Abdullah A.

Al-Barrak & Sons Company OHSAS 18001:2007

Rev. No. 00
11 Sept -2019
Contractor EHSS Plan Page 1 of 44
Doc. No. OHS&E/P-04

Fabrication and Installation of 6” Piping

For

Petrokemya ABS Plant

PR# 76000988

Rev. Date Prepared by Reviewed by Approved By

No

Asfaque Ahmed Qasir Iqbal Shahid Munir

HSE Supervisor HSE Incharge HSE Manager
01 06 April 2020

PETROKEMYA Date Reviewed by Approved By

1
 Table of Contents

Sr. No Description Page

No.
1.0 Scope of work 04
2.0 Introduction 05
3.0 Purpose 05
4.0 Objective 06
5.0 Safety Goal 05
6.0 Statement of Declaration 06
7.0 Occupational Health & Safety Responsibilities 07-09
8.0 Safety & Health Training 09
9.0 Job Skill Trainings 10
10.0 Safety Orientation 10
11.0 List of jobs require Petrokemya Certifications 10
12.0 Behavior Observations 10-11
13.0 Safety Meetings 11
14.0 Near Miss Reporting 11
15.0 Injury Reporting 11-12
16.0 Emergency Reporting 12
17.0 Incident Reporting & Investigation 12-13
18.0 Safety Inspections 13
19.0 Safety Reports & Records 13
20.0 Camp Standards 14
21.0 General Safety Rules 14-15
22.0 Medical Care 15-16
23.0 Food & Water Safety 16
24.0 Traffic and Vehicle Safety 16-18
25.0 Personal Protective Equipment 18-22
26.0 Petrokemya Plant Operations 22
27.0 Security Procedures 22
28.0 Ladders 23-25
29.0 Fire Prevention 25-27
30.0 Materials Handling 27
31.0 Manual Handling 27-28
32.0 Working with electrical equipment 29-30
33.0 Hand Tools 30-30
34.0 Hydrogen Sulphide Hazards & Precautions 31
35.0 Work Permits 32-33
36.0 Use of Mechanical and Heavy equipment 33-34
37.0 Working on scaffold 34
38.0 Fall protection 35
39.0 Blinding 36
40.0 HOT work (cutting, grinding & welding) 37

2
41.0 Works inside confined space 38-39
42.0 Hazardous Materials 40
43.0 Identification and labeling of hazardous materials 41
44.0 Crane operation 41-42
45.0 Housekeeping 43
46.0 Waste Management 43
47.0 Demobilization Plan 44

1.0 Scope of Work

3
ABIS will perform all the Mechanical work and Pipe Replacement activity as per the inspection
report.
ABIS shall provide necessary personnel, equipment, supervision and transportation to perform
the activities in Petrokemya Plant.

2.0 Introduction

4
ABIS has developed this Site Safety Program to demonstrate its familiarity and knowledge of
safety, health & environmental regulations including (Petrokemya) Safety Standards.

ABIS believes in the dignity and importance of the individual employee and his right to expect
that he will be provided with a safe workplace.

ABIS shall provide sufficient resources i.e. tools, equipment, welfare facilities to employees to
work safely and efficiently.

This Site Safety Program is applicable to Mechanical works/Line replacement/Hydro

testing crew, materials in (Petrokemya).

3.0 Purpose

The purpose of this plan is to set the requirement and expectation for conducting the
Mechanical and Line replacement work in a manner that assures the HSSE of all employees and
protect the environment and equipment.

4.0 Objective

 To manage all T/A safely and Successfully

 Plan /Schedule activities in advance to avoid any delay
 Arrange adequate resources to manage the line replacement job
 Prepare presence to meet the Petrokemya requirements

5.0 Safety Goal

 Zero recordable injuries

 Zero Fire
 Zero Property Damage
 Safe Shutdown

6.0 Statement of Declaration

5
This is to declare that all ABIS employees are authorized to stop any unsafe work carried out by
any ABIS employees or sub-contractor employees hired by ABIS.
Unsafe work may include any activity during course of construction, maintenance or repair
work, which has the potential to cause harm to employees themselves, fellow beings or public.
It may include the damage to equipment, plant, machinery or infrastructure.

7.0 Occupational Health & Safety Responsibilities

6
OHS responsibilities & accountabilities lie with each & every person working on the project from
Site In charge to the worker. All employees are equally responsible for creating a workplace
free of recognizable hazards.

Here below are the OHS responsibilities listed with the designation.

Site In charge

 Ensure corporate OHS policies and procedures are communicated to all

employees working on the project.
 Aware of the requirements of Safety Manual of Petrokemya and relevant
part of Saudi Labor law and ensure that they are complied with.
 Coordinate safety activities with Petrokemya.
 Ensure the preparation & implementation of Site Safety Program &
Hazard Identification Plan.
 Closely monitor job site condition for compliance with all Petrokemya
safety codes and regulations.
 Include safety as a first agenda topic in all project coordination meetings.
 Monitor project accident rate and costs. Discuss with Site HSE In charge
to implement corrective action if necessary.
 Ensure that all employees prior to mobilization to worksite receive ABIS
safety orientation and safety orientation from Petrokemya.
 Ensure all accident investigation is conducted in timely manner.
 Enforce disciplinary action procedure for violation of safety rules.
 Reports all type of incidents to Petrokemya Plant Representative
immediately after occurrence.
 Ensure that adequate welfare facilities i.e. ablution blocks, rest shelter,
mess hall, prayer hall are available to employees working on the project.
 Ensure that proper work method statements are available and being
followed during the course of work.
 Make sure that all safety issues/ concerns reported by the site safety
officer are corrected in timely manner.
 Provide personal protective equipment to all employees working on the
project.

Safety Officer

 Advise site management on injury/ damage prevention at project site.

 Ensure provision of flame retardant clothing to all employees.
 Ensure that tools & equipment to be used on the project are inspected by
Petrokemya Plant Equipment Inspection department.
 Take part in incident investigation and determine the root cause of the
same and recommend means of preventing recurrence of such incident.

7
  Record and analyze all information on injuries, damage, loss of property
etc.
 Participate in Management Safety Walkthrough; prepare the report of the
same and distribute copies to all concerned.
 Shall be aware of Sabic EHSS requirements; provide guidance to Site
Management on Petrokemya Safety Requirements.
 Coordinate with Petrokemya for safety orientation of their employees.
 Submit Monthly Safety Statistics Report to Petrokemya.
 Impart trainings to ABIS employees about emergency assembly area and
emergency response plan of their work area.
 Carry out hazard identification and develop appropriate measures to
mitigate hazards and safeguard employees prior to start of work.
 Support project team with knowledge of all applicable safety regulations
of Petrokemya.
 Conduct safety orientation of employees prior to mobilization to worksite.
 Ensure daily toolbox talks are conducted in each work area by job
supervisor prior to start of work. Daily toolbox talks record to be
submitted to Petrokemya Plant.
 Conduct daily job site inspection and in case of any unsafe act/ unsafe
condition found, he is authorized to stop unsafe work. Work can be
resumed only once the correction action has been taken and
discrepancies are rectified.

Site Engineer & Supervisor

 Ensure that safety is integrated to the work plan prior to starting any
work activity.
 Shall provide leadership & guidance and maintain communication,
cooperation and teamwork of their assigned employees.
 Ensure proper personnel protective equipment is provided and worn by
employees as necessary.
 Ensure that tools & equipment are checked before use and are industrial
standard, free from all defects.
 Conduct daily toolbox talk for their crew members before start of work.
 Inspect work area on daily basis and take necessary action to maintain a
safe working environment.
 Report all near misses, accidents to the Site In charge and Site HSE In
charge immediately.

Worker’s Responsibilities

 Use right tools for the job. Carryout daily inspection of tools before start
of work. Only use certified and inspected tools.
 Report any unsafe condition to immediate supervisor.
 Report all type of incidents to immediate supervisor.
 Participate in daily toolbox talk.

8
  Follow the safety sign boards and comply with Petrokemya Plant safety
requirements.
 Do not interfere with Plant operations or safety equipment installed at
the plant.
 Never indulge in horse play.

8.0 Safety and Health Trainings

 Supervisors will initially trained employees on how to perform assigned job/

tasks safely.
 Supervisors will give employees verbal instructions and specific directions on
how to do the work safely.
 Supervisors will observe employees performing the work. If necessary, the
supervisor will provide a demonstration using safe work practices.

Safety Training Matrix

Sr. Safety Trainings Attended By Duration Schedule Remarks

No
1. All employees Once upon
Safety Orientation 2 hrs.
joining
2. Specific Orientation (on All employees On job To be given by
2 hrs.
job) assignment Petrokemya
3. Permit to Work System All employee To be given by
1 day Once
Training Petrokemya.
4. Daily Toolbox Talk by All employees
10 min Daily
Line Supervisor
Weekly Safety Talks All employees
5. either by Site HSE
15 min Weekly
Personnel or Area In-
charges
6. Safe use of hand tools All employees 1/2 day Monthly
Use of personal All employees
7. 1/2 day Monthly
protective equipment
8. Personal Hygiene All employees 1/2 day Monthly
9. Safe use of equipment All employees 1/2 day Monthly
10. Safe Driving All employees 1/2 day Monthly
11. Safe Lifting method All employees 1/2 day Monthly
Emergency response to All employees
12. 1/2 day Monthly
fires and accidents
13. First aid and CPR All employees 1/2 day Monthly
Employee safety All employees
14. Monthly
suggestion program 1/2 day
15. Driver safety program All employees 1/2 day Monthly

9
9.0 Jobs-Skill Trainings

Sr. No Craft Training Required

1.0 First Aider Third Party
2.0 Permit Receiver Petrokemya

10.0 Safety Orientation

All ABIS employees shall receive safety orientation from Petrokemya before they start work at
the process areas.

11.0 List of Jobs require Petrokemya certification

Sr. No Jobs Remarks

1. Work Permit Receivers As per Petrokemya training Matrix
2. First Aider Third Party

12.0 Behavior Observations

ABIS shall constantly observe the behaviors of its employees during the course of project. It
should take appropriate measures to correct unsafe behavior if demonstrated by any individual.
In case employees violating ABIS safety procedures/ norms or Petrokemya safety procedures
are breached, company shall take stern disciplinary action to avoid recurrence of the same.

ABIS should also appreciate safe behaviors of employees and should encourage the same with
some appreciation programs. ABIS shall also run certain behavior-based safety programs to
promote positive safety culture among employees.

Every employee working with ABIS is obliged to work safely and if he is working on any job or
any location with all safety requirement and compliances with the rule and regulation of the
company, he shall be rewarded and appreciated by the company for his performance.
The criterion for evaluation of the personnel including supervisor, foreman, and craft personal
performing their job with strict compliance to safety is through regular safety audits and
observations.

Each employee is responsible for their own safety. Managers are responsible for supervisors,
Supervisors are responsible for foreman, and foremen are responsible for each crew member
including equipment operators.

10
On a given day, anyone can write up anyone if there is evidence of a safety violation. If
coworkers are not following proper procedures, disciplinary action shall be taken as per
company disciplinary action procedures.

13.0 Safety Meetings

ABIS site supervisory staff shall ensure to conduct daily toolbox talk with the workers before the
start of work. Job specific safety hazards and their precautions shall be discussed with the
employees. Such toolbox talks should not be less than 15 minutes and should cover work
hazards and related precautions, hazard identification plan etc.

ABIS site supervision and safety staff should conduct weekly meeting discussing the site safety
issues with corrective action plan to address those issues. Such meetings should be on regular
basis and should be documented/ recorded. Site Management shall attend and participate in
weekly meetings without fail.

ABIS site management should attend meeting with Petrokemya Plant personnel as requested by
them. Such meetings include safety coordination meetings, safe operation meetings or safety
committee meetings etc.

14.0 Near Miss Reporting

ABIS shall immediately inform Petrokemya Plant about near miss/ dangerous occurrence,
occurring during the course of work activities.

ABIS shall participate in the investigation and resolution of near misses as directed by
Petrokemya Plant.

In order to promote near miss reporting culture, ABIS shall initiate “Best Near Miss Reported
Award” on monthly basis.

ABIS shall ensure that near misses with high potential of damage should be investigated and
lesson learned should be shared with the employees to avoid reoccurrence of the same in
future.

15.0 Injury Reporting

ABIS shall report all on job injuries or occupational illnesses immediately to Petrokemya Plant
through Incident/ Injury Report Form.

In case any employee is injured on job, the witness employee should immediately call for
medical help. The injured person should be taken to onsite medical facility for initial treatment.

11
ABIS shall participate in incident/ accident investigation as requested by Petrokemya Plant.

16.0 Emergency Reporting

Workplace emergency can pose a serious threat to the safety of employees at work, the
environment and property. Emergency situation can be brought under control using the
resources and emergency response procedures.

All ABIS employees shall report any kind of emergency by calling on Emergency number of
Petrokemya

When calling emergency number, reporter should provide the following below information:

1. Exact location
2. Nature of emergency (fire, explosion or gas release)
3. Type of service required
4. Number of injured person
5. Reporter name and badge number

Actions to be taken during Emergencies:

Upon hearing an emergency alarm, workers should:

 Stop all work immediately

 Safely shutdown all equipment
 Evacuate to the predetermined assembly point

Job supervisor shall:

 stop all work immediately

 safely shutdown all equipment
 evacuate all personnel to predetermined assembly point
 Conduct a roll call or head count to account for every person. In the event a person is
missing, his name and last known location shall be communicated to the incident
commander immediately.
 Prevent personnel from returning to work until notification has been received from
Petrokemya Plant.

17.0 Incident Reporting & Investigation

ABIS employees deployed on the project shall immediately report to their supervisor about any
incident occur on the worksite during work.

Incident reporting include job related fatalities, all on job injuries and occupational illnesses,
damage to property or equipment, all fires and explosions, oil spill leaks and gas leaks and all
near misses.

12
In case of any incident, the job supervisor has following responsibilities:

 Submit all on job incident reports to Petrokemya Plant

 Provide assistance in incident investigation

ABIS shall do its own incident investigation to find out root cause of the incident and corrective
action plan to avoid recurrence of such incidents in future.

18.0 Safety Inspections

Site Management and safety officer shall carryout daily job site inspection which include;

 Monitor work activities; inspect facilities to ensure that the Petrokemya

Plant safety requirements are being complied with.
 Identified hazards are adequately addressed by established procedures
and ensure that safe work procedures are developed to deal with them.
 Report both positive & negative findings of inspection promptly in writing
and ensure follow up actions.

Safety officer in the course of inspection shall make use of suitable inspection checklist to
record the findings.

A weekly documented site inspection shall be conducted, and weekly inspection checklist shall
be used and implemented.

ABIS shall participate in the Quarterly Safety Inspections (QSIs) as conducted by

Petrokemya Plant. ABIS shall take appropriate actions to close the inspection observations as
identified during safety inspection.

19.0 Safety Reports & Records

Safety officer need to maintain proper record of all safety trainings, safety inspections,
equipment and tools inspections, toolbox talks, incident reports etc. All above records to be
presented to Petrokemya upon their request. ABIS shall be using below formats for record
keeping.

 Safety Talk Record

 Monthly Safety Statistics Report
 Incident Notification Report
 On-Job Injury Investigation Report

Safety officer need to submit daily toolbox talk record to Petrokemya. Also monthly safety
statistics report shall be submitted to Petrokemya on monthly basis.

13
20.0 Camp Standards

ABIS shall be providing good and hygienic camp facilities to its employees as per Petrokemya
standard. Camps shall be provided with fire alarm system as well.

 Camps shall be provided with portable water supply system.

 Maintenance crew should be available 24/7 to look after the
camps.
 Camps design, structure and buildings shall meet Petrokemya
standard.
 ABIS shall inspect, operate, manage and maintain
accommodation camps so as to ensure good standards of living
with proper facility maintenance, hygienic standards, fire and life
safety, pest control and food safety as per Petrokemya
standard.
 Camps should be fully air conditioned and periodically
maintained.
 Fully equipped kitchen and mess hall shall be provided with
tables, chairs, utensils and cutlery.
 Camp residents shall be provided with three meals/ day.
 Cooking in camps shall be strictly prohibited.
 Camp building should be equipped with portable fire
extinguishers.
 Electrical items to be used inside camp should be UL listed.
 Camp facility should be provided with adequate lighting for all
streets, parking areas, walkway, buildings and outdoor facilities.

21.0 General Safety Rules

No employee shall work in surroundings or under working conditions that are dangerous to
health and safety. Employees shall be physically & mentally fit and have proper attitude and
should be qualified, trained and experienced.

All ABIS employees shall attend Safety orientation from Petrokemya before entering in the
plant.

Instructions to employees:

 Personal protective equipment is mandatory for all employees at all

worksites.
 Full body harness with double lanyard shall be worn while working above
1.8m height.
 No work activity should be carried out without valid work permit from
Petrokemya.

14
  Employees shall report all occupational injuries, accidents, near misses
immediately to their supervisor for appropriate preventive measures.
 Horse play is strictly prohibited.
 Smoking is permitted only in the designated smoking areas.
 Safety devices and safety guards of any equipment shall never be
removed.
 Employees shall not interfere with safety equipment, plant installations
etc.
 Drivers shall follow driving safety rules.
 Parking of vehicle is permitted only at the designated parking area. All
site employees shall be familiar with emergency assembly point and
emergency response procedure.
 All employees shall attend daily toolbox talk meeting in their work area
prior to start the job.

22.0 Medical Care

ABIS shall be providing adequate medical care to its employees as per Ministry of Health
Guidelines and Saudi Arabian Labor Law. Medical care includes provision of first aid, emergency
care, hospitalization of sick/ inured employees and emergency and disaster response.

First Aid Arrangements: ABIS shall be providing 10 first aid kits on work site to provide first
aid treatment to employees in case anyone is injured on job. If 50 or more employees are
working at site, 3 first aid kits shall be provided.

In case working crews are working 300 meter apart, a separate first aid kit shall be provided for
each group of worker. ABIS shall be deploying certified first aid attendants to be responsible for
each first aid kit and to ensure sufficient stock of all supplies all the time.

 First aid supplies shall always be kept readily available in first aid kits
and stored in sanitary condition .
 ABIS shall provide appropriate number trained first aider on work
site.
 Medical logbook shall be maintained at each first aid station by the
first aider who shall log all injuries/ illnesses treated.

Onsite Medical Clinic: Initially ABIS shall be deploying around 25 employees

on this project. In case ABIS has to increase manpower beyond 50 employees,
ABIS shall set up its own medical clinic at site to furnish medical treatment to its
employees who are injured on job or illness cases. Worksite medical facility shall
be fully established and in operation before work begins and shall:

 Have the capability to provide first aid, urgent care, pre-hospital and
resuscitation care, stabilization and prompt transfer to nearest
hospital.

15
  Have an emergency response plan detailing the response
capabilities.

ABIS shall appoint a qualified male nurse to look after the medical facility which should be
licensed from Saudi Arabian Government MOH and shall possess the necessary experience,
training, qualifications and required certifications.

In case ABIS deploy more than 50 employees on the project, ABIS shall provide a dedicated
ambulance at work site medical facility to transport injured/ ill personnel to the nearest hospital.
Ambulance shall comply the requirement of Ministry of Health MOH and that of Petrokemya.

Ambulance shall be kept in safe, clean, sanitary and maintained conditions. Ambulance driver
should be first aid/ BLS certified and possess valid driving license from Saudi Arabian
Government.

If any injury requires further medical treatment; the injured person shall be transferred to local
hospital in Petrokemya. ABIS employees are insured by GOSI and Medical Insurance from
Tawunyia as well.

In all injury or incident/ accident cases, ABIS shall inform to Petrokemya immediately as per
Petrokemya Injury/ Damage Reporting procedure.

23.0 Food & Water Safety

ABIS employees are residing in a camp located near Jubail Petrokemya Plant. All ABIS
employees are provided with fresh food for breakfast and dinner which is cooked in the camp.
For lunch; fresh cooked food is transported to Petrokemya with food van which is equipped with
air conditioner to keep the food fresh.

ABIS is supplying potable drinking water to its employees in the camp as well as on worksite. A
dedicated vehicle is appointed to transport water to worksite. ABIS has established drinking
water stations in work areas where water cooler with potable water is placed and empty coolers
are collected. Water coolers are washed and sanitized on daily basis and sealed with masking
tape and date is marked on it. ABIS shall carry out periodic water testing and food testing to
ensure food safety standards is met.
ABIS has set up mess hall in its temporary facilities where employees take their lunch during
the lunch time.

24.0 Traffic & Vehicle Safety

ABIS shall ensure that drivers deployed on this project are competent, skilled and experienced
for the assigned job. They should undergo Defensive Driving Training as conducted by ABIS
HSE Department before they start working on the project. They should also possess valid SAG
license as required by the Traffic Police Department.

16
Drivers are responsible for the overall safety of their vehicles and passengers. Drivers shall
abide by all traffic laws while they are working at the plant areas or outside plant premises.
They should ensure that their vehicles are inspected and maintained properly.

ABIS expect that its drivers shall observe defensive driving behaviors at all times. All drivers
shall behave courteously at all times to other drivers and pedestrians.

Following below are the minimum requirements to be followed by the drivers while they are
behind the wheel.

 Driver shall hold a valid driving license at all times before operating any motor vehicle.
 Driver must undergo defensive driving training as conducted by ABIS HSE department.
 Vehicles shall be maintained in a safe operating condition and any unsafe condition shall
be corrected or reported immediately.
 Driver should follow the preventive maintenance plan as endorsed by ABIS transport
department.
 Drivers shall check vehicles daily for serviceability of such basic equipment as tires,
brakes, lights, fluid levels, glass, and mirrors. Deficiencies should be corrected
immediately. Before each trip a 360 degree walk around inspection is recommended
before getting into the vehicle.
 All occupants should wear seatbelts. Driver should insist that all passengers should wear
seat belts before starting the vehicle.
 Vehicle shall not be left unattended while engine is running.
 Vehicles shall not be operated in restricted areas unless appropriate work permits are
authorized for such purposes.
 Vehicles shall not be fueled with the engine running or while using any electrical device.
 Drivers shall never exceed the Saudi Arabian Government or Petrokemya posted
maximum speed limits. Unless otherwise posted, the speed limit on Petrokemya facilities
is 25 kph.
 Passenger shall be carried only in the passenger compartment of the vehicle. Driver
shall not carry passengers in open vehicles.
 Driver must obey the direction of flow, driving on the wrong side of a divided highway is
prohibited.
 Drivers must bring vehicles to a completed stop at stop signs and red traffic lights
before proceeding again.
 Drivers must yield the right of way to pedestrians crossing the street in a marked cross
walk or intersection.
 Drivers must use turn signals when changing lanes and turning.
 Driver must use vehicle headlights, not parking lights or running lights, during nighttime.
 Tailgating or following another vehicle too closely is prohibited.
 Heavy items (tools, water cans, and spare tire) in any vehicle must be properly secured.

17
  Materials shall not extend over the side of a truck; loads extending beyond the front or
rear of the vehicle must be marked with a red flag in the daytime and red light at night.
 All loads on delivery trucks shall be secured. Stake bed trucks shall have all side panels
installed while moving.
 Tires shall be inflated to the correct pressure. Tires should be routinely checked for
correct inflation pressure during each refueling or when otherwise indicated. Tires which
have exposed tread wear indicators, breaks or cracks in the casing or have fabric
showing, shall be replaced and not be used.
 Company employees are prohibited from using mobile phones, even in the hands-free
mode while driving.

25.0 Personal Protective Equipment

Personal protective equipment is considered as last line of defense against job hazards and
risks. When a hazardous situation is recognized, steps shall be taken to mitigate the risks
associated with exposure to hazard by first evaluating whether or not the hazard can be
eliminated. If this proves infeasible, then hierarchy of controls i.e. engineering or administrative
controls shall be used. If engineering and administrative controls don’t adequately mitigate the
hazard, personal protective equipment shall be used.

ABIS employees shall use hard hats, safety glasses, safety shoes and fire-resistant clothing as
minimum requirement at worksite. Additional PPEs shall be selected and used based upon the
results of a documented risk-based PPE needs analysis which shall consider the exposure
hazards, materials handled, and activities performed by workers.

Job supervisor shall ensure that their crew members are trained in inspection, use, maintenance
and storage of PPEs. General PPE requirements are listed below.

 PPEs shall meet applicable ANSI requirements.

 Proper PPE shall be provided to employees.
 PPE shall be visually inspected by the user before each use. Defective or
damaged PPE shall not be used and shall be immediately replaced.
 Clothing shall be free of holes, excessive wear and other defects. Only
proper work clothing shall be worn by personnel performing maintenance
work.

Head Protection

18
Employees shall wear standard hard hats in designated work areas where there are overhead
objects or activities can result in falling or flying objects or when performing activities that have
potential electric shock or burn hazards to the head. Hard hats shall meet ANSI Z89.1 type 1
class E requirements and shall consist of a shell, suspension, cradle and a chin strap.

 Hard hat suspension cradles shall be properly adjusted. There

shall be a minimum 1.5 inches clearance between the top of the
cradle and inside of the hard hat shell.
 Hard hats shall bear identification on the inside of the shell stating
the name of the manufacturer, ANSI Z 89.1 compliance, date of
manufacturer and class of the hard hat.
 When earmuffs, welder’s shields or face shields are required they
should be compatible with the hard hat used.
 Metallic hard hats shall not be used.

Eye & Face Protection

Eye and face protection devices shall meet ANSI Z.87.1 requirements. Below are the minimum
safety requirements for eye and face protection.

 Standard safety glasses with side shields shall be worn as needed

to protect workers eyes from flying particles, chemicals.
 Safety face shield shall be worn over safety glasses while doing
welding, cutting, grinding work. This is called double eye
protection.
 Employees working with hazardous liquids shall wear splash proof
goggles with rubber seals that fit flush against the face including
with a face shield if required.
 Personnel performing welding operations shall wear standard
welder helmet with proper lens shade. Torch welders, cutters and
brazers shall wear special shaded goggles.

Hand Protection

Gloves shall be selected and worn based on the material or equipment being handled. Gloves
shall be resistant to hazards specific to the job i.e. hot surfaces, corrosive or toxic chemicals,
abrasion, sharp edges, high voltage/ electrical and cold surfaces. The most common types of
protective work gloves are listed below.

19
Disposable Gloves: Disposable gloves usually made of lightweight plastic can help guard
against mild irritants.

Fabric Gloves: Cotton or fabric blends are generally used to improve grip when handling
slippery objects. They also help insulate hand from mild heat or cold.

Leather Gloves: These gloves are used to guard against injuries from sparks or scrapping
against rough surfaces.

Chemical Resistant Gloves: These gloves are made of rubber, neoprene, polyvinyl alcohol,
vinyl etc. These gloves protect hands from corrosives, oils and solvents.

Gloves shall be of proper size to ensure proper grip. Gloves shall not be worn near moving
machinery/ rotating equipment or when they could present a safety hazard.

Foot Protection

ABIS employees shall use footwear complying ASTM F2413 standard. Safety footwear shall be
selected and used based on the need for oil, abrasion, chemical, impact resistance, heat
protection and comfort.

 Safety footwear shall fit properly and shall be worn to cover the entire
foot including the heel.
 Safety footwear shall have leather uppers and leather composition with
steel or non-metallic composite toecaps. Soles and heels shall be of the
non-slip type. When working in water or wet areas requiring waterproof
footwear, rubber safety shoes shall be used instead.
 Nonconductive safety shoes shall be worn by anyone working on
electrical equipment. Safety shoes shall not be used when working on
electrical equipment if the shoe becomes wet, the rubber sole is worn
through or metal particles become embedded in the shoe sole or heel.

Hearing Protection

ABIS employees shall use hearing protection on the project site where high noise is observed
85 dB or higher. Generally ear plugs are used for hearing protection. Earmuffs should be used
over the ear plugs if hearing protection with ear plugs seems inadequate. This is called double
hearing protection. Plain cotton ear plugs shall not be used for hearing protection. Disposable
ear plugs shall be discarded at the end of each shift.

20
Body Protection

ABIS shall ensure the provision of adequate body protection to its employees to protect them
against hazards such as flash fire, electrical arc flash, grit blasting, welding and handling of
hazardous material. This protection may include flame resistant clothing. FRC shall be provided
to and worn by ABIS employees in the work locations where fire hazard exists.

Fall Protection

ABIS employees shall wear full body harness meeting ANSI Z359.1 Standard while working
above 1.8 m height. Personal fall arrest system shall include a full body harness, shock
absorbing lanyard or self-retracting lifeline.

Suspension trauma safety straps (foot stirrups) shall be provided with each full body harness.
Fall arrest equipment shall limit the maximum arresting force on the user body to 1800 lbs. Full
body harness shall safely support 2268 kg dead weight (minimum breaking strength).
Employees shall be trained on proper use of full body harness and ensuring 100% tie off all the
time.

Respiratory Protection Equipment

Respiratory Protective Equipment shall be provided and used by personnel exposed to air
containments exceeding the permissible exposure limit PEL. It should be meet ANSI Z88.2
requirements. In case, self-contained breathing apparatus is used, it should be positive pressure
type. Breathing air compressors shall be operated and maintained as per Petrokemya standard.

Breathing air quality shall meet Grade D requirements and shall be supplied via SCBA, airline
cascade system.

 An atmosphere supplying respirator shall be used when an

unknown or oxygen deficient atmosphere could exist or in the
presence of toxic hazards where a cartridge filters is inadequate.
 Personnel shall perform a face seal fit check to ensure a proper
seal prior to every use.
 Respiratory protection equipment shall be inspected by the user
before and after each use.
 Respiratory protection equipment shall be cleaned and sanitized
after use.
 Respiratory protection equipment shall be stored in a manner to
protect from physical damage, dust, sunlight, heat or damaging
chemicals.

21
The following PPE’s standard shall be used by ABIS during the project.

Sr. No PPE’s Type Brand Standard

1. Safety Helmet Crystal ANSI Z89.1

2. Safety Goggles Crystal ANSI Z87.1

3. Ear Muff/ Ear Plugs 3M 1110 ANSI S3.19-1974

4. Safety Shoes SLIC (Saudi Leather) ASTM 2413

5. FRC coverall Norman EN 11612 / NFPA

2113 / NFPA 2112
6. Safety Harness with Lanyard Vaultex EN361:2002/ANSI
Z359.1:1992
7. Leather Gloves Panther EN388:2003

8. Face Shield Honey Well Z87.1

9. Welding Face Shield CSA Z94.3:15

10. Half Face respirator with Cartridge 3M 6003 Cartridges

Use for (SO2,HCL,
Cl2, ClO2, HF, H2S,
NH3, CH3NH2, CH2O
11. Dust Mask 3M N-95 , 8210

26.0 Petrokemya Plant Operations

ABIS will make sure that its employees shall not interfere in Petrokemya Plant operations,
opening or closing of valves, electrical switches or any other electrical, mechanical or safety
equipment.

Any ABIS employee found indulged in interfering with Petrokemya Plant operations is subjected
to stern disciplinary action.

27.0 Security Procedures

ABIS shall ensure that its employees entering in the Petrokemya plant shall not carry mobile
phones, cigarette lighters, any kind of weapons, ammunition, camera, knives etc. Any ABIS
employee violating any security procedure is subject to disciplinary action as per ABIS
Disciplinary action procedure.

22
ABIS employees intend to enter inside the plant shall possess Petrokemya plant ID. The use of
Petrokemya plant ID by any other employee is considered as forgery and subject to stern
disciplinary action as per ABIS disciplinary action procedure.

ABIS employees shall fall in line while entering inside the plant or leaving the plant after
finishing the work/ end of shift.

ABIS employees shall not interfere with plant operation/ equipment inside the plant. They
should park their cars in the designated parking area. Parking of the cars should not obstruct
any safety equipment/ firefighting equipment etc.

All ABIS employees shall follow Petrokemya plant security rules all the times.

28.0 Ladders

ABIS shall provide Petrokemya approved ladders (metal type) for ingress to and egress from
workplaces where other means of ingress and egress are not available.

Every job supervisor is responsible for ensuring that every worker under his supervision has a
safe working place and safe means of ingress and egress. Where work cannot be done safely
from ground, scaffold platform or ladders shall be provided.

A ladder shall be of proper length for the job to be done. It shall rise to a height of 36 inches
above the landing place or above the highest rung to be reached. Metal ladders, ladders with
metal reinforced side rails shall not be used near electrical equipment.

Ladders with split side rails, missing, broken, loose, damage rungs or cleats shall not be used.
Ladders shall not be supported on their rungs or cleats. Rungs or cleats shall not be used to
support planks. Ladders shall be set at an angle of 75 degrees to horizontal grounds 4:1 slope.

 Splicing or lashing of ladders together shall not be permitted.

 One person should ascend or descend ladder at a time.
 Men ascending or descending ladders shall not carry tools/ materials in
their hands.
 Men working on or from a ladder shall always maintain 3 point contact all
the time.

Portable ladders and step ladders shall meet applicable ANSI or European standards including
proper labeling and marking. Portable ladders shall be rated to support at least four times the
maximum intended load.

 Portable ladders and step ladders shall be maintained in good condition

at all times. Joint shall be tight, rungs, hardware and fittings shall be
securely attached. Movable parts shall operate freely without binding or
excessive looseness.

23
 Portable ladders and stepladders shall be inspected before each use.
Damaged or weakened ladders shall be immediately removed from
worksite. Examples of unacceptable damage include i.e. split or broken
side rails, missing or damaged rungs, bent or missing hinges, any other
damage that hinders safe use of the ladder.
 Aluminum portable ladders and stepladders shall not be painted.
 Side rails shall have smooth surfaces (without silvers) with no projections.
 Rungs of portable metal ladders shall be corrugated, knurled, dimpled,
coated with skid resistant material or otherwise treated to minimize the
possibility of slipping. Ladders shall be maintained free of oil, grease or
other potential slipping hazard.
 Ladders shall extend at least 1 m above the landing surface to which the
ladder is used to gain access.
 Basis of ladders shall be equally supported on firm level surface. Boxes,
blocks, barrels and temporary work platforms shall not be used as a
means of support.
 Ladders shall not be used on slippery surfaces unless secured or provided
with slip resistant feet. Slip resistant feet shall not be used as a substitute
for care in positioning, securing of holding a ladder that is used on
slippery surfaces when unavoidable.
 Bottom rungs of ladders shall not be more than 30 cm (1 ft) above the
lower level used to mount the ladder. The area at the base of a ladder
shall be kept clear.
 Ladders shall not be used in horizontal position as platforms, walkways or
scaffolds.
 Ladders shall not be supported on their rungs. Rungs shall not be used to
support scaffold planks.
 Metal ladders or ladders with metal reinforced or conductive side rails
shall not be used near electrical equipment. Portable metal ladders shall
not be used near electrical equipment.
 Aluminum ladders shall not be used where there is a likelihood of contact
with materials that chemically react with aluminum such as caustic
liquids, damp lime, wet cement or acids.
 Ladder sections shall not be spliced, lashed, tied or fastened together to
provide longer sections.
 Personnel shall ensure that their shoes and the ladder are free from
grease, oil, mud before climbing a ladder.
 Only one person shall be on a portable ladder or step ladder at a time.
 If work is performed while standing on a ladder and the individual is
more than 1.8m (6ft) above the ground/ lower surface, a properly
anchored personal fall arrest system shall be used.

24
  If the work is more than 1.8 m (6ft) above the ground/ lower surface and
is long term in nature or requires heavy physical exertion, other methods
such as a scaffold or personnel lift shall be used instead of a ladder.
 The user of a ladder shall not overextend his body past the ladder side
rails.
 Ladders shall not be moved, shifted or extended while personnel are on
the ladder.
 Ladder use shall be restricted to the purpose for which the ladder is
designed.
 Ladders shall not be loaded beyond the maximum intended load for
which they were built, nor beyond the manufacturer rated capacity.

Stepladders

 Stepladders shall have folding cross-braces (spreaders) that are hinged.

Both sections shall be fully opened with hinged braces flat & taut before
use to ensure stability.
 Stepladders shall be positioned with the steps pointing towards the work
location.
 Personnel shall not stand on step ladder top platform, top stem, pail shelf
or braces.
 The rear section of stepladders (cross bracing on the back section) shall
not be used for climbing or standing unless the stepladder is designed
and provided with proper steps for climbing on both front and rear
sections.
 A step ladder shall not be left unattended with tools or materials stored
on it.
 A stepladder shall not be used to gain access to a roof or other elevated
surface.
 Stepladder shall only be used when equally supported by four legs.
 Stepladder shall not be used in the partially closed/ open position or as
an upright or straight ladder (leaned against a wall or other support).
 Flip up types of stepladders that could also be used as a straight ladder
shall not be used and are prohibited.
 Stepladders shall not exceed 6m (20 ft.) in length.

29.0 Fire Prevention

Appropriate measures shall be taken to avoid the risk of fire on the worksite. The following
principles shall be used to minimize the fire risks:

25
 Operation having a high fire risk such as welding and open flame
activities shall be isolated or specially protected from flammable and
explosive materials.
 Storage of flammable and combustible material shall be restricted to the
minimum quantities necessary for an uninterrupted cycle of maintenance
activities.
 Work sites shall be provided with the numbers and types of fire
extinguishers suitable for the hazards and as needed to meet standard
requirements. Fire extinguisher and other firefighting equipment locations
shall be clearly marked on site layout plan.
 A fire prevention inspection checklist shall be used to evaluate work site
and storage areas.
 Combustible materials shall be neatly stacked taking into consideration
the stability of the stack and shall in no case be higher than 6 meters.
 Flammable materials (paints, fuels, chemicals) shall be separated and
stored in designated flammable liquid storage areas away for heat
sources, electrical equipment and other ignition sources.
 Incompatible materials shall not be stored together.
 Electrical equipment shall be regularly checked for defects.
 Ground fault circuit interrupter GFCIs shall be provided with electrical
equipment.
 Smoking in only permitted in designated areas. No Smoking signs shall be
prominently displayed, particularly where flammable or combustible
materials are stored.
 Welding equipment, heating appliances and other open flames or hot
surfaces shall be segregated from flammable and combustible materials.
 Precaution shall be implemented as needed to control indirect sources of
ignition i.e. hot welding slag falling from a height.
 Open fires and open burning of materials are strictly prohibited.
 Proper bonding and grounding techniques shall be used for any operation
where static electricity could become an ignition source.
 Ignition sources shall be immediately removed if there is a hydrocarbon
liquid or gas leak.
 Any cutting, welding or burning operation requires an assigned qualified
fire watch who shall remain in the work area during these activities and
for no less than 30 minutes after the work is finished.
 Flammable materials shall not be stored in direct sunlight or in such a
manner that they could be subject to heat above their auto ignition
temperature.

26
  Flammable storage areas shall be secured and located at least 15 meters
away from the nearest building or storage area for other combustibles.
No other materials shall be stored with flammable liquids.
 Appropriate warning signs Flammable Liquids, No Smoking, Flammable –
Keep Away shall be posted at flammable storage areas.
 Portable and mobile firefighting equipment shall be located as needed to
address job site hazards. Firefighting equipment shall be located at
convenient, conspicuous locations and be easily accessible.
 Firefighting equipment shall be maintained in good working order and be
protected from harsh environmental conditions as needed.
 The area around firefighting equipment shall be kept clear so that they
are readily accessible in case of an emergency.
 Fire protection system and equipment shall be inspected and maintained
properly.

30.0 Materials Handling

ABIS shall prepare material storage areas with due consideration of security and safety aspects.
Storage areas should be protected from drainage, rain and sandstorms etc. Following below are
the minimum safety requirements which ABIS shall follow while storing materials.

 Materials should not be stored under energized electrical buses or power

lines or near energized equipment.
 Storage areas shall be planned to minimize the reversing and
maneuvering of vehicles, especially into and out of congested/ tight
areas.
 Access ways should be wide enough to allow passage of emergency
response equipment.
 Adequate firefighting equipment shall be readily available and accessible
in storage areas.
 Cribbing timber, racks or pallets shall be used to ensure that materials
are stored off the ground.
 Protection shall be provided for the materials that could be damaged by
moisture.
 All machinery, equipment and valves shall be maintained fully assembled
and securely closed. All machine surfaces shall be covered and fully
protected from exposure to weather.
 The quantity of material on site at any time shall be restricted to a
minimum stock. Flammable stores shall be kept separated.
 Material coordinator should be appointed who is responsible for materials
planning, unloading, storage and distribution.

27
31.0 Manual Handling

Manual handling of materials shall be avoided as much as possible. Instead, mechanical aids
should be used for transporting materials from one place to another. In cases where
mechanical aids are not possible, manual handling is allowed only by following correct manual
handling techniques.

Listed below are the minimum safety precautions to be taken while performing manual handling
jobs.

 Assessment of size, shape, weight and dispositions of materials to be

handled and plan the most efficient and safest method to accomplish the
task.
 Workers shall be instructed in proper manual handling techniques and
practices prior to their work assignment.
 Manual material handling tasks shall consider personal physical limitations
that vary among individuals. Care shall be taken so as to not exceed
these limitations.
 Heavy materials requiring manual lifting shall be stored below waist
height. The proper tools/ lift assist devices shall be provided for the job.
 Personal protective equipment shall be worn as required.

There are four key requirements for performing a proper manual lift:

 Ensure maximum use of the palm of the hand, the ball of the thumb and
base of the fingers.
 The person back shall be kept straight to maintain its most natural and
strongest position. This means that the knees and ankles must be bent
and the chin kept well into the chest. The body must be positioned as
close to the load as possible.
 Feet shall be spread apart the width of the hips with one foot slightly in
front of the other.
 Arms shall be kept as close to the body as possible.

Personnel shall:

 Avoid extreme range of motion and twisting their body when lifting.
 Minimize reach and distance the load is carried.
 Avoid lifting loads above shoulder height.

28
  Minimize weight of loads (by mechanical aids, balancing contents)
 Keep objects as close to the body as possible.
 Seek assistance when performing manual/ material handling tasks that
may be beyond one’s physical capabilities.

In the event an object cannot be handled by just one individual or by a mechanical device, two
or more individuals shall handle the object. The movement of object shall be coordinated in
unison.

32.0 Working with Electrical Equipment

Utmost safety precautions should be taken while working with electrical equipment. Only
properly equipped personnel who are trained and certified for electrical work shall perform
maintenance or operation work on electrical equipment.

While working with electrical equipment, following below are the minimum safety precautions to
be taken care of.

 Employees with potential exposure to arc flash hazards like electrician or

welders shall be trained and certified as per Petrokemya standard. They
shall be familiar with the specific work procedures and tests.
 Personnel authorized to conduct electrical work on equipment shall pass
the electrical hazard recognition training provided by Petrokemya.
 Personnel shall not wear rings, wristwatches, jewelry or other similar
metallic objects while working within arm’s length of energized
equipment.
 RCDs including ground fault circuit interrupters GFCIs and earth leakage
circuit breaker ELCBs or ground fault isolation systems shall be used for
portable electrical tools, temporary wiring, confined space entry activities
and in potentially wet or damp areas.
 Electrical and static producing equipment including air movers shall be
properly grounded and bonded and shall be provided with ground fault
protection.
 When electrical equipment is to be worked on while de-energized, it shall
be properly isolated (disconnected from all power sources, locked,
tagged, cleared and energization attempted to prove effectiveness). For
electrical systems, appropriate isolation shall include locking or removal of
switches, circuit breakers, fuses or other isolating devices or
disconnection of all power supplies.

29
  Metal ladders shall not be used when working on or near energized
electrical equipment or conductors; only nonconductive ladders i.e. wood,
fiberglass shall be used.
 Personal protective equipment PPEs to protect against shock, hazards,
including rubber insulated gloves, rubber insulated sleeves, goggles and
face shield and dielectric shoes shall be worn when conducting electrical
work on or near energized electrical equipment.
 Rubber insulated blankets shall be used to provide insulation from nearby
exposed energized conductors.
 Rubber insulating gloves shall be inspected and air tested prior to each
use. If the inspection date is expired, the gloves shall not be used.
 Hand & power tools and personal ground cables shall be visually
inspected by the user prior to each use.
 Defective electrical equipment and tools shall not be used and shall be
immediately removed from the job site.
 Electrical testing equipment shall be periodically calibrated and tagged by
a testing laboratory.
 Personal ground cables shall be properly inspected/ tested and tagged.
 Noncurrent carrying metal parts of electrical equipment shall be properly
grounded to prevent buildup of static electricity and allow capacitive
voltage to discharge.
 When operating or closing a disconnect switch, personnel shall remove all
jewelry, wrist watches, stand to the side of the switch and move the
switch with a quick upward or downward single motion. Personnel shall
turn their head away from the switch except wearing an arc rated face
shield.
 Vehicles shall not be allowed to pass over exposed cables, unless the
cables have been adequately protected.
 Confined space entry shall not be permitted until the atmosphere inside
has been tested for hazardous atmosphere and is found to be safe.
 Work platforms and mobile equipment used near energized electrical
equipment shall be properly grounded.
 Work shall not be performed on energized electrical equipment.

33.0 Hand Tools

ABIS shall use only industrial standard, inspected and color-coded hand tools on the job.
Homemade or modified hand tools are strictly prohibited on the job site. Employees should use
right tool for the job. Misuse or horseplay with tools can result in personal injury or incident.
While using the hand tools, employees should follow the safety precautions which are listed
below.

30
  Work permit shall be obtained for the work to be carried out by using
hand tools.
 Appropriate personal protective equipment shall be used by employees all
the times when using hand tools (hard hat, safety glasses, goggles,
hearing protection, safety shoes, gloves, face shield).
 Employees shall not operate any tools unless they are appropriately
trained in their selection, use, inspection and storage.
 Tools shall be kept clean and properly maintained all the times.
 Tools shall be inspected before and after use as well as before storage.
 Defective or deformed tools shall not be used. If excessive wear, defect
or damage is observed, the tools shall be immediately tagged and
withdrawn from use.
 Proper racks and boxes shall be provided and used for storage of tools.
The correct type, size and weight of tool shall be used for each task.
 Only properly insulated or nonconductive tools shall be used when work
is performed on or near electrical equipment.

34.0 Hydrogen Sulfide Hazards & Precautions

Hydrogen sulfide is an extremely toxic gas and considered as silent killer. ABIS employees
working in a potentially Hydrogen Sulfide presence areas shall take extreme safety precautions
which include below but not limited to.

 Air supplied respiratory protection equipment i.e. self-contained breathing

apparatus; airline respirator shall be used by the personnel who may be
exposed to an H2S release.
 Air supplied respiratory protection equipment shall be worn by all
personnel in an area where H2S concentration equals or exceeds 10 ppm.
 Personnel shall not rely on their sense of smell to detect H2S because
higher concentrations can quickly deaden the sense of smell.
 Personnel working in areas with H2S smell shall be trained on the hazards
and effects of H2S exposure and proper use of applicable respiratory
protection.
 Personnel shall not open or enter lines, vessels, tanks or equipment that
contains H2S without a properly prepared procedure.
 Personal H2S monitors shall be worn where H2S concentrations have the
potential to equal or exceed 10 ppm.
 Personnel shall use calibrated gas monitoring equipment when
performing work in areas where there is an H2S hazard.
 Warning signs and barricades shall be posted advising personnel of the
potential presence of H2S in the work area.

31
  Personnel shall not be allowed to enter in areas where atmosphere
contains an H2S concentrations of 100 ppm or greater. An atmosphere
containing 100 ppm of H2S is considered immediately dangerous to life or
death (IDLH).
 Only properly trained personnel wearing a SCABA shall attempt to rescue
a victim of H2S exposure.
 Personnel expected to use a SCABA as part of their normal or emergency
duties shall be medically approved before donning the device.
 ABIS shall provide proper training to its employees who are working in
the areas where there is a potential H2S exposure.

35.0 Work Permits

ABIS shall take valid work permit from plant operations to carry out the work at plant areas.
ABIS shall certify its permit receivers from Petrokemya. Permit receiver certificates shall be
signed by the Proponent Manager/ Section Head. Permit receivers shall carry their cards with
them all the time.

Certified permit receiver shall request permit from certified issuer. Both should go for joint site
inspection. Permit receiver should follow the safety precautions as mentioned by the issuer on
the permit. Permit receiver shall remain present in his work area during the course of work. All
work permits to be closed after the completion of work/ end of shift.

In case of any emergency situation all permits shall be cancelled.

ABIS shall comply with Petrokemya work permit procedure.

ABIS permit receives shall:

 Maintain in their possession a valid work permit receiver certificate. They shall
attend and pass the work permit certification course and required prerequisite
courses.
 Receive the proper work permit from a certified issuer prior to executing any job.
 Participate in the join site inspection, including hazard analysis with the issuer or
his designated representative.
 Perform the work in accordance with the conditions and requirements agreed
upon with the issuer and specified on the work permit.
 Remain at the job site and monitor the work to make sure all work permit
conditions and applicable safety and health requirements are being met.
 Immediately stop work if a change occurs in the work activities or site
conditions.
 Close work permits after completion of the job or when the permit duration has
expired.
 Remain at the job site at all times. However if receiver must leave the work area,
he shall give the permit to another certified permit receiver.

32
Work Permit Requirements:

 The issuer and receiver are jointly responsible for the job to be done safely.
 Work shall not begin before the work permit has been signed.
 Employees not involved in performing the work must be kept away from the job
site.
 Before starting the work, all sources of energy and hazardous material shall be
isolated.

Gas Test Requirements:

Atmospheric gas testing shall be conducted with Petrokemya approved gas monitoring
equipment prior to initiating work activities.

 Hot work is not allowed if LEL is above 0%.

 Work is not permitted if the atmosphere has an oxygen concentration above
23.5%.
 Work is not allowed in areas where atmosphere is at or above 10% LEL or
hydrogen sulfide concentration is at or above 100ppm.
 Confined space entry is not permitted if the atmosphere is at or above 10% LEL,
H2S Concentration is at or above 100ppm or carbon monoxide CO concentration
is at or above 1000 ppm.
 A breathing apparatus shall be used if any of the following atmospheric
conditions exist:

 Oxygen concentration is below 20%

 Flammable/ combustible mixtures are at or above 5% LEL
 H2S concentration is at or above 10ppm
 CO concentration is at or above 35ppm

Types of Work Permits

ABIS shall follow all main work permit and certificates as endorsed by Petrokemya.

36.0 Use of mechanical & Heavy Equipment

ABIS shall use properly maintained, inspected and third party certified mechanical & heavy
equipment at worksite.

Below are the minimum safety requirements to be fulfilled for using mechanical and heavy
equipment.

33
  How work permit shall be obtained prior to use of equipment with
internal combustion engines in restricted areas.
 Mechanical and heavy equipment shall be inspected on a regular basis by
a competent heavy equipment inspector or mechanic as per manufacturer
recommendation. Equipment shall have valid inspection sticker issued by
Petrokemya or SABIC approved third party inspection agency.
 Pre-use inspections shall be conducted for all mechanical and heavy
equipment.
 Only authorized personnel shall be allowed to enter the work area where
mechanical and heavy equipment is in operation. When entering the work
area, authorized personnel shall make direct eye contact with the
equipment operator to ensure their presence is known.
 Flagman shall be used when human traffic is present in heavy equipment
work area.
 Operators shall ensure the work area is clear prior to operating
mechanical and heavy equipment.
 When an operator cannot see the entire area around the equipment,
attendants/ spotters wearing high visibility fluorescent vests shall direct
and assist the operator.
 Reverse/ back up alarms shall be audible at a level at least 10dB above
ambient noise on all heavy equipment.
 Preventive maintenance schedules shall be established and strictly
followed for each equipment.
 During maintenance or repair work, operator shall dismount from
equipment and the immediate area around the equipment shall be
cleared of unauthorized personnel.
 Equipment shall be located to prevent exhaust fumes from affecting
personnel in area.
 Engines shall be stopped, the parking brake applied and wheels choked
when mechanical or heavy equipment is left unattended including
overnight.
 Personnel shall not ride in or work off any part of the equipment, unless it
is specifically designed for each work.
 Personnel shall not rest or sleep under or around mechanical or heavy
equipment at any time.
 Equipment shall be stopped and engines turned off before refueling.
 Gasoline and diesel-powered equipment shall only be refueled in well
ventilated areas. Exhaust pipes shall be kept away from combustible/
flammable materials.
 During TA, vehicles shall follow speed limit 10 Km/h.

37.0 Working on Scaffold

ABIS employees intend to work on scaffold platforms should be trained on work at height safety
precautions. This training should be given by ABIS HSE department. The employees should

34
know to wear the full body harness correctly and ensure 100% tie of all the time while working
above 1.8 m height.

Listed below are the minimum safety requirements for working at scaffold platforms.

 Any scaffold tagged with a red scaffold tag shall not be used, except by scaffold
craftsman for the purpose of erecting, dismantling, altering or correcting scaffold
deficiencies. Any unauthorized person using a scaffold with a red scaffold tag will
be subject to disciplinary action.
 Yellow tag scaffold can be accessed by the workers with the condition of wearing
full body harness and ensuring 100% tie off all the time.
 Employees should do visual inspection of scaffold platform before its each use
for any missing structural member, unauthorized modification etc. They should
not just rely on tag itself.
 ABIS employees are not authorized to do any kind of modification in the scaffold
platform. In case, any such modification is required for the work to be
performed, they should contact to authorized person from Petrokemya.
 Scaffold platform should not be loaded with material in any case.
 Throwing of material to or from scaffold platform is not allowed. Canvas bags
should be used for transferring of the material.

Non-use of Red Tag Scaffold

ABIS employees shall not use red tag scaffold; any employee found using red tag scaffold will
be penalized as per ABIS disciplinary action procedure.

38.0 Fall Protection

Fall from height is a major cause of personal injuries including fatalities at work sites. Fall
prevention methods should be used to prevent falls of workers while they are working at high
elevation i.e. scaffold platforms, sky climber, using man lifts etc. Following below are the
minimum safety requirements for performing works at high elevations i.e. above 1.8 m height.

 Workers intend to work at high elevation shall be trained on work at

height hazards and subsequent safety precautions.
 Where possible, work shall be performed on the ground to minimize
exposure to fall from heights.
 Each person who could fall from 1.8 m height shall be protected from
falling by a fall protection system.
 Guard rail system should be used with scaffold platforms.

35
  Above 1.8 m height, workers should use full body harness and ensure
100% tie off all the time.
 Standard lifelines shall be provided as anchorage point to tie off full body
harness hooks.
 Where a fixed fall protection system cannot be installed, a personal fall
arrest system which is designed to stop personnel should be used.
 Personal fall arrest systems shall include a full body harness, shock
absorbing lanyard or self-retracting lifeline and a substantial anchor point.
 Shock absorbing lanyards shall be either a Y lanyard or double leg
lanyard each with their own individual deceleration device in order to
protect the user during hooking/ unhooking transitions.
 Workers working on aerial lifts or sky climber shall continuously wear a
full body harness with the lanyard securely attached to an appropriate
anchorage point.
 Personnel shall inspect fall protection equipment, including full body
harnesses, lanyards and D-rings prior to each use.
 Fall protection equipment shall be kept clean, in good condition and
stored properly when not in use.
 Safety belts shall not be used as part of a personal fall arrest system.
Lanyards shall not be tied back onto themselves.
 Self-retracting lifelines shall not be connected to a lanyard but shall be
directly attached to the D-ring on the full body harness.
 Personal fall arrest systems shall comply with ANSI Z359.1. Other types
of fall protection equipment shall not be used.
 Fall arrest equipment shall limit the maximum arresting force on the user
body to 818 kg.
 Full body harnesses shall safely support 2268 kg dead weight.
 Personnel performing work at heights and their supervisors shall be
trained in the nature of fall hazards in the work area. They should be
trained in use, inspection and maintenance of fall protection equipment.

39.0 Blinding

Before starting maintenance activities on any equipment/line, ABIS shall perform piping
isolation by blinding. This process involves the installation of a solid metal plate between two
pipe flanges to prevent any materials from being released.

ABIS shall:

 Develop a written procedure for tanks blinding. The blinding procedure should
include:

36
  Drawings P&IDs, isometric drawings indicating all isolation points,
drains and vents.
 Blind list to track installation and later removal of all blinds.
 Steps for depressurization, draining and purging of line or
equipment and associated piping before blinds are inserted,
including proper disposal of any drained material.
 Site preparation steps (covering sewers)
 Proper sequence for installing blinds

 Prepare a blind list when more than two blinds are used to isolate equipment to
ensure proper installation and removal. The blind shall at minimum include
information on blind number, location, date of installation, blind rating, installer
name, date of removal and appropriate signatures.

The breaking of any flange containing hazardous material shall always be performed under the
impression that the line is pressurized. The stud bolts must be loosened so that cracking the
flange connection occurs at the 5 O clock position (down and away from the person performing
the work) to allow any potential gases or liquids to be released away from workers.

The pressure/ temperature rating of a blind shall be the same as for the flange joint and fully
rated for service. Each blind shall be stamped with the corresponding pressure rating.

While inserting blinds, the following safety precautions should be taken into account:

 Blind shall be inserted only at the isolated side (downstream) of each isolation
valve that has been locked closed and tagged. Valves shall remain locked closed
while any blinds are in place.
 Blinds shall be installed with matching gaskets to ensure effective isolation, with
all stud, bolts in place and properly tensioned. Blind gaskets shall be inspected
for damage prior to installing/ swinging blinds.
 Slip blinds shall be equipped with a tail or T handle drilled with a hole to attach a
hold tag. Blinds shall be tagged for identification as an isolation device.
 The first blind inserted shall be the last to be removed.

40.0 Hot Work (Cutting, grinding and welding)

Welding, cutting and grinding are considered as a high-risk activity. Appropriate safety
precautions shall be taken to perform any HOT work job i.e. cutting, grinding and welding etc.

Minimum safety requirements for performing HOT work activity are listed below:

37
  Ensure gas test has been conducted and LEL is 0% for any HOT work
activity.
 HOT work permit shall be issued prior to start any welding or cutting
activities
 ABIS supervisor will ensure that all the line are isolated as per the P&ID
prior to start the activities.
 ABIS will prepare the area before starting the job i.e. covers the area
with fire blanket; remove any combustible material from job location.
 A qualified fire watch man shall be assigned at the HOT work location to
avoid any fire occurrence.
 Provide fully charged fire extinguisher and water hoses at the job location
so it can be use in emergency if required.
 ABIS supervisor will inspect all power tools prior to use and if any sign of
defective immediately remove from site.
 Cover all the sewer line around 23 meters of the HOT work area.
 All the employees shall use appropriate PPE’S as per the job
requirements.
 All welding machine shall have Petrokemya inspection sticker.
 All welding machine shall be grounded prior to use and only authorized
person shall operate it.
 ABIS will provide full time of supervision for all welding or cutting
activities.
41.0 Works inside Confined Space

Working inside confined space shall be considered as high-risk activity. Appropriate safety
precautions shall be taken while working inside confined spaces i.e. tank, vessel, column etc.

Minimum safety requirements for working inside confined space are listed below:

 Confined space entry permit shall be issued prior to entry into confined
space. Other permits may be required (hot work or cold work) depending
upon the type of work to be conducted within the confined space.
 ABIS shall appoint a designated confined space entry supervisor on every
confined space job.
 ABIS shall prepare a confined space entry plan and submit to Petrokemya
EHSS.
 A qualified standby man shall be assigned at each confined space job to
continuously monitor the confined space entry while personnel are inside
the confined space. In certain situations more than one confined space
standby man are required.

38
 Standby man shall be provided with adequate means of communication
to ensure continuous communication with entrants and with proper
personnel in event of an emergency.
 Fire extinguisher shall be provided near each confined space entry point.
 Confined space entry checklist shall be used to help ensure safety
requirements are met.
 Standby man and entrants shall be physically/ medically fit.
 Designated entry points shall not be blocked or obstructed with
equipment while entrants are inside the space.
 Confined space warning signs and barricades shall be posted outside the
confined space to notify personnel that confined space entry is in
progress and to prohibit entry by unauthorized personnel.
 Mechanical ventilation (air movers) shall be used to ensure removal of all
hazardous airborne contaminants in confined spaces where a hazardous
atmosphere exists or could develop during the course of planned work.
 The proper personal protective equipment shall be provided to personnel
entering a confined space and to each standby man. PPE shall be
continuously used during the confined space entry.
 Personnel entering/ exiting a confined space shall sign a log in / out
sheet.
 Only properly trained and authorized personnel shall enter a confined
space.
 Electrical equipment, including lighting shall be UL listed.
 Residual current devices including ground fault circuit interrupter and
earth leak current breakers shall be utilized on all electrical powered
equipment (including portable lighting) used inside a confined space.
 Adequate lighting shall be provided to safely enter, exit and work inside a
confined space.
 Explosion proof lights shall be used inside confined space.
 In case, electrical power cords are used inside confined space, protection
shall be provided near sharp edges and through entry points to prevent
damages to the power cords.
 Compressed gas cylinders shall not be placed inside confined space.
 Internal combustion engines shall not be positioned inside a confined
space or at a location that could allow exhaust to enter the space. Such
type of equipment shall be positioned downwind from confined space
entry / exit points and air mover intake.
 For non-entry rescue, retrieval system shall be used whenever an entrant
enters in confined space that requires vertical entry.
 Fall protection shall be used if personnel could fall more than 1.8 m
height when working inside the confined space.

39
  Confined space entrants shall be given breaks as needed and allowed to
take rest outside in an open area.
 Flammable/ combustible materials shall not be stored inside a confined
space.
 For hydro jetting operations, low drain points shall remain open to
eliminate water accumulation.
 Rescue equipment and a rescue team shall be available in the event of an
emergency requiring evacuation of the confined space.
 In case the confined space entry activity is suspended, the entry point
shall be barricaded and NO ENTRY sign shall be posted.
 At completion of work, the confined space shall be returned to normal
service. The confined space shall be inspected to ensure all equipment
and tools have been removed.
 Periodic atmospheric gas testing should be done by Petrokemya certified
gas tester.
 Mechanical ventilation (air movers) shall be used to ensure the removal
of all hazardous airborne containments in confined space where a
hazardous atmosphere exists or could develop during the course of
planned work activities i.e. painting, welding etc.
 Confined space entry supervisors, standby men, entrants shall receive
confined space entry training that is appropriate to their specific
responsibilities.

42.0 Hazardous Materials

While using potentially harmful chemicals or hazardous substances at project, certain safety
precautions shall be taken into account to ensure that workers don’t swallow, inhale or allow it
to contact with their skin. Important safety precautions for use and handling of hazardous
materials are listed below.

 Hand shall be washed thoroughly after handling chemicals or hazardous

substances.
 Personnel shall be trained to remove contaminated clothing, promptly flush
affected areas with clean water for at least 15 minutes and seek medical
attention when harmful chemicals contact the skin or eyes.
 Chemicals shall not be subjected to undue physical shock, pressure or heat.
 Excess chemicals no longer needed shall be safety disposed of.
 Personal protective equipment including respiratory protection equipment as
stipulated in the Material Safety Data Sheet shall be used when working with
hazardous materials.

40
  While handling volatile liquids, threshold limit value TLV of the vapor shall be
determined and not exceeded. When exhaust ventilation is unavailable, good
mechanical ventilation shall be provided.
 Exhaust ventilation, fans, blowers and proper handling procedures shall be used
to keep personnel from breathing hazardous vapors and dust. Respiratory
protection shall be provided and used when necessary.
 Respiratory protection equipment shall be used when chemical concentrations in
air exceed the TLV.
 Equipment, piping or filter cartridges containing pyrophoric materials shall be
kept wet to prevent spontaneous ignition upon opening of equipment and
contact with air.
 Emergency eye wash stations and showers shall be provided when eyes or skin
may be exposed to chemicals or hazardous substances.
 Hazardous materials shall not be allowed to accumulate. Extra amounts shall be
removed from the work area immediately.
 Waste shall be immediately removed from the work area.
 Smoking and use of devices not classified as explosion proof are prohibited near
flammable liquids.

43.0 Identification and labeling of hazardous materials

 All materials or substances shall be identified and evaluated for their potential
physical or health hazards.
 ABIS shall prepare a complete inventory of all chemicals at project site.
 Hazardous materials containers shall be properly labeled to indicate its contents
and hazards.
 Portable containers into which hazardous materials are transferred shall also be
identified as to their contents.
 Labels shall be prominently located on each container of hazardous materials so
as to legible while the container is in the upright position.
 Labels on containers exposed to direct sunlight or adverse weather shall be
periodically inspected to verify that the label is clear and conspicuous and has
not been damage or destroyed.
 Complete and current MSDS for each chemical or hazardous substance stored/
used on site shall be readily accessible to employees and emergency response
personnel.
 ABIS shall provide effective HAZCOM training to its employees on the proper use
and precautions for hazardous materials in their work area. Chemical specific
information identified from labels i.e. MSDS shall be included in this training
which shall be documented.

41
  Specific storage and handling recommendations for hazardous materials provided
in MSDS shall be followed.
 Incompatible materials shall not be stored near each other or be mixed together.
Reactive substances shall not be stored near flammable or corrosive materials.
 Hazardous materials shall be stored in containers that are safe for storage,
transportation and use.

44.0 Crane Operations

While using cranes for blinding or loading/ unloading of materials, below safety requirements
should be met strictly.

 Crane lifts shall be conducted as per Petrokemya Standards.

 Crane operators shall be Third party certified for the crane type & model.
 Appropriate work permit shall be issued for crane operations.
 Cranes shall be inspected by the crane operator before each lift.
 Cranes shall have a valid crane inspection sticker issued by Petrokemya approved
third party inspection agency.
 Crane cabs shall provide maximum visibility i.e. curtains; cardboard shall not
obstruct the operator view during operation.
 Cabs shall be kept clean and clear of items such as rubbish and loose tools.
Windows shall be kept clean at all times and shall be replaced if the glass
becomes pitted, cracked or broken.
 Riggers should be approved from third party. Only certified riggers shall rig loads
to be lifted. The rigger shall have the responsibility for coordinating activities of
all personnel involved with the lift.
 Personnel with both an approved crane operator and rigger certification shall not
be allowed to act in both capacities for the same lift.
 Crane lifts shall not be performed in wind speeds exceeding 32 km/ hr.
 Crane lift areas shall be barricaded and secured. Only authorized personnel shall
be permitted inside the barricaded area. Warning signs shall be placed around
lifting radius of the crane.
 Cranes shall be leveled and located on properly compacted foundation prior to
performing any lift.
 Cranes outrigger shall be fully extended and lowered to raise the wheels and
level the crane. The cranes wheel shall be raised completely off the ground.
 Outrigger mats shall be used under all crane outrigger float pads during crane
lifts. Outrigger mats shall be designed to support the total weight of the crane
and load to be lifted.

42
  Tag lines shall be used to control suspended loads. Tag lines shall not be tied
around the hand/ wrist; they shall be fully gripped by all fingers.
 Crane operator shall not leave the controls at any time while a load is attached.
 Crane operators shall only pick up loads when the bottom head and hook are
centered directly over the load.
 All crane lifts shall be partially lifted to ensure rigging and lift integrity prior to
proceeding with the actual lift.
 A designated signalman shall be used at all times during the lift, moving and
setting of a load. Only one designated signalman shall give signals to the crane
operator. Universal hand signals shall be used. In the event that the crane
operator cannot see the signal man, radio communication shall be used.
 When a crane is operating near an energized power line, a designated signalman
shall be assigned to ensure minimum safe distance is maintained.
 Personnel shall not ride a hook or auxiliary headache ball at any time.
 Welding on, or modification of, hooks and other lifting equipment is strictly
prohibited.
 Cranes shall be secured during high winds or after working hours by snubbing to
structures, laying down lattice booms, withdrawing hydraulic boom extensions.

45.0 Housekeeping

Good housekeeping is an important part of this Site Safety Program. It is responsibility of all
employees and supervisor to practice good housekeeping.

Housekeeping Guidelines

Housekeeping guidelines include the following:

 Work areas, passing ways, stairways and all other areas should be kept free of debris,
equipment and materials.
 All waste material and rubbish should be removed immediately from work area as the
work progresses.
 Employees shall not pour, bury or burn nor in any way dispose of a chemical on the work
site.
 A sufficient number of skips shall be provided throughout the work areas; metal
(dumpster type) container shall be used and emptied promptly.
 A safe means of entry and exit shall be provided at all times and work areas shall be kept
clear and unobstructed.
 Storage areas should be kept clean and materials should neatly stack or placed.
 Materials should be stored or placed in an orderly manner.

46.0 Waste Management

43
ABIS shall place skips for waste collection in its temporary facility and site work areas. Solid
nonhazardous waste produced i.e. office waste; food waste shall be collected in the provided
skips and will be disposed of periodically at Sanitary Landfill located nearby.

Estimated waste generated from office facility and worksite will be around two skips/ week.
ABIS shall ensure that waste profiles are completed properly. Waste manifest and records shall
be maintained as per Petrokemya waste management procedure.

47.0 Demobilization Plan

On satisfactory completion of the job, ABIS shall prepare a detailed demobilization plan. This
plan shall include the removal of all manpower, equipment and camp facilities in a phased
manner.
ABIS shall follow Petrokemya security gate pass procedure while demobilizing tool containers,
office blocks and any kind of equipment from plant premises.

44