. It is normally connected to the high-pressure
system by a high-pressure hose assembly. The gun is made up of a control valve mounted within a guard, a
lance section, and a nozzle assembly which may include one or more nozzles.

Lancing:
An application where a rigid or flexible lance and nozzle combination is inserted into and extracted from the
interior of a pipe or tubular opening.
Moleing:
A hose fitted with a nozzle is inserted into and retracted from the interior of a pipe. It is commonly used with a
self-propelling nozzle for cleaning the internal surface of pipes and drains.
Nozzle Operator
The member of a HPWJ Team who holds a gun, lance, or delivery hose and controls the motion and direction of
the jet(s).
Stinger
Rigid tubing or pipe mounted behind the nozzle assembly for use with a flexible lance or hose. Stingers are
generally used on small-diameter piping and heat exchanger tubes.
Whip Check
A short length of wire or cable looped over each end of two hoses that are connected by a coupling. A whip
check is designed to stop the ends of hoses from whipping around if the coupling breaks

Note:
- Civil Engineer shall establish load carrying capacity of soil for safe use of mobile industrial equipment in or
around excavation.
- All Work Permit forms shall be retained for minimum 3 months period.
- In case Permit Issuer has to leave his shift for any valid reason, he has to delegate the responsibility to
another “Permit Issuer” of equivalent authority or above to carry out the responsibilities and make
endorsement.
-Using power / machine excavation in areas where underground electrical system exists is not allowed.
- Provide adequate shoring or sloping of the trench wall, if the depth exceeds 1.2 meters.
- Use confined space entry permit for excavation more than 1.2 meters deep.
- Do not place excavated materials or mechanical equipment within 1 meter of the edge of any excavation.
- Also, keep equipment and other heavy objects at least 2 meters from the edge of the excavation.
- Do not cut red concrete as the red color concrete is used to mark underground electrical systems.
- Do not use mechanical excavation within 1 meter of any underground services.
- Provide ladders or other suitable means of access / egress to excavations at a maximum spacing of 30 meters
on the perimeter of open excavations.
- Provide ladder on 7.5 meters for trench excavations greater than 1.2 meters in depth.
- All sloping shall be sloped at an angle not steeper than 1.5:1 or 34 degree [1.5 meters (5 feet) horizontal to 1
meter (3 feet) vertical] this would be for all excavations of less than 6 meters (20 feet) deep.
- Ensure the slope of the angle greater than 45 degrees when shoring is not installed.
- An easy and safe means of exit shall be provided if the excavation is 1.2 meters (4 feet) deep or greater. This
exit shall be within 7.5 meters (25 feet) of every worker.
- If a ladder is used as an exit, the ladder shall be secured and extend 1 meter (3 feet) above the landing.
- Combustible gas detector instruments shall be used only in atmospheres containing oxygen range between
19.5%~21%
- Flammable material in confined spaces / piping that is purged with Nitrogen or other inert material.
- Use chemical reaction tubes, such as Dragger tubes, or other such instruments to check concentration of
toxic or corrosive substances.
- Oxygen content above 23% can cause explosions or vigorous burning of flammable materials, including hair
and/or clothing

- If entry is required for testing purpose, gas tester shall be wear Self Contained Breathing Apparatus (SCBA)
or supplied air respirator and with a standby man outside the confined space.

- Before an employee enters the confined space stop ventilation / purging at least 15 minutes, or based on risk
assessment, prior to conducting the gas tests, to allow gas concentration to equalize.

- When the gas detector indicates more than 0% of ell of flammable gas in any confined space, personnel shall
immediately come out

- Stop hot work activities inside confined space if the flammable gas concentration exceeds 0% of lel.

- At least one person in each confined space entry shall have a calibrated pocket sized oxygen meter with
alarm.

- The gas test shall be carried out no more than 2 hours prior to the issue of the permit.

- The standard gas tests every 2 hours. But in case of Hot work the issuer can specify gas test <2hrs (e.g. every 1
hour)

- If gas detector indicates more than 0% of the LEL, hot work shall not be carried out.

- Confined space entry is not allowed if the gas test reading is more than 0 % of the LEL.

- An external, independent vendor or his representative will do calibration on a quarterly basis to ensure
correct performance of the unit. Quarterly=3months

- Which permit is required for vehicle Entry in hydro-carbon area or potential hydro-carbon existence. (Hot
Work Permit)

- Ensure to relocate all moveable fire hazards in the vicinity at least 15 meters from the hot work site.

- Provide local exhaust ventilation, Self-Contained Breathing Apparatus (SCBA) or an airline respirator when
welding, heating or burning galvanized or cadmium-plated metal.

- Purge hoses individually, before lighting the torch for the first time each day. Hoses shall not be purged into
confined spaces or near ignition sources.

- Use friction lighters for ignition. Do not use matches, cigarette lighters or hot metals for lighting torches.

- For safety during welding, the Negative terminal of welding machine must be connected as close as possible
to the work piece. This ensures that the return current flows back to the machine through shortest path and
hence prevents overheating and sparking in that area.
- The welding machine operator shall inspect welding cable for wear or damage before each use and
Maintenance Department, and shall inspect every six months for wear or damage of welding cable.

- In case entry is not made inside the confined space within half hour after Confined Space permit issued, the
confined space work permit shall be considered as suspended and need to do the gas test and reconfirm all
requirements again before entering the confined space permit.

- The default maximum frequency for gas test inside the confined space is every 2 hours. In case of continuous
gas test requirement, this frequency (logging in Gas Test Log sheet in task related work permit) shall not exceed
30 minutes.

In case of radiation activity inside confined spaces, The RSO shall not allow any entrants including stand by
Man to enter the barricaded area except radiographers.

- It is recommended that a particle strainer be in-stalled to prevent blockage of the small orifices in the air
movers/ fan.

- The pressure requirement and supply volume of air shall match the equipment specification to achieve the
desired ventilation.

- Only explosion proof electric fans/air movers shall be used to ventilate confined spaces

- The use of nitrogen or any other compressed gas (e.g. oxygen) to operate an appropriate type air
mover/ventilate confined space is prohibited

- Ventilation of vessel showing only the bottom man way open this ensures that the whole vessel is ventilated.
If the Middle or top Man way is opened the air flow will short circuit and there may be hydrocarbons in the
bottom of the vessel.

- Sight Glass connected to a process flare or drains must be blinded. Local sight glass need only be isolated and
drain valve open and drain proved to be clear and not blocked.

- Keep compressed gas cylinders and welding machines outside, when welding or cutting is being performed in
any confined space as Welding gas cylinders are not permitted inside the confined space.

- Any person entering to confined space shall have inspected O2 meter showing Oxygen concentration
continuously and alarm in case of oxygen variation. In case of group entry, one person out of four shall have
pocket oxygen meter.

- Each person entering confined space with vertical entry shall wear a full body harness attached to a lifeline at
all times with provisions made for rescue from the point of entry. The free end of the lifeline shall be secured
outside the confined space (One end is hooked to entrant, other end must be secured (hooked, tighten)
outside for retrieval purpose).

- Use of rope ladder is not allowed unless no other alternative method is being possible to be used and shall be
controlled through approved formal JSA.
- N2 connection source to the confined space shall be blinded before allowing entry. In case of N2 header
(plant/unit/complex) at battery limit is not blinded, N2 utility stations surrounding the confined space shall be
blinded unless N2 source is highly needed; the source can be used through the approval of formal JSA.

- Equipment to be entered shall be decontaminated and cleaned utilizing different methods as applicable,
which include;
a) Draining
b) De-Pressurizing
c) Purging.
d) Flushing.
e) Washing, and Steaming

De-contamination shall be perform for the equipment to ensure free of toxic/hydrocarbons before handling
the equipment.

- Purge with inert gas if the equipment previously contained flammable material.

- Purge with air. Open manholes and atmospheric vent lines. If oily sewer is close by, it should be covered to
avoid ingress of hydrocarbon vapors into the confined space

- Ensure the low point drains of confined space shall remain open to eliminate water accumulation.

- Only pneumatic driven blower, fans and movers are allowed to ventilate the confined spaces.

- For any confined space, minimum of 10 cycles of continuous air force ventilation is mandatory before
conducting gas test.

- Fans and air movers shall be ensured that it is electrically bonded and grounded to the vessel.

- The ventilation rate inside the confined space including the ventilation rate in the breathing zone shall be 15-
20 complete air changes per hour or one cycle every 2-3 minutes for a confined space. It can also be
calculated by dividing ventilating equipment flow rate (capacity) over volume of confined space using the same
unit system.

- Do not use Oxygen/Nitrogen to ventilate confined spaces, as this could lead to oxygen enrichment/deficiency
of the space.

- Stop ventilation / purging at least 15 minutes prior to conducting the initial gas tests, to allow gas
concentration to equalize.

On first time, Gas tester shall wear SCBA to enter in the confined space.

Pneumatic tools to be used inside confined space shall only be connected to an air compressor approved for
breathing air service and monitored to guard against contamination of the intake air.
For any confined spaces, only 24V explosion proof light shall be used for illumination.

Fall protection shall be adhered as per Working at Height procedure (SHEM-SP-08.09) requirements and
anchorage points / lifelines shall be as per NFPA 1983 certified or equivalent (1/2” 9000Ib strength – Static
Kern mantle Construction Rope)

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 seawater.

No gas torches shall be left unattended inside any confined space.

Do not permit welding or cutting activities in an oxygen-enriched atmosphere.

Any hot work shall consist of minimum dry chemical fire extinguishers located at the work site outside the
confined space in addition to any unit fire protection equipment available at the area. Water hose, fire
resistant blankets etc. shall be readily available for use whenever and wherever hot work is performed. Ensure
all measures taken for fire prevention & fire protection.

Fire blankets shall be UL listed (Under Writer laboratory) FM approved (Factory Mutual) or any other certified,
recognized international organization.

Disposable (white/light) coverall is not allowed to be worn during any hot work activities.

Do not permit more than one Hot Work Activity at same time in one confined space.

No Confined Space Entry is allowed without approved Rescue Plan.

Rescue plan shall be conducted by a formal team consisting of Fire Captain/ Incident Commander/Fire
Manager, Operation (Supervisor & above) and Maintenance (Supervisor & above).

Ensure availability of a retrieval system (retrieval line, full body harness, and a lifting device) to retrieve
personnel from vertical type confined spaces more than 1.5-meter deep “if applicable by rescue plan”.

On columns, vessels etc., personnel who enter from one manhole and intend to exit from another manhole
shall register at the manhole they intend to exit from i.e. they shall sign the confined space log sheet and
inform the entry attendant at the manhole of their planned exit, before entering the vessel.

Excavation means any activity where the surface of the ground is penetrated starting from 10 cm depth.
Use of a cable locator and/or other techniques such as exploratory excavation to identify the location of
underground services shall be implemented.

In the presence of any underground services is indicated, the underground services shall be exposed and
exactly located by hand tool excavation only.

No mechanical excavation shall be made within 1 meter of any underground services and is only allowed to a
depth where it is confirmed that no services are in place.

Excavation more than 1.2 meters ( 4 feet) deep shall be treated as work requiring a Confined Space Entry
Permit in addition to the Excavation Work permit.

Radiation safety officer (RSO) is responsible for the survey of radiation level around the sources and whenever
it is required during NDT, to safeguard the safety of the personnel, and is responsible for maintaining the
monitoring equipment, distribution and collection of TLD badges and documentation of personal exposure
recorded.
 SHEM-SP-08.04
Prevention of Fires and Explosions from Combustible Dust

Measure to prevent creation of dust clouds and the leakage or escape of dust from process equipment or
ventilation system.

Use of appropriate conductive or static dissipating and earth dust collection system and filters are required to
prevent static energy build-up

Utilization of surface that minimize dust accumulation.

Each area owner as applicable developed procedure for housekeeping that prevent a dust/powder build-up
greater than permitted in NFPA 654 ( usually less than 1/32 inch to 1/16 inch ( 0.8 mm to 1.6mm) ( prevent
secondary explosions)).

Monthly Housekeeping inspection is conducted as per the schedule.

Providing access to all hidden areas to permit inspection.

Inspection for dust residues in open and hidden areas on frequently.

Use of cleaning methods that do not generate dust clouds, as external ignition sources may be present and
static electricity (a source of ignition) can be generated during the operation.

Limiting vacuum cleaners to those approved and rated for Combustible Dust collection in hazardous areas
(e.g., NEC Class II Div. 1-air suspended or Div. 2-surface accumulated, non-air suspended).

Developing and implementing a combustible dust inspection, testing, housekeeping, and control program (in
writing and with established frequency and methods).

Preventing maintenance procedures, Site procedures shall include procedures for preventive maintenance of
equipment used or intended to mitigate the risk of combustible dust generation or ignition.
 SHEM-SP-08.09
Working at Height

Scaffold or structures with guardrails to be provided to work at a height of 1.8 meters (6 feet) or greater from
the ground level.

if scaffold or structure with guardrails cannot be personnel working at height shall wear provided then Full
body Safety harness attached to a permanent structure.

The use of half body/Safety belt as a fall protection is prohibited.

All personal fall protective equipment (full body harness) shall be inspected visually by the user prior to each
use.

Lanyards and drop lines/lifelines attached to the Safety harness to be secured as required by the applicable
local standards/regulations requirements. In the absence of any local standard/regulation, these can be
secured in a manner to limit falls to < two feet (0.61 m) and shall be capable to withstand a load of 2455 kilos
(5400 lbs.).

Lifeline (minimum 19mm nylon rope) shall be supported independently of the scaffold, carriage, or platform
from which the work is being done.

Full body harness with double lanyards as per our stander (EN361/362) to be worn by personnel and 100% tie
to be achieved while working on a scaffold.

Process pipelines shall not be used as far as practicably possible. If it is unavoidable and pipe line has to be used
its diameter shall be at least 10 cm (4 inch) or larger.

Surface temperature of the piping shall be given due considerations as lanyard and drop line made of nylon
and polypropylene drop line may get damaged due to heat.
Cages shall have a steel ring at the top for passing the sling or shall have four steel rings at each top corner.
Cages should be tested, certified and tagged by third party inspection agency.

Cages shall be fastened to the crane hook through sling. If the cage has one steel ring at top in the center then
one chain or steel sling to be used. If the cage has four rings, one at each corner then four chains or steel
slings shall be used.

Cage flooring shall meet the applicable local standards/regulations requirements. In the absence of any local
standards/regulations, it shall have a raised pattern with a 6 mm (1/4 inch) nominal thickness.

Wall and floor of cages shall be free from any protruding to avoid injury to the personnel.

Cages shall have a top railing with a vertical height of 1 meter (3.3 feet) from upper surface of top railing to the
floor. It shall have intermediate railing halfway between the top railing and the floor.

All pipe railing shall be seal welded and be of adequate strength. It shall be capable of supporting at least 4
times the maximum intended load or lifting.

Cages shall have the entrance from top with top rail completely closed (3600) or shall have a safety chain at
the entrance and equipped with a proper latch type hook at its moveable end. The chain shall not hang
excessively and the maximum deflection shall not exceed 8cm (3 inches). The safety chain at the cage entrance
shall always be at the rear side of the person in cage.

Cage toe plates shall be minimum 8.9 cm (3 ½ inch) high, securely fastened and with not more than 1.2 cm
(1/2 inch) clearance above floor level.

Annual inspection and load testing at 1.25 times of the working load shall be carried out and the date of testing
shall be marked on the load indicating plate

Crane hook used for the cage shall have a safety latch.
If the cage is to be raised more than 10 meters in height, two 1.2 cm (1/2 inch) diameter guy ropes shall be
tied to the cage on either side, in order to prevent the swing action. These guy ropes shall be held by person(s)
on the ground to control the swinging.

Wind direction and speed shall be considered before start and during the job. Work will be stopped in case of
wind speed higher than 20 miles per hour (32.40 km/hr.)

Ladders shall not be used on slippery surfaces unless secured or provided with slip-resistant feet to prevent
accidental movement.

The top portion of ladder shall protrude about 1.10 meters (3 Feet) beyond the top support

Ladder shall not be ascended or descended by more than one person at a time except for double-cleated
ladders.

Double-cleated ladders or two or more ladders shall be provided when ladders are the only way to enter or
exit a work area where 25 or more employees work or when a ladder serves simultaneous two-way traffic.

Non-self-supporting ladders shall be used at an angle where the horizontal distance from the top support to
the foot of the ladder is approximately one-quarter of the working length of the ladder.

Area owner (SHEM specialist or supervisor) shall inspect the fixed ladders annually & all other types every six
months using Ladders Inspection.

Portable Ladders shall support at least four times the maximum intended load. Extra heavy-duty type 1A metal
or plastic ladders shall be capable of sustaining 3.3 times the maximum intended load.

When portable ladders are used for access to an upper landing surface, the side rails shall extend at least 3 feet
(90 cm) above the upper landing surface.

Metal spreaders or locking devices shall be provided on stepladders to hold the front and back sections in an
open position when ladders are being used.
Single ladders longer than 9 meters (30 feet) shall not be permitted for use.

Straight ladders shall be set against the wall (support) at a four-to-one ratio (this means that for every 1.2
meters (4 feet) between the ground and the contact point between the ladder and an object/wall, set the
ladder feet out 0.3 meters (one foot). For example, a ladder reaching 4.9 meters (16 feet) should have the base
of the ladder 1.2 meters (four feet) from the wall).

Two-section extension ladders longer than 18 meters shall not be permitted for use.
All single and two-section ladders shall be equipped with at least a 1.8 m long rope of adequate strength to
prevent accidental breakage to secure the top of the ladder.

Fixed ladders shall be able to support at least two loads of 114 kg (250 pounds) each, concentrated between
any two consecutive attachments.

Horizontal bands shall be spaced not more than 1.2 meters (4 feet) on vertical centers and fastened to the side
rails of rail ladders or directly to the structure, building or equipment for individual-rung ladders. (Cages for
fixed ladders).

The top of the cage shall be a minimum of 1.1 meters (42 inches) above the top of the platform, or the point of
access at the top of the ladder, with provision for access to the platform or other point of access.(Cages for
fixed ladder).

The uppermost work platform height shall not exceed 3 times the minimum base dimensions of any mobile
scaffold used outdoors, and 3.5 times the minimum base dimensions for use indoors.

Designs for scaffoldings standing over 37 meters height to be prepared by contractor with third party approval
and reviewed/approved by a qualified Civil/Structural engineer.

Scaffolding supervisors & inspectors they shall have third party certificate (i.e. TUV, ITS or any third party
certification)
Scaffold tube shall be 4.83 cm (1.9 inch) nominal outside diameter. It shall be of mild steel and normally
supplied in lengths of 6.3 meters

A tube shall not deviate from a straight line by more than 1/600 of its length measured at the center.

Bases of the scaffold shall be at least 1.5 times the depth of excavation away from edges of excavation
(including trenches)

Screw jacks shall be used to level scaffoldings. Make-shift shims of blocks of wood, bricks, or concrete shall not
be permitted.

Timber sole plates shall be at least 23 cm wide by 3.8 cm thick (not scaffolding planks).

All planks or platform shall be overlapped as per minimum 0.3 meters or secured from movement.

Appropriate precautions shall be taken while erecting, dismantling and working on scaffolding near to hot
surfaces (temperature greater than 70°C). It is as protection against potential hazards like fire to scaffolding
material, direct contact to hot surfaces by workers, radiation effect to employee, etc.

All Scaffolding planks shall extend over their end supports not less than 15 cm. and more than 46 cm.

Scaffolding planks shall not be used for shuttering for concrete, shoring for trenches, or as sole plates for
scaffolding.

All decking shall be a minimum of 2 cm construction grade plywood, clean and free of obvious defects such as
cracks, knotholes, etc., and uncontaminated withal, paint, concrete or other substances that may weaken the
plywood.

For heavy duty scaffolds (more than 240 kg/sq. m), scaffolds over 37 m or special scaffolds, a scaffold plan
approved by Structural or Civil Engineer from CMD/ AED /PD&C or any Civil Departments is required.
Wooden Platform: Always used wooden material near Electrical equipment

Metal Platform: Metal boards shall fixed near steam leak or high temperature areas or any hot surfaces
(boilers, furnace, reactor, etc...)

Metal or wet ladders and scaffolding material shall not be used near electrical equipment or while using
electrical tools.

(International Rope Access Trade Association (IRATA),

Mobile Elevated Working Platforms (MEWPs)

Body Belt:

Strap with means both for securing it about the waist and for attaching it (with lanyard) to a lifeline or
anchorage. Used to provide personnel positioning limits against a fall, i.e., keep wearer away from the edge of
a roof.

Box tie:

An assembly of tubes and couplers forming a frame around a column or other part of a building to provide and
anchor point for scaffolding tie.

Castor (Caster):

A pivoting wheel that contains wheel lock and is attached to a vertical post of a mobile scaffold to assist for
Manual movement of the scaffold.

Gin Pole:

A supported pole with line attached with which loads may be raised or lowered through a sheave or block
secured to the crosspiece (gin pole).

Plywood decking shall be used to span an opening up to maximum width of 60 cm. The decking shall extend
the full width of standard scaffolding planking 5 cm x 23 cm minimum, which shall be used for support.
Slopes in decking shall not exceed 1 vertical to 4 horizontal and stepping cleats at 0.3 meters intervals shall be
provided.
Couplers Requirements of BS:

Type of Coupler Type of Load EN74 Class Rated Safe

Working Load
(SWL)**
Joint Pin Tension - 0 kN (0 lb.)
Bearer Coupler - Putlog Force to pull the tube - 0.53 kN (120 lb.)
or Single Coupler axially out of the coupler
Right Angle Coupler - Slip along a tube B 9.4 kN (2,100 lb.)
Double or Load Bearing
Coupler
End-to-End Coupler - Tension B 3.0 kN (675 lb.)
Sleeve Coupler
Bending B 0.59kN-m (435 lb.-
ft.)
Adjustable Coupler - Slip along a tube A 5.3kN (1,190 lb.)
Swivel Coupler
Scaffolding Spacing:

Scaffold Spacing for Standard Scaffolds

Scaffold Type Light Duty 120 kg/sq. m Medium Duty 240 kg/sq.
(25 PSF) m (50 PSF)
Bearer Span Runner Span Bearer Span Runner Span
“Cup-lock GR 43” System Max. is Max. is Max. is Max. is
scaffolding – EN 10219 min. 2.5 m 2.5 m 2.5 m 2.5 m
yield of 275 N/mm2 (8.25 ft.) (8.25 ft.) (8.25 ft.) (8.25 ft.)
Tube & coupler scaffolds Max. is Max. is Max. is Max. is
using tubing stamped with 1.2 m 2.4 m 1.2 m 1.8 m
ASTM A 500 (Grade B), ASTM (4.0 ft.) (8.0 ft.) (4.0 ft.) (6.0 ft.)
A 53 (Grade B) or BS 1139

Scaffolding tube shall be fabricated in accordance to any of the following standards:

1. ASTM A5000 Grade B.
2. ASTM A53 Grade B.
3. BS 1139, part 1, section 1.1.
4. EN 10219.
Electrical Clearance distance for Scaffolding:

Clearance
< 300 volts (insulated lines) 1 meter (3 feet)

300 volts to 50 KV (insulated lines) 3 meters (10 feet)

< 50 KV (un-insulated lines) 3 meters (10 feet)
> 50 KV (insulated lines) 3 meters (10 feet) plus 10 cm (4 inches) for each
KV above 50 KV
> 50 KV (un-insulated lines) 3 meters (10 feet) plus 10 cm (4 inches) for each
KV above 50 KV

Minimum overlap for two section ladders

Size of Ladder (meters/feet) Overlap (meters/feet)

Up to and including 11.4 / 37 0.9 / 3

Over 11.4 up to and including 14.4 / 47 1.2 / 4
Over 14.4 / 47 up to and including 18.0 / 60 1.5 / 5

Safety Latch:
Any latch having a stop or other device to prevent it from being accidentally opened.
 SHEM-SP-08.06
Lifting Equipment

Level Authorization
Certified Rigger level -I Less or above 40 MT- (Authorize to Prepare & Approve Critical
& Non Critical lifting Plan)
Certified Rigger Level-II Up to 40 MT - Authorize to Prepare only Non Critical lifting Plan
(Can do Mobilization & demobilization for critical & non-critical
lifting).
Certified Rigger Level-III Up to 10 MT - (Not Authorize to prepare lifting Plan)

Tandem lift:
When lifting heavy or oddly shaped objects, it is sometimes desirable to use two cranes in tandem rather than
a single higher-capacity crane. Tandem lifts can be very useful, and they are often used to place structural
beams for bridges, move large loads, and lift long components from horizontal to vertical positions. However,
tandem lifts have the potential to become very dangerous if not handled properly.

Tailing lift:
The process by which components such as
columns and vessels are moved from their
horizontal transport position and set in their
vertical installation position.
Man basket lift:
Man baskets, which are also called crane cages, construction
baskets or forklift baskets are aerial work platforms that
elevate a worker or workers to perform various overhead
job site tasks.

Fly jib lift:

A fly jib is a lifting device which assists a crane operator in picking and placing a load at a target area.

SWL (Safe Working Load):

The maximum amount of the load applied to the lifting equipment/tool.

What is the difference between rigging and slinging?

Rigging is the process of lifting and moving objects. Slinging is the name for the materials used to connect the
load to the crane or any other type of lifting device
Load Chart:

A load chart is a summary of what a crane can and cannot do. It gives a brief overview of the crane's
capabilities and goes over the cranes' features and characteristics, including the loads it can handle given
certain specifications — lift height, lift angle, Boom length, capacity etc.

Rigging:
Rigging is the equipment such as wire rope, turnbuckles, clevis, jacks used with cranes and other lifting
equipment in material handling and structure relocation. Rigging systems commonly include shackles, master
links and slings, and lifting bags in underwater lifting.

Lifting:
Lifting refers to the act of moving something from a position on a lower surface to a higher one.
Steps in detail of lifting procedure:
1-Request for lifting and rigging job to crane/rigging supervisor.
2-Site visit to the load with crane operator, and the working area for lifting, crane radius positioning and
maneuvering possibility. Obtain information regarding the load, etc.
3- Weight, volume, center of gravity, Hooking position, Location, Possible crane positioning, possible
obstruction, Equipment nearby, activities of other hazards nearby.

4-Prepare the Lifting Plan, Rigging and Lifting Job Safety Analysis and other information required in the Lift
Matrix. Review Lifting Plan with rigging crew and crane operator.
5-Review and seek approval of lifting plan base on Lift Classification Guidelines.
6-Lifting Plan & Vehicle Certificate (for non-critical and critical activity from plant area supervisor).

7-Proceed to the area, perform take two (review lifting Plan with the crew), set up the crane and fill the first
part of Crane Mobilization / De-Mobilization & Setup Checklist then proceed the required lifting activities.
Ensure that Crane Operator conduct crane inspection check with Daily Inspection Checklist Mobile/ Crawler
Crane and Boom Truck before lifting start.

8-Fill the second part of Crane Mobilization / De-Mobilization & Setup Checklist then Perform housekeeping
activities, retract the crane, move out crane from the location and closed all permit.

Lifting classification matrix:

Critical Lifting:

1-Lifting Personnel with a crane through (Man Basket) cages.

2-Any two crane lift (Tandem/Tailing Lift)
3- Any lift in which the net load weight is greater than 15 tons
4- Lifting over live electrical power lines, process equipment, & pipelines and hazarders classified area.
5- Any lift where load or crane boom passes over occupied buildings trailer, or process control process
6- Any lift greater than 1500kg where load or crane passes over multi-business unit pipe band or utility main, or
equipment requiring joint permit issuer signatures.
7- Lifting any object greater than 5,000kgs, having a vertical dimensions of greater than 8 meters.
8- Lifting in the immediate vicinity or excavation works (distance < 5 m and or depth ≥ 1.5 m).
9-Load lifting in congested areas (crane entrance, crane boom movement, object to be lifted).
10- Any crane lifting with fly jib, boom extension or super lift counter weight.
11-Above 100-ton capacity Crane setup on unstable ground surface (gravel, sand, etc).

Non critical lifting:

1-Lifting outside operating areas

2-Any lifting if the net load weight less than 15 tons.

Gantry & Overhead cranes:

Gantry crane:

Overhead crane:
1-Rail sweep in overhead cranes:

A device attached to the crane and located in front of the crane's leading wheels to remove obstructions

2-Bridge bumpers in overhead cranes:

All cranes shall be provided with bumpers or other automatic stopping means providing effect, unless the crane
travels at a slow rate of speed and has a faster deceleration rate due to the use of sleeve bearings, or is not
operated near the ends of bridge and trolley travel, or is restricted to a limited distance by the nature of the
crane operation and there is no hazard of striking any object in this limited distance, or is used in similar
operating conditions.

The bumpers shall be capable of stopping the crane (not including the lifted load) at an average rate of
deceleration not to exceed 0.9 m/sec2 (3 ft/sec2), when traveling in either direction at 20 percent of rated
load speed.

The bumpers shall have sufficient energy absorbing capacity to stop the crane when traveling at a speed of at
least 40 percent of rated load capacity.

The bumpers shall be so mounted such that there is no shear on bolts.

3-Guard in overhead cranes:

Each guard shall be capable of supporting without permanent distortion the weight of a 90 kg (200 lb.) person
unless the guard is located where it is impossible for a person to step on it.

Foot operated brakes shall not require an applied force of more than 30kg as rated brake torque.
4-Hoist in overhead cranes:

Holding brakes for hoist motor shall have not less than the following percentage of the full hoisting torque at
the point where the brake is applied:
a) 125 percent when used with control braking means other than mechanical.

b) 100 percent when used in conjunction with a mechanical control braking means.

c) 100 percent each if two holding brakes are provided.

Holding brakes on hoists shall have ample thermal capacity for the frequency of operation required by the
service.

Holding brakes on hoist shall be applied automatically when power is removed.

The wearing surface of all holding brakes drums or discs shall be smooth. Each independent hoisting unit of a
crane handling hot metal and having power control braking means shall be equipped with at least two holding
brakes.

Brakes may be applied by mechanical, electrical, pneumatic, hydraulic, or gravity means.

Power Control Braking:

A power control braking means such as regenerative, dynamic or counter torque braking,

Mechanically control braking:

Mechanically controlled braking means shall be capable of maintaining safe lowering speeds of rated loads.

Control Braking:
The control braking means shall have ample thermal capacity for the frequency of operation required by
service.

Thermal Capacity:

Thermal capacity is defined as the quantity of heat necessary to produce a unit change of temperature in a unit
mass of a material.

Lifting Plan:
A lifting plan provides a systematic approach towards planning a lift and ensures that the lifting operation is
properly managed.

Anti-two blocking:
A positive acting device shall be used which prevents contact between the load block and the boom tip (anti-
two-blocking device), or a system shall be used which deactivates the hoisting action before damage occurs in
the event of a two-blocking situation (two-block damage prevention feature).
Lifting shall be suspended in the cases given below:

Task Wind Speed

Normal lifting with Crane 40.2 kmph /25mph /9 mps
Critical lifting with Crane 32 kmph /20mph /9 mps
Man Basket Crane Lifts 25 kmph /15mph/7 mps
Derrick:
A derrick is either a crane for lifting material or a
framework over an oil well that allows the drilling
machinery to be raised and lowered.

Carbon Tetrachloride:

CARBON TETRACHLORIDE is a commonly used liquid in fire extinguishers to combat small fires. It has no flash
point, it is not flammable. However, when heated to decomposition, it will emit fumes of extremely toxic
phosgene and of hydrogen chloride.
Chemical Formula: CCl4
Auto ignition Temperature: Not flammable...
Vapor Density (Relative to Air): 5.3 (NTP, 1992)
PACs (Protective Action Criteria): 1.2 ppm

Limit Switch:
Limit switches are safety devices that can cut power to certain functions of your hoist. If you exceed a certain
weight or lift a load too high, the limit switch will shut off the crane's electricity or other system.

Over hoist limit switch:

Over hoist limit switch is a safety device that is provided to allow the setting of the hoist travel within a
prescribed travel range. Hoist: The upper limit of hoist travel is achieved through a hook operated type limit
switch and the lower limit of hoist travel is achieved through a drum-activated limit switch.

Lifting lugs:
Small projections attached to, or built into, heavy components. The lugs have an opening in the center to
which cables can be attached for lifting. Lifting lugs are in the construction of storage tanks and multi-grade
dispensers. Some tank manufacturers insert threaded lifting lugs in pipe openings.
Lifting Gear:

Lifting gear: any chain, rope, chain sling, webbing sling, rope sling, ring, hook, shackle, swivel or eyebolt and
any cage or work platform used for carrying persons while suspended from the load line of a crane.

Load Hitch:
A vertical hitch, or straight hitch, is the most basic hitch used to directly connect a load to a lifting device. On a
vertical hitch, the eye of a single chain sling, wire rope sling, or synthetic sling is connected to the crane or hoist
hook, while the other eye is connected to an attachment point on the load.
Lifting clamp:
is a tool used to position, hoist and transfer materials either horizontally or vertically from one station to
another

Types of lifting clamps:

Vertical Lifting / Locking Clamps

Vertical Lifting / Non-Locking Clamps
Locking Clamps
Horizontal Lifting / Non-Locking Clamps
Locking / Screw Clamps
Non-Locking Clamps
Pipe Grabs
Beam Clamps
Plate Clamps

Do not use plate clamps on hard or polished plate unless they have been specifically designed for that purpose.
Never use packing between the plate and the jaws of the clamp.

Never attempt to lift more than one plate at a time.

Swivel:
A swivel is designed to allow a load to rotate freely to make for a
more controlled safer lift / pull;

Lifting beam:

Lifting beams convert lifting loads into bending forces on the beam. A lifting beam has a simple design
consisting of a beam with a single attachment point centered on the top side of the beam for connecting to a
crane, hoist, or other lifting machine.
Shackles:
Lifting Shackles are connection link, used to make a connection
between the load lifting device (hoist hook / sling) and the load to
be lifted.

Notes:
High lift trucks shall be equipped with an overhead guard.

The eccentricity of the center of gravity should be no more than 5%.

All forklift trucks shall be equipped with a dry chemical fire extinguisher fixed in an accessible area.

Spinner knobs on the steering wheels are prohibited.

A Forklift is considered unattended when the operator is 7.5 m or more away from the vehicle which remains
in his view, or whenever the operator leaves the vehicle and it is not in his view. When a forklift is left
unattended or the operator dismounts and is not within 7.5 meters of the truck, load engaging means should
be fully lowered, controls should be neutralized, power should be shut off, and brakes set to prevent
movement. Wheels shall be blocked if the truck is parked on an incline.
Forklift trucks that are defective, in need of repair or are unsafe, shall be tagged “Danger – Do Not Operate,”
and taken out of service until restored to safe operating condition.

General lighting shall meet the applicable local standards / regulations requirements. In the absence of any
local standards/regulations, it shall be less than 2 lumens per square foot, auxiliary directional lighting shall be
provided on the TRUCK

Vehicles shall be kept free of excess oil, and grease. Noncombustible agents should be used for cleaning trucks.
Low flash point (below 100°F 38°C) solvents shall not be used. High flash point (at or above 100°F 38°C)
solvent may be used. Precautions regarding toxicity, ventilation, and fire hazard shall be consonant with the
agent or solvent used.

MEWP (Mechanically Elevated Working Platform)

Concentration levels of carbon monoxide gas created by powered industrial truck operations shall meet the
applicable local standards / regulations requirements. In the absence of any local standards/regulations, it shall
not exceed 50 ppm (based on OSHA 1910.1000 Permissible Exposure Limits).

Additional counter weighing of forklift trucks shall not be allowed unless approved by the manufacturer.

Eccentricity:
Eccentricity is a measure of how non-circular the orbit of a body is. A particularly eccentric orbit is one that
isn't anything close to being circular. An eccentricity of zero is the definition of a circular orbit

Never allow lifting gear to lie on the ground for any length of time, or on wet surfaces, rusty steel or near
corrosive substances. Keep all lifting gear away from burning and welding operations.

The load wire or chain of the lifting appliance must not be used to wrap round the load to form a sling.

Do not use defective blocks, slings or accessories and never use the block chain as a sling.

Position the hook directly over the center of gravity so that the line of pull is vertical.
All lifting equipment shall be color-coded as per Color Code of Lifting Equipment

Chain blocks shall have the maximum safe working load clearly marked upon them, the Safe Working Load
(SWL) shall not be exceeded.

The hoist limit switch which controls the upper limit of travel of the load block shall never be used as an
operating control.

The crane shall not be loaded beyond its rated load except for test purposes

The load shall be attached to the load block hook by means of slings.

Fiber slings (which must be dry) may provide electrical isolation if it is necessary to weld on a suspended load.

The load shall be secured and properly balanced in the sling or lifting device before it is lifted more than
approximately 5 cm.

The operator shall not leave his position at the controls while the load is suspended.

Do not mix slings of different material. They will have different stretch and recovery characteristics.

Chain blocks and lever hoists should be operated by one person at a time.

For any use of slings safe working load should not exceed the 85 % of the sling rated capacity or be reduced by
15% to allow for higher dynamic loads.

Dynamic load:
A dynamic load is any load that changes over time. These type of loads exert forces onto a structure that are
often much greater than their static equivalents

Load Line (also known as Hoist Line)

In lifting crane service it refers to the main hoist rope. The secondary hoist rope is referred to as a whip line or
auxiliary line.

Freight containers are intended to be lifted by the special 'twist lock' fitting and their corner fittings are
designed accordingly.

Twist Lock:
This twist lock is used vertically to stack two shipping containers on top of each other.

The cab shall be located to afford a minimum of 7.5 cm clearance from all fixed structures within its area of
possible movement. (For overhead and cantilever cranes)

Access to the cab and/or bridge walkway shall be by a conveniently placed fixed ladder, stairs, or platform
requiring no step over any gap exceeding 30 cm. (For overhead and cantilever cranes).
The clearance of the cab above the working floor or passageway should be not less than 2 meters. (For
overhead and cantilever cranes)

To give sufficient access to the opposite side of the trolley, there shall be provided either a foot walk mounted
on the trolley, a suitable foot walk or platform in the building, or a foot walk on the opposite side of the crane
at least twice the length of the trolley.

Foot walks should have a clear passageway at least 56 cm wide except opposite the bridge motor, where they
should not be less than 38 cm. The inner edge shall extend at least to the line of the outside edge of the lower
cover plat or flange of the girder.
Toe boards shall be 10 cm in height from its top edge to the level of the floor, platform or ramp. It shall be
securely fastened in place and with not more than ¼-inch clearance above floor level. Handrails shall have a
vertical height of 105 cm from upper surface of the top rail to the floor, platform or ramp. A standard railing
shall consist of top rail, intermediate rail, and posts. The top rail shall have a smooth surface throughout the
length of the railing. The intermediate rail shall be approximately half way between the top rail and the floor.
(Refer SASO Section 2.5 for additional requirements.)

Foot walks should be located to give headroom not less than 2 meters. In no case shall less than 1.2 meters be
provided. If 1.2 meters of headroom cannot be provided, foot walks shall be omitted from the crane and a
stationary platform or landing stage built for workman making repairs.

Foot walks shall be of rigid construction and designed to sustain a distributed load of at least 50 pounds per
square foot (250 kg/sq m).

A carbon dioxide or dry chemical hand fire extinguisher shall be kept in the cab. Carbon tetrachloride
extinguishers shall not be used.

SOC (Safe Operation Committee);

During lifting should not be exceed the 80 % of crane rated capacity except load test purpose or when use the
super lift counter weight.

Only during counter weight mounting & dismounting lifting load must not exceed 90% of crane capacity,
contingency shall not be added in the actual weight.

Any crane above 100-ton setup on unstable ground (gravel, sand etc.) shall be required steel mates based on
GBP (Ground Bearing Pressure) as per Civil engineer evaluation and recommendation.

Civil Engineer approval is required in case underground facility, required backfilling, compaction or crane
capacity above 100 ton.
For man basket lifting gross load weight shall not exceed the 50% of crane rated capacity as per crane load
chart configuration.

Calculate weights shall add 25 % for formerly in-service equipment or for removal of equipment and 10%
contingency for new equipment for installation or loading/ unloading.

Whenever fix crane nearby an excavation, the distance shall be no less than 2 meters.

A crane which has been idle for a period of one month or more, but less than 6 months, shall be given an
inspection conforming to the requirements of Preventive Maintenance for Mobile Cranes.

Foot operated brakes shall not require an applied force of more than 30Kg as rated brake torque.

Minimum clearance of 7.5 cm (3 inches) overhead and 5 cm (2 inches) laterally shall be provided. And
maintained between the crane and obstructions. Where passageways or walkways are provided, obstructions
shall not be placed so that safety of personnel will be jeopardized by movements of the crane.

Anemometer is used to check the wind speed.

If hoisting ropes run near to other parts to make fouling or chafing possible, guards shall be installed to prevent
this condition.

Tagline shall be used to control long or unwieldy loads.

Exhaust pipes of the cranes shall be guarded or insulated in areas

Cranes mounted on rail tracks shall be equipped with limit switches limiting the travel of the crane.

Cranes and derricks with variable angle booms shall be equipped with a boom angle indicator that is readily
visible to the operator.
Cranes with telescopic booms shall be equipped with a device to indicate clearly to the operator, at all times,
the boom's extended length.

There is no specific training or qualification requirement for flagman.

All cranes shall be fitted with a load/radius indicator chart & wind speed indicator (Anemometer).

A mobile crane and boom truck with a rated capacity of 10 tons or more must have a device that measures and
indicates the weight of the load on the load hook and disengages crane functions whose movement can cause
the mobile crane and boom truck to lift beyond the rated capacity.

For crane’s electrical equipment, the requirements shall be in accordance with the following:
The control circuit voltage shall not exceed 600 volts for A.C. or D.C. current.

The voltage at pendant push buttons shall not exceed 150 volts for A.C. and 300 volts for D.C.

The voltage at pendant push buttons shall not exceed 150 volts for A.C. and 300 volts for D.C.

Cranes resistors:

When overhead cranes are used in industrial facilities, crane resistor banks are frequently used for control of
hoisting and lowering speeds, as well as positioning the crane itself.

Enclosures for resistors shall have openings to provide ventilation, and shall be installed to prevent the
accumulation of combustible matter near hot parts. Resistors shall be free from vibration.

Pendant station in overhead cranes:

Pendant Controls for Overhead Cranes. A pendant control hangs down from the hoist or off of a separate
festoon track and allows the operator to control the crane and the load as it moves down the runway

An under-voltage trip for the main circuit breaker operated by an emergency stop button in the pendant push
button station.

All cranes using a lifting magnet shall have a magnetic circuit switch of the enclosed type with provision for
locking in the open position and a battery back-up system. Means for discharging the inductive load of the
magnet shall be provided.

If a service receptacle is provided in the cab or on the bridge of cab-operated cranes, it shall be a grounded
three-prong type permanent receptacle, not exceeding 300 volts.

Sheave groove in crane:

A properly machined sheave groove allows a wire rope to pass through unhindered by friction or
obstructions.

Sheaves carrying ropes which can be momentarily unloaded shall be provided with close-fitting guards or other
suitable devices to guide the rope back into the grove when the load is applied again.

The rated load divided by the number of parts of rope shall not exceed 20 percent of the normal breaking
strength of the rope.

No less than two wraps of rope shall remain on the drum when the hook is in its extreme low position.

When a newly installed rope has been in operation for an hour, all nuts on the clip bolts shall be re- tightened.

Rope clips attached with U-bolts

Frequent inspection:

Daily to monthly intervals. Frequent inspections will be performed by crane operators who have been trained
with regard to the operation and inspection techniques of cranes as defined in this section.

Periodic inspection:

1 to 12 month intervals. Periodic inspections shall be performed by appointed personnel who have been
trained in the operation and proper inspection techniques regarding overhead and gantry cranes as defined in
this section.
 SHEM-SP-08.11
Control/ Isolation of Hazardous Energy Including LOTO

LOTO Supervisor:

1. Is responsible for registering of all Locks type in

Lock Registration sheet
2. Is responsible for record LOTO used in LOTO
Certification Control Sheet
3. Manages the keys in the LOTO Supervisor
cabinet in such a way that no unauthorized persons can obtain any such key as these keys control the safety of
all persons working under LOTO with regards to isolated energy sources in the plant/unit.
4. Is responsible for proper hand over and received
back of all LOTO activities after his working hours
5. Has a clear overview of all ongoing LOTO
activities within their area of responsibility.

LOTO Authorized Employee:

1. Is authorized to Lock and or tags out machinery

and/or process equipment in order to perform service or maintenance work on that machinery or process
equipment as per Work Permits procedure.
2. Has received instruction on writing (LOTO
Certificate) and deploying procedures for performing LOTO activities and about the prohibition relating to
attempts to restart or re-energize machines or equipment under LOTO.
3. Ensures that each LOTO point is signed on the
LOTO specific procedure.
4. Define (tryout) on the applied LOTO tools and
locks. LOTOTO

LOTOTO: Lock Out Tag Out Try Out

LOTO Affected Person:

Defined as a person who is required to work on machinery or process equipment under Lock-Out/Tag-Out and
therefore required to use a personal lock and tag to guarantee their individual control.

LOTO:

To control releasing the energy associated with the service, maintenance and or installation of machinery
and/or process equipment shall be always apply a physical Lock-Out and Tag-Out device to each energy
isolation device.
To Control the release of energy:

1. Rem
oval of an isolating circuit element (e.g. fuses);
2. Block
ing of a controlling switch;
3. Utiliz
ing an extra energy isolating device; or
4. The
removal of a valve handle to reduce the likelihood of inadvertent energization.

What is the principle of LOTO?

One Lock, One Key, One Tag and One Person

What are the steps of LOTO?

Shutting down, isolating, blocking, drainage (depressurizes) and securing machines or equipment to control
hazardous energy. Placement, removal and transfer of LOTO devices and define the responsibility. Testing a
machine or equipment to determine and verify the effectiveness of LOTO devices and other energy control
measures to verify the zero energy state of the machine or equipment, e.g. using multi-meter to verify zero
voltage, using start/stop push bottom to verify the rotating equipment movement. Ensure all relevant energy
sources (including stored energy) are assessed. DE-LOTO the equipment back into service after work
completion.

LOTO Supervisor shall maintain the following to control all LOTO activities:
1. LOTO
Certificate (Appendix SHEM-SP-08.11E).
2. Lock
Registration Sheet (Appendix SHEM-SP-08.11H).
3. LOTO
Certificate Control Sheet.

LOTO Process:

1-Preparation for LOTO:

Fill and singe the LOTO Certificate before work execution.

2-Securing LOTO:
a) De-energize the Equipment/System according LOTO Equipment specific procedure.
b) Perform LOTO the equipment or system.
c) Control the execution of LOTO
d) Verify de-energizing.
3-Try out and verification:
a) Try-out by the person(s) who is going to work on equipment or system.
b) Put personal lock on the LOTO box or satellite box.
c) Get the work permit.
d) Start working.

4-LOTO removal (Temporary Release or Work finished):

a) If work is not finished, yet leave the locks on the LOTO box. If you remove the locks you have to go back to
step 3
b) When work is finished, remove personal lock from the LOTO box.
c) Remove LOTO equipment according LOTO Equipment specific procedure.

Verification of the isolation:

Verify by testing the equipment that full isolation resulting in a zero-energy state has been accomplished
before beginning the work.

Return Operating Controls to the “Neutral” or “Off” Position after the Test.

Check LOTO Flow Chart (Appendix SHEM-SP-08.11A) for full understanding of the LOTO process status.

Release from LOTO:

The work area is inspected and that nonessential items have been removed.
The machinery or process equipment components are operationally intact.
The work area shall be checked to make sure everybody is safely positioned or removed during the restart
process;
That after the LOTO devices are removed and before the machinery or process equipment is started, the LOTO
authorized person(s) shall notify all affected persons working in the area that the LOTO device(s) have been
removed and it is safe to return to an operating state.

What steps shall be followed when the employee who applied the lockout and/or Tag-Out device is not
available to remove LOTO devices or the lock key missing or lost?

Shall be reported immediately & formally to owner, LOTO Supervisor, executer supervisor, Department Sr.
Manager and Operation Sr. Manager.

Verification by Department Sr. Manager (LOTO person) including the LOTO Supervisor that the LOTO
authorized employee who applied the device is not at the facility.
The owner Supervisor has made reasonable efforts to contact the authorized employee, who placed the LOTO
device, to inform him that their lockout and/or Tag-Out device has been removed; (including requesting the
employee to return to remove the lockout/Tag-Out device(s).

Confirm the work activity completed and all work permit and certificate closed. “The LOTO certificate to be
attached with the Personal Lock Cutting Form (Appendix SHEM-SP-08.11D).

Confirm that no worker working in the isolated equipment.

Communicate to the affected area before lock cutting.

The cut out or damaged lock number shall be removed from registration sheet.

The Lock Cutting Form (Appendix SHEM-08.11D) shall be filled by LOTO Supervisor and approved by concern Sr.
Manager and Operation Sr. Manager before cutting the lock.

How we will ensure that the equipment is empty or not?

Consider the arrangement / orientation of the system being isolated and drained and ensure the drain is
located as close to the lowest point in the system as possible

If pressure indication is available within the isolations use this as a secondary measure for determining if the
system is drained and de-pressured but take care to note that a de-pressured system is not confirmation of a
drained system.

Always drain slowly when draining as high rates can cause static sparking.

Protocols of draining:

Always drain to a safe location, including consideration of volatility, temperature and composition of the
material

Ensure adequate vents are provided

Confirm there are no Work Permits live / issued in the adjacent area.

Use of correct standard of drain hose for service and ensure they are secured at the drain point to prevent
whipping under pressure.

Always drain slowly when draining as high rates can cause static sparking.

Never leave a drain open when unattended.

Any open end created or temporary hose fitted should be recorded in the appropriate register.

Inspect and verify that the equipment is de-energized after draining is complete.

Lock Type Lock Color

Owner (Isolator Qualified Red

Person)
General (LOTO authorized) Green
Personal (LOTO Affected Yellow
Person)
LOTO Supervisor Lock Black

Satellite Box:

The satellite box can be utilized in additional to LOTO Lockbox if there is extra group of workers from different
disciplines work in same isolated equipment or for workers work in the same group.

LOTO Lock Box: Moveable or Fixed

LOTO Key Cabinet: Fixed

(LOTO devices) shall indicate the identity of the person applying the device(s) and the reason for its use.

(Tag-Out devices) shall warn against hazardous conditions such as:

Do Not Start.
Do Not Open.
Do Not Close.
Do Not Energize.

Do Not Operate-Danger tags for field/process isolation

LOTO Tools:

LOTO Lockbox. A lockbox is used if one or multiple persons need to work simultaneously on the same
equipment in order to create the opportunity for all individuals to apply their personal lock and tag on that
lockbox and in that way individually control the keys within that box.

Other LOTO tools include lockout stations, cables, chains, multi-lock hasps and specific LOTO aids to help
placing a lock and tag at some locations.
Isolation:

A set of measures taken to make and maintain safe a process, an electrical or mechanical facility or an item of
equipment, such that energization of the equipment is not possible and energy/power cannot re-circulate in it
without deliberate action by all the authorized persons.

Mechanical Isolation:

Is usually achieved by such means as blinding or blanking, removal of pipe sections or spool pieces, double
block and bleed, blocking/ disconnecting all mechanical linkages. Energy sources include electrical, mechanical,
hydraulic, pneumatic (air), chemical, thermal, radioactive, gravity…

What are the steps that should be considered for making safe electrical isolation?

The following key steps shall be applied when making safe electrical isolation:
a) Identify
b) Isolate
c) Secure
d) Discharge
e) Test

What should be analyzed before choosing the type of process isolation?

a) Information on the line and its content (pressure, inventory, type of product)

b) History of passing valves;

c) Volume or inventory freed if the isolation barrier fails;

d) Presence of natural ventilation or confinement;

e) Number of exposed persons needed to perform the isolation;

f) Risks inherent in implementing the isolation, such as breaking containment, critical lift, passing valves, etc.

What are the types of mechanical isolation?

a) Physical disconnection (such as the removal of a removable spool piece);

b) Blinding/Blanking/Spading (spade, blind or plug, spectacle blind);

c) Double block and bleed;

d) Double block; e) Single block (and bleed).

Physical Disconnection:

A piece of pipe (generally a removable spool piece) is removed from the piping and a blinding device (usually a
blind) is installed on the pressure side, downstream or at the closest relief valve to wear the work is being
performed as well as the isolated process side. The separation equipment has the same nominal characteristics
as the piping.

Physical disconnection can be used for long-lasting isolations with any type of fluids.
Blinding/Blanking/Spading:

Spading consists in installing a blinding device (spade or equivalent, i.e. blind or plug, spectacle blind or plate)
as closely as possible to the equipment to be isolated

A spade is an isolation device with a handle approximately 5 cm (2 inches) or more that extends beyond the
flange. The characteristics of the spades could be marked/stamped on the handle to identify the intended
purpose of this tool.
A Spade (or slip plate) and a Spectacle Blind (or spectacle plate) applied correctly will form a positive barrier
across the bore of a pipe and are held between flanges of the pipe.
Double Block (Isolation) and Bleed:

Double block and bleed isolation is provided by shutting two isolation valves and opening a valve (bleed (drain,
vent)) between them. The theory is that any leakage past the upstream valve will come out via the bleed (drain,
vent) instead of leaking through to the downstream valve (Control valves, trip valves or non-return valves are
not isolation valves). A potential risk is blockage of the bleed valve where (an unobserved) pressure build up
can occur and possibly leak through to the second isolation valve and potentially into the isolated process side!

Double Block:

Double block isolation only could be acceptable, with the required precautions, if backed by the risk
assessment. Keep in mind that this might not give a true indication if a full successful isolation has been made.
SAFER process may be necessary to identify and mitigate the remaining risk.

Single block (Isolation):

A single block isolation is used only when there is no possible alternative and the risk is acceptable, and is
accompanied by compensatory measures (see figure 2 for an example). The leak-tightness of the single-valve
isolation is demonstrated.
How will you check that the equipment is empty/de-pressurized or not?

Ensure zero pressure in the system by assuring vents/drains are opened.

Line Break:
Line breaking is the intentional opening of a pipe, line, or other part of a process that contains or has contained
material capable of causing injury by virtue of temperature, pressure or chemical properties to people and/or
the environment.

Note:

Equipment valves isolation shall include an attachment of P&ID drawing copy with all valves marked and
numbered what to be opened and what to be closed.
Equipment Isolation shall be the nearest isolation valve to the equipment.

Equipment blinding shall be done as per approved Equipment/ system blind list.

For any Confined Space Entry Work, a blind/blank/spade isolation device shall be used as a minimum for all
connected piping.

An owner or isolator LOTO lock is a unique lock with one unique key in combination with a general LOTO tag. It
shall be used in the isolation point at the field.

A general LOTO lock (LOTO authorized) is a unique lock with one unique key in combination with a general
LOTO tag. It shall be used to lock the lock box only

A Personal and Executer LOTO lock (YELLOW) is a unique lock with one unique key in combination with a
personal LOTO tag. It shall be used to lock the lock box or satellite box.

Transition Tag (DON’T OPERATE TAG):

Tag used in conjunction with a Transition Lock to indicate that no one is currently performing work on that
equipment.

Each lockout and or Tag-Out device shall be removed from each energy isolating device only by the LOTO
authorized employee who applied the device.

Immediately after applying the LOTO devices to all required energy isolating devices for the machinery or
process equipment, all potentially hazardous stored or residual energy shall be relieved, drained,
disconnected, restrained and otherwise rendered safe by the authorized employee(s) performing the work;

The equipment\system qualified area owner shall put the owner lock in the energy source (equipment\system)
to isolate it.

The LOTO authorized (owner) shall verify that all LOTO verification points are isolated as per equipment LOTO
specific procedure and blind list.

The key of General lock shall be maintained inside the LOTO Key Cabinet (fixed). One LOTO Key Cabinet shall
be provided for LOTO Supervisor.

The key of owner lock RED shall be maintained inside the LOTO Lockbox (Movable or fixed).

The LOTO authorized (owner) shall lock “Green” LOTO Lockbox by the General lock.

The LOTO Supervisor shall lock LOTO Key Cabinet by LOTO Supervisor Lock. (Black color)
All LOTO affected persons shall lock LOTO Lockbox by their personal locks (Yellow Color).

The LOTO supervisor shall control and maintain the LOTO Lockbox.

The LOTO affected supervisor shall control and maintain the satellite box.

The Lockbox number and satellite box number to be register in LOTO Certificate

NO spare keys shall be allowed under any circumstance.

Lockout devices and Tag-Out devices shall be the only devices(s) used for controlling energy, and shall not be
used for other purposes

Tag-Out devices shall be constructed and printed so that exposure to weather conditions or wet and damp
locations will not cause the tag to deteriorate or the message on the tag to become illegible.

Tags including their means of attachment shall be substantial enough to prevent inadvertent or accidental
removal without the use of excessive force; shall not deteriorate when used in corrosive environments such as
areas where acid and alkali chemicals are handled and stored.

.
 SHEM-SP-08.07
Tools Handling

Protocols for hand tools:

Select a suitable and correctly sized tool, non-conductive and/or non-spark tools, do not substitute tools, Faulty
tools shall not be used, no tools shall be altered or repaired without authorization,

What type of defects are found in tools?

Mushroomed or burred heads on impact tools such as chisels, hammers, driving bars, etc.
Loose, over or under sized handles.

Open-ended wrenches with jaws spread or distorted.

Cracked box end or socket wrenches.

Splintered or cracked handles.

Improper/missing/bent handles and control bars.

Defective extension or power cords such as chafed, kinked, weather cracked, male or female plugs broken or
not installed properly, no ground wire, etc.

Defective or inoperable guarding mechanisms.

Evidence of abuse, which negates safe operation.

Hack saw blade selection guidelines:

Blade Selection (As a thumb rule, Pitch of the blade teeth shall be half or less of work piece’s thickness).
Guards:

Fixed enclosure guards shall be installed. However, if fixed enclosure cannot be installed then any of the
following method may be used as a guarding protection:

a) Presence Sensing Devices

b) Interlocking guards
c) Automatic guards
d) Remote control, placement, feeding, and ejecting.

Interlocking:

An interlocking barrier shall be considered when an enclosure guard is not practicable. The interlocking barrier
shall shut off or disengage the power to prevent the starting of the machine when the guard is open.

Common Mechanical hazards:

Instability All machine tools must be securely mounted and assembled to prevent
the possibility of collapse or overturning.
Entanglement of hair, clothing Machine tools of all types including lathes, milling and drilling
etc. machines, drive belts, exposed shafts, gearwheels, pinch rollers,
mixers, fan blades
Friction or abrasion Abrasive wheels, belt sanders, rim of centrifuge basket, fast moving
conveyor belts
Cutting Band saw, disc cutter, circular saw, power hack saw
Shear Guillotine blade, planning machine, rotating wheels on machine tools
Stabbing or puncture Bursting of abrasive wheel, twist drill, high pressure air or fluid
injection
Impact Traversing machinery such as planning machines
Crushing Between machine tool table and a fixed structure
Drawing-In In-running nip between rollers, meshing gears or belts and pulleys
Hand damage Vibrating tools

Write the names of PPEs that are required for hydro jetting?

Wear waterproof coat made of leather or PVC or other water resistance material.

Wear waterproof gloves made of leather or rubber or other water resistance material with sufficient
mechanical strength

Ware rubber gum boots or any waterproof boots that shall protect up to knee.

For operating crew and workers within 6 meters radius should wear face shield.
The machine and working area shall be properly cordoned off / barricaded.

What will be checked before starting the hydro jetting machine?

Automatic pressure relief valve is depressed into load position.

Valve is not pressed by the operator.

Trigger of spray pistol is not pulled.

Suction filter is not choked.

Water supply valve is open.

High pressure hose shall not have kinks, cuts or chipping on outer rubber. Hose shall have pressure rating
engraved on its couplings. High pressure hoses shall be pressure tested, once every year by a competent
authority. Records of all such test shall be kept

Lance nozzle shall be designed to prevent release from mounting by impact. Mounting for the lance to vessel
shall be so designed that falling scale is deflected from the mounting.

Only calibrated pressure gauge(s) shall be used

For the hydro jetting machine a third party certificate should be provided with the machine before it enters
the premises.

All safety device including actuators, safety valves on high pressure side shall be tested yearly or after each
pop-up or repair done by any competent authority. All test results shall be recorded.

Abrasive Blasting:

Abrasive blasting, a process used for removing old paint or rust from large steel surfaces prior to repainting or
applying Belzona coating or rubber lining etc.,
The guideline requires that less than 5% silica shall be in abrasives used for outdoor blasting.

The abrasive blast operator shall be equipped with a special purpose, supplied-air hood, with strong apron,
and leather gauntlet gloves. Heavy quality overalls are recommended for body covering. The supplied-air hood
shall be kept in good condition.

Other employees working near (or attending) the abrasive blaster shall wear approved respirators and goggles
offering a tight seal around the face.

Abrasive blasting shall not be performed from a ladder.

During the actual job of abrasive blasting, the user shall have complete control of the hose nozzle, which shall
be fitted with a self -closing valve (dead-man valve). In this way the blaster has complete control of the nozzle
on hand if he drops the nozzle, the self-closing valve will automatically shut off the compressed air supply.

Abrasive blasting may develop severe sparking at the nozzle through static electricity. Accordingly, the nozzles
of all grit blasting guns shall be grounded to prevent the possible ignition of any flammable vapors that may be
present

Note:

The entire area is to be barricaded by canvas or tarpaulin during hydro jetting.

When the Foot Control is deactivated, the water is dumped by the dump valve.

A colored tape marker should be fixed on the HP hose 1 meter from the nozzle tip, in order to alert the
operator to release pressure before completely withdrawing the hose from the tube on return path when
cleaning of heat exchanger tubes using HPWJ.

It is always preferable to use pneumatic rather than electrically driven portable tools including the cordless
type. Apart from the hazards of sparks etc. from electrical tools causing ignition of any flammable materials
present, air operated tools are usually more powerful than electrically operated tools of the same size, and
therefore more suitable for the larger, heavier jobs.

Swarf (metal waste) is regularly removed and stored for disposal. Do not handle Swarf without abrasion
resistant gloves.

During hydro jetting for operating crew and workers within 6 meters radius should wear face shield.

Rings on fingers, bracelets or gloves shall not be worn when operating lathes, drill, presses or machinery with
rotating shafts.

Personnel with long – shoulder length hair shall wear a suitable cap or hair net when operating lathes, drill,
conveyors, presses or machinery with rotating shafts.

Use “V” blocks for supporting round shafts or pipes.

Appropriate guards within one meter shall be installed on the conveyors and machines that have moving part.
The guard shall be provided in a space from the floor or platform to a height of 2.1 meters.

Guards above and below the base plate shall be provided for all portable power driven circular saws with blade
diameter of greater than 5.08 cm. Guards shall cover the blade to the depth of the teeth.

To prevent the hands and fingers of operator from coming in contact with in-running nip points guards shall be
provided on portable belt sanders.
Portable abrasive wheels, buffers, and brushes shall be guarded except when used for internal work. Maximum
guard opening is 180 degrees. The guard should be positioned so it is between the operator and the wheel so
that pieces of an accidentally broken wheel will be deflected away from the operator.

Moving equipment shall be properly guarded if the moving equipment is located less than 2.1 meters from the
floor or working platform - if the moving part is more than 2.1 meters above ground level or from the nearest
point of access, it may be considered “safe by position” and no localized guarding is required. Care shall be
taken in the event that temporary access for maintenance is required.

Pneumatic Impact Tools shall be provided with an automatic closing valve actuated by a trigger located inside
the handle where it is reasonably safe from accidental operation. The machine shall operate only when the
trigger is depressed.

Pneumatic Impact Tools shall have heavy rubber grips to reduce vibration and fatigue to the workers.

Water / moisture should be removed from the air before connecting the air hose to the pneumatic tool.

In hand tools Use narrow angle phosphor bronze wedges (in opposing pairs wherever possible) to provide
good grip.

Use only hot sticks with non-metallic heads on electrical equipment.

Do not use steel wedges (except for small fox wedges when aligning components during welding)

Adjustable wrenches shall generally be used for light jobs only.

Hammer shall have a securely wedged handle to the type of head used. However, use of hammer with wooden
handle is not allowed. Oil free handle.

Pliers, screw drivers shall have insulated handles

Power supply to electrical tools shall be disconnected when not in use.

Torque shall not be increased by using extensions like pipe with tools handle.

All users shall inspect the hand tools before use and return damaged or worn hand tools to the tool-room for
advice on replacements, upgrades, inspections or maintenance.

Electrical power tools operated within confined space shall have individual ground fault circuit interrupters
(GFCI)
Portable electric tools shall have preferably 110 volt (yellow cable and plugs unless otherwise authorized) with
single-phase supply from a double wound transformer with secondary winding earthed to ensure maximum
voltage to earth is 55 volts

Electrical operated tools shall be grounded with a grounding conductor excluding battery powered or shall be
double insulated type, where the complete tool is enveloped in a non-conductive (e.g. polypropylene) body.

Tools shall not be passed from one to another person by throwing.

When climbing ladders with hand tools use a carrying belt or shoulder bag; they shall not be carried by hands
or hooked over users arm.

Heavier or more cumbersome tools shall be placed in a bag or toolbox.

Small and light in weight Tools shall not be carried in pockets. Small tools should carry on a tool belt

Tie off hand tools when working at height where a fall could endanger people or damage equipment.

All portable powered & non-powered tools shall be inspected on every 3 moth & inspection certificate must be
documented using Tools List & Periodical Inspection Record for Tools.

All workshop machines shall be inspected on yearly basis using Machine Shop Inspection form.

Grinding wheels shall never be used at greater than the rated speed. Before using the grinding wheel, on a
portable grinder, ensure that RPM of the grinder is less than the maximum specified limit of the grinding
wheel.
For portable grinding, the maximum angular exposure of the periphery and sides shall not exceed 180° and the
top half of the wheel (the portion facing the user) shall always be enclosed.

Guards shall be adjustable so that operators will be inclined to make the correct adjustment rather than
remove the guard.

Safety guards of the grinding wheel shall cover spindle end nut and flange projections

The tongue guard shall be maintained within ¼ inch of the grinding wheel.
 SHEM-SP-08.01
General EHSS Rules

Ensure that material and equipment shall not be stored, parked or left in a manner that obstructs access to;

Fire extinguishers,
Fire / water / gas valves,
Electrical switches,
Emergency showers / eyewashes, etc.
All Storage shelves, racks, cabinets, files, etc. shall be anchored and secured to prevent tipping hazard.

Red / White barricade tape

Red / White barricade tape is used in area where, probability of death or serious injury if accident will
occur/Fire Prevention and Protection Equipment.

Black / Yellow barricade tape

Black / Yellow barricade tape is used in area where, Severity is minor or moderate injury/ physical Hazards.

Barricade Fence

Barricade fence is used in area where there are excavation jobs.

Notes:

Caution signs shall have yellow as the predominating color, black upper panel and borders, yellow lettering of
“caution” on the black panel, and the lower yellow panel for additional sign wording.

The sign words shall be in English and Arabic and shall be readable at a minimum distance of 1.50 meters or
such greater distance as warranted by the hazard.

Solvent soaked or oily rags used to clean and lubricate office machines should be thrown in special metal
containers and not in general waste paper baskets.

Weather resistant material should be used for the thread and tag.

Danger tag shall be white tag having a black square with a red oval in which “Danger” written in white

Metal waste baskets are recommended as plastic ones generate toxic vapors if they catch fire and burn.

Fire extinguishers as per the applicable area shall be provided at a maximum travel distance of 10 meters.

Always utilize a grounded (3 pin) plug and do not remove the ground pin.

Chemical samples, compressed gases & Flammable materials for office use should be stored in “Safety Cans” in
a locked and identified flammable storage cabinet.

File cabinets more than 2 drawers high should be secured from tipping by bolting to the adjacent cabinet or to
the wall. Evaluate the hazard and if tipping over can be managed by some other safe means, then bolting
requirement can be exempted. The filing cabinet drawer height is generally between 12 and 16 inches. Standard
practice should be to load the file cabinet so that it is not top heavy.

Should not extend over the sides. If the load extends 1.2 m (4 feet) or more beyond the body of the vehicle, a
red flag or cloth at least 0.2 m (12 inches) or reflective lights or other type of warning lights shall be provided at
the extreme rear end of the cargo to provide greater visibility. Traffic EHSS Rules.

Parking of vehicles within five (5) meters of the fire hydrants, in the driving lanes, or entrances/exits to parking
lots or buildings is prohibited.

The maximum permitted speed limit within shall be 30 Km/hr,

FSD (SSGS) shall ensure regular preventive maintenance after 1000kms, 1500kms and 5000kms for newly hired
vehicle and from thereafter every 10,000km run, for all other vehicles after every 10,000km run. FSD (SSGS) to
send these hired vehicles to the contracting agency for carrying out preventive maintenance.

The minimum walkway width shall be 112cms.

 SHEM-SP-08.02
Laboratory SHE Rules

Ensure Chemical Hygiene Plan (CHP) is developed and implemented in PQA Laboratory.

Provide softcopy on ECM OMS Folder for easy access to all laboratory personnel.

SDS for all the chemicals handled in the PQA laboratory are maintained for all hazardous chemicals.

Controlled areas shall be prominently marked with warning and restricted access signs.

Telephone numbers of emergency personnel/facilities to be contacted in the event of fire, accident, severe
weather, or hazardous chemical spill.

Location signs for safety showers, eyewash stations and other safety and first aid equipment.

Food and beverages storage and its consumption locations.

Warnings at areas or equipment posing special or unusual hazards.

Emergency escape routes and exits.

A hood or other local ventilation device is provided when working with any volatile substance with threshold
limit value (TLV) of less than 50 ppm.

All the exhausted air/gases from lab fume hood are not to be re-circulated.

The fume hoods space design is 0.75 meter/person.

The Air Velocities are maintained to be (400 m3/h – 1200 m3/h) as per the local standard and in absence of
this standard it should be ( 22.9 m/min-38.1 m/min) or (36.6 m/min-45.7 m/min) with at least 18 m (60 feet)
per minute for face velocity if there is any handling with carcinogens.

The Glove Boxes are maintained by monitoring the Oxygen & Moisture Conc.
content as per the following: It
ems
Oxygen < 10 ppm
Moisture < 10 ppm

The fume hoods for working with Ethylene oxide are provided with water scrubber to absorb hazardous gases.
All ventilation systems equipped with filters prior to regular exhaust duct systems. Hood air velocity is
displayed on the fume-hoods.

Flame & explosion proof fans & blowers shall be used in gloves box.
Perchloric acid is not used in PQA Laboratory. In case of using Perchloric acid in future, it will only be used
inside a specially designed acid fume hood consisting of corrosion-resistance ductwork wash down facilities.

Laboratory Information Management System (LIMS).

Chemicals used for performing analysis are transferred to small containers to minimize the spill in the area in
case of container brake or leak.

Spill control kits are provided in the laboratory

 SHEM-SP-08.03
Material Handling and Storage

SCBA:

Self-contained breathing apparatus (SCBA) that has a full face piece and is operated in a pressure-demand or
other positive-pressure mode in combination with an auxiliary self-contained positive-pressure breathing
apparatus to be available and ready for use in case of Emergency or planned entry into unknown
concentrations or IDLH conditions.

Objects over 23 Kilograms (50.7 pounds) shall be handled by two or more employees depending upon the
shape of the objects. In particular cases like PPS if employees need to handle bags of 25Kgs it is recommended
to utilize back supports", "lumbar support belts", "weight lifting belts", or "abdominal belts" to avoid back
injuries or as per the recommendations provided in Health and Safety Risk Assessment.

Flammable liquid containers installed for filling shall be electrically grounded and bonded to prevent static
electricity from causing a spark. The bond or ground or both shall be physically applied or shall be assured by
the nature of the installation.

Flammable liquid storage cabinets should not have a capacity for more than 455 liters (120 gallons) of
flammable liquids.

No more than three cabinets should be located together in a single fire area. Groups of cabinets must be
separated by no less than 30 meters.

When flammable liquids are transferred from one container to another, a means of bonding the two
containers shall be provided prior to starting the transfer.

Not more than a 1 day supply of flammable liquids in approved portable containers (or not more than 95 liters
(25 gallons), whichever is greater) may be stored in a single fire area outside of an approved flammable liquid
storage cabinet.

Acetylene cylinders shall always be stored valve end up.

Store cylinders in a dry well-ventilated area away from heat and ignition sources. Keep cylinders at least 20 ft.
from flammable materials such as paint, oil or solvents.

Cylinders should never be stored in unventilated lockers or closets.

Provide separate storage areas for the cylinders according to their contents: Flammable, oxidizing and/ or
inert gases.
Toxic gases (e.g. Carbon monoxide, hydrogen cyanide, nitric oxide, and phosgene)

Corrosive gases (e.g. ammonia, chlorine, nitrogen dioxide, nitric oxide, sulfur dioxide, etc.)

Flammable gases (e.g. acetylene, ammonia, ethylene, etc.)

Explosive (e.g. Hydrogen, etc.)

Oxidizers (e.g. Fluorine, oxygen, etc.)

Simple asphyxiates (e.g. Carbon dioxide, helium, nitrogen, sulfur hexafluoride

Why we can’t store cylinder in temperature below freezing?

A flame should never be exposed to any part of a compressed gas cylinder. Also, do not store cylinders where
temperature can drop to below freezing as this can cause the cylinder metal to become brittle resulting in
metal fatigue and failure.

Regularly inspect bottom of the cylinder and confirm that it is free from rust.

Can we use hammering for the open of valve wheels on cylinders?

Hammering on valve wheels to open them should be strictly prohibited. For valves that are hard to open,
contact the supplier for instruction.

Ordinary soap solution may contain oils that are unsafe when used with oxygen cylinders.

Use approved leak detection liquid to detect flammable gas leaks; a flame should never be used.

Consider the following points while working with cylinders:

Never roll a cylinder to move it.

Never carry a cylinder by the valve.

Never leave an open cylinder unattended.

Never leave a cylinder unsecured.

Never force improper attachments on to the wrong cylinder.

Never grease or oil the regulator, valve, or fittings of an oxygen cylinder.

Never refill a cylinder.

Never use a flame to locate gas leaks

Never attempt to mix gases in a cylinder.

Never discard pressurized cylinders in the normal trash.

Never store or expose cylinder where temperature above 54C (130F).

Never lift cylinder by their cap.

Cylinder outlet valve shall be threaded in opposite directions to prevent the interchange of fittings between
cylinders containing combustible gas and non-combustible gas. Non-combustible gases like oxygen, nitrogen,
argon and air shall have right hand threads.

Hose colors on cylinders:

Red for fuel gas
Green for oxygen
Black for inert gas and air.

When parallel lengths of oxygen and fuel gas hose are taped together for convenience and to prevent tangling,
not more than four inches per foot shall be covered in tape.
Hose connections shall be fabricated to withstand, twice the pressure to which they are normally subjected in
service, but in no case less than 300 pounds per square inch (psi).

Cylinder Flash-back protection

Use Flashback protection provided on oxy-acetylene lines by a UL approved flame arrestor to prevent burn-
back into hoses and the regulator.

Smoking and open flames shall not be permitted in storage areas or within 20 ft. (6.1m) of storage areas.
Cylinder storage areas shall be fenced off and clearly marked with “NO SMOKING” and “NO OPEN FLAME”
signs.

Oxygen cylinders shall be stored at least 6 meters away from cylinders containing combustible gases, or from
any highly combustible materials.

Chlorine and Ammonia cylinders separately at least 6 meters (19.7 feet) away from all other compressed gases
and it shall not be stored together.

Storage of multiple groups of cylinders of flammable gases, each 2500 scf (70.79 m3) or less, in one fire area
shall be permitted where the groups are separated by a minimum distance of 100 ft. (30.5 m) Exception: The
separation distance shall be permitted to be reduced to 0 ft. when separated by masonry walls with a fire
resistance rating of 2 hours.
Liquefied flammable gas cylinders shall be stored in the upright position or such that the pressure relief valve is
on the vapor space of the cylinder.

Do not use oxygen cylinders, equipment, pipelines, or apparatus interchangeably with any other gas. Tag all
oxygen regulators and used in oxygen service only.

Do not utilize acetylene at a pressure in excess of 15 pounds per square inch gauge (psig) or 30 pounds per
square inch absolute (psia).

Outlet should be wiped clean with a clean cloth free of oil and lint; also, the valve should be opened shortly and
closed immediately before connecting a regulator to a cylinder valve. This action, generally termed cracking, is
intended to clear the valve of dust or dirt that otherwise might enter the regulator.

Don’t open acetylene cylinder valve more than three-fourths of a turn. This is so that it may be closed quickly
in case of emergency.

Do not place anything on the top of cylinders when it is used that may damage or interfere with the quick
closing of the valve.
Prohibit tapping of electrodes against a cylinder for arcing.

Never use compressed gas from cylinders without reducing the pressure through a suitable regulator attached
to the cylinder valve or manifold.

Keep away for cylinders from radiators, piping systems, layout tables, etc., that may be used for grounding
electric circuits such as for arc welding machines.

To lift cylinder to high elevation use proper cage with proper lifting, never use ropes wrapped around.

Don’t place or store cylinders in areas where they may become part of an electrical circuit.

Valve shall not be opened for more than 3 full turns and it should be opened slowly. An exception being
breathing air cylinders that should be either fully opened or fully closed.

Regulators shall be used only to control pressure, not to stop flow. Likewise, manual valve shall not be used as
a substitute for a pressure regulator.

In addition to a pressure regulator, a pressure relief device (suitable to protect downstream system) shall be
installed to protect the downstream system.

Personnel shall stand to one side with the regulator pointing away from their body.

Any cylinders are being used shall be in area well ventilated.

Don’t move cylinders with regulator in place, with possible exception of breathing air cylinders mounted on
portable trolley carriers.

Following shall be considered while cylinders heavier than 20 kg are being lifted.
Cylinders shall be lifted only by using a suitable cradle platform.
Cylinders shall not be lifted using ropes, chains, or slings unless the cylinder was manufactured with lifting lugs.
Where gastight valve outlet caps or plugs are provided, the user shall keep such devices on the valve outlet at
all times except when compressed gas cylinders are being filled or connected for use.

Plan owner shall ensure all sample cylinders are tagged with (85 mm * 50 mm) metal tag contains the
following:
a) Sample cylinder number
b) Sample point
c) Sample description e.g. (Oxygen, Ethylene Oxide, Butane etc.)

All personnel handling CO shall be made aware of the exposure possibility and shall be provided with portable
CO monitors to detect a rising or high level of CO. In addition, an air mover should be provided for situations in
which CO levels are encountered or can accumulate at concentrations, as per the applicable local standards /
regulations requirements. It shall be provided above 50 ppm, to keep the work area safe throughout the work
process.

Escape:

(APF = 50) any air-purifying, full-face piece respirator (gas mask) with a chin-style, front- or back-mounted
canister providing protection against the compound of concern/any appropriate escape-type, self-contained
breathing apparatus.

Up to 350 ppm: (APF = 10) any supplied-air respirator.

Up to 875 ppm: (APF = 25) any supplied-air respirator operated in a continuous-flow mode.

Up to 1200 ppm: (APF = 50) any air-purifying, full-face piece respirator (gas mask) with a chin-style, front- or
back-mounted canister. Any self-contained breathing apparatus with a full face piece.

Fixed area CO monitoring shall be provided in all those process areas where there is a possibility of CO
concentrations of greater than 50 ppm because of continuous CO generation or accumulation.

The signs shall be clear by painted by 2” black color letter with yellow background & shall be posted at the
base of the tank near the access stairway(s). For storage tank, follow the sign. Personnel gauging shall wear
appropriate respiratory protection or inspecting the roof of Nitrogen blanketed tank, to avoid exposure to
Nitrogen.
For equipment that normally operates under a nitrogen purge just above the man ways used for entry the sign
is as follows:-

Nitrogen is called as silent killer

Adequate ventilation to ensure oxygen level of 20.8% is maintained shall be provided in the area or building
where nitrogen is being used.

Nitrogen should not be used for instrument air.

Spillage of liquid nitrogen can cause embrittlement of structural material.

Ensure any connection to the nitrogen system shall have check valves in series placed in horizontal position,
one in the branch line close to the main header and the other at the utility nitrogen station outlet.

Connectors or couplings at Nitrogen utility stations shall not be compatible with other utility connectors such
as steam, water or air.
Utility air stations should be installed with Web luck to prevent whipping / swaying of hoses in case of rupture
/ failure of hose connected to the station.

Air lines / hoses used for cleaning up shall meet the applicable local standards / regulations requirements. In
the absence of any local standards / regulations, it shall be equipped with a pressure controlling / regulating
device limiting pressure to a maximum of 29 psig. (2.04Kg/cm2). Vacuum cleaning is preferred over air
cleaning.
 Electrical Safety SHEM 08.05
Q-Pulse:
Q-Pulse is an electronic quality management system that eliminates bureaucracy, provides accountability and
streamlines business processes for regulatory compliance, safety management and risk management.
Capacitor:
A device for storing electrical energy, consisting of two conductors in close proximity and insulated from each
other
Grounding and bonding:
Bonding is the connection of non-current-carrying conductive elements like enclosures and
structures. Grounding is the attachment of bonded systems to the earth
Arc flash:
A phenomenon where a flashover of electric current leaves its intended path and travels through the air from
one conductor to another, or to ground
Static Electricity:
A stationary electric charge, typically produced by friction, which causes sparks or crackling
Continual improvement process:

1-
Identifying performance targets (KPI)
2- Gap
identification
3- Probl
em solving tools and techniques
4- Track
ing and monitoring mechanism

Effects of Electric Current on Human Body:

Level of Exposure Effects on Human body

More than 3mA Painful shock

More than 10mA Muscle contraction “no-let-go” danger

More than 30mA Lung paralysis- usually temporary

More than 50mA Possible ventricular fib. (heart dysfunction,

usually fatal)
100Ma to 4 amps Certain ventricular fibrillation, fatal

Over 4 Amperes Heart paralysis; severe burns. (Usually by >600

volts)

AIR Accident Incident Recommendations

ALARP As low as reasonably practical
DCR Design Change Request
EHSS Environment , Health, Safety and Security
Department
EJP Electrical Job Plan
EL Element Leader
EMS Environmental Management System
ERP Emergency Response Preparedness
GM General Manager
HAZTRACK HAZOP Tracking (for HAZOP items follow-
up)
HLVI High Learning Value Incident
HLVIR High Learning Value Incident
Recommendation
JQP Job Qualification Program
KPI Key Performance Indicators
LMS Learning Management System
MCC Motor Control Center
MOC Management of Change
MTC Maintenance
OMS Operations Management System
PDC Project Document Controller
PHA Process Hazard Analysis
PI Performance Indicators
Q-Pulse Quality Pulse (SHEMS Data Base)
RA Risk Assessment
RACI Responsible, Accountable, Consulted,
Informed
SAE Safe Attitude Encouragement
SCD Safety Critical Device
SEL Sub-Element Leader
SHE Safety, Health & Environment
SHEM Safety, Health & Environment
Management
 SHEMC Safety, Health & Environment
Management Committee
SHEMS Safety, Health & Environment
Management System
SHEQ Policy Safety, Health & Environment Quality
Policy
SI Electrical Manager
SMT Senior Management Team
SOC Standard Operation Committee

Note:
-All capacitors in electrical power circuits shall be discharged and short circuited before performing any
maintenance or handling.
-Work on energized circuits shall not be performed except when de-energizing creates a greater hazard or
except when the voltage does not exceed 50 VAC between phases or between phase and earth or 120 VDC
between poles.
-SABIC Assurance for EHSS Risks (SAFER)
-Ladders used while working on electrical circuits shall be made of non-conductive material
-All live parts of electrical equipment operating where the voltage exceeds 50V AC between phases or between
phase and earth or 120V DC between poles shall be guarded against accidental contact.
-For lines rated 50 kilovolt (kV) or below, the minimum clearance between the lines and any part of the crane
or load shall be 3 meters.
-In transit with no load and boom lowered crane, the equipment clearance shall be a minimum of 1.2 meters
for voltages less than 50 kilovolt (kV), 3 meters for voltages over 50 kilovolt (kV) up to and including 345
kilovolt (kV) and 4.8 meter for voltage up to and including 750 kilovolt (kV).
-Original Equipment Manufacturer (OEM)