A Safe Operation
Safety tips for Pipeline Workers
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2. Use proper personal protective equipment (PPE).
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ipeline work presents safety hazards similar to any other jobsite, but the risk of injury is increased with the addition of heavy equipment, suspended loads, terrain and jobsite conditions, inexperienced or untrained workers and pressure to “get the job done.” Remember: you are responsible for your safety and the safety of those around you. Help to foster a culture of safety on your pipeline site by following safe work practices and looking out for your fellow worker and the public. When needed, make sure instructions are translated and clearly understood by all workers. Most jobsite accidents are preventable with careful attention to a few basic principles.
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1. Perform a thorough Job Safety Analysis (JSA). At the start of each shift, collectively identify and analyze the list of tasks to be performed that day. Record potential hazards involved and actions necessary to eliminate or reduce the risk of injury (e.g. safe work procedures, personal protective equipment, fall protection, etc.). Job Safety Analyses are not performed in a vacuum (by a safety manager in a trailer) but should be done by the entire group on the jobsite. Document environmental conditions that may affect each step of the job including temperature, high winds and precipitation. Be sure to note hazardous underfoot conditions as well. Re-evaluate the jobsite with a fresh JSA each time conditions change and notify all personnel of JSA results. Retain JSAs on site for your records.
Personal protective equipment includes any apparatus or garment intended to protect you from injury or illness. Eye and hearing protection, safety boots, gloves and hard hats should always be worn on pipeline jobsites. Proper footwear protects against falling objects and helps prevent slips. Reflective vests should be worn in hightraffic areas and while working along roads. Reflective clothing is always a good idea, making employees working on the ground more visible to equipment operators. The JSA may identify certain tasks that require the use of special devices or clothing (fire retardant clothing, respirators, etc.) beyond the basic PPE. It is your responsibility to know what PPE is necessary, ensure it fits properly and understand how to correctly inspect, use and maintain it. Know its limitations and safely dispose of any damaged equipment. In case of a machine roll-over or collision, another crucial piece of equipment is designed to keep you safely within the roll-over protection structure (ROPS) - Always wear your seat belt.
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3. Follow safe excavation procedures. Make the One Call before digging, verifying that all underground utilities are marked and their depths noted. Before beginning work in an excavation, consider the hazards and ensure the competent person has inspected the trench for proper sloping or benching and the use of protective systems. Use a spotter for safe operation in tight spaces or near overhead power lines. Keep tools, equipment and spoil at least 2 feet from the edge of the excavation. Fixed egress is required for depths of 4 feet or greater. Sloping, benching or shoring techniques are mandated for excavations of more than 5 feet*. Remember: an excavation can be considered a confined space if a hazardous atmosphere exists. Use PPE, conduct atmosphere monitoring and follow safe work practices for confined spaces.
* According to OSHA regulations. For jobsites outside the U.S., consult local law and regulations.
4. Safely operate heavy equipment. Equipment operators must read and understand the Operation and Maintenance Manuals (OMMs) of all equipment they operate on the jobsite. Before stepping into a machine, be sure you understand the operating controls, proper operation procedures and have assessed the operating conditions. Checklist Understand equipment operation on a slope and how it differs from operation Walk Around Inspections on flat ground. Be aware of your surroundings and recognize any ✔✔ Use your senses: sight, smell, hearing and touch. adjustments that must be made due to changing conditions. Follow the OMM ✔✔ Do a walk around any time guidelines and conduct frequent walk you get off the machine and always at the start and end of around inspections. These inspections your shift. only take a few minutes and are one of ✔✔ ✔Be aware of any changes in the the best ways to detect/prevent machine’s operation. mechanical problems and safety ✔✔ Pass all relevant information hazards. Any necessary repairs should to other operators and your be made immediately. Operators must supervisor. understand the importance of completing the walk arounds, and supervisors must allow time for a thorough evaluation. Take note of the equipment, terrain, workers and other obstacles in your area. Be sure your backup alarm is functioning at all times. Whenworking on the ground around equipment, be aware of operator visibility. Maintain eye contact with machine operators when approaching equipment.
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5. Be aware of walking and working surfaces. Slips, trips and falls are best avoided with good housekeeping. Keep walkways clear of tools (welding leads, extension cords, etc.) and debris; clean spills immediately; and, make it clear others are expected to do the same. Be aware of conditions that compromise safe footing: rain, mud, steep terrain and other jobsite conditions.
Checklist
Mounting and Dismounting ✔✔ Do not mount or dismount a moving machine. ✔✔ Maintain three points of contact. ✔✔ Never jump off a machine. ✔✔ Do not carry tools or supplies when mounting or dismounting a machine. ✔✔ Do not use controls as handholds when entering or exiting the operator compartment.
Properly enter and exit machines. Start by taking the proper approach. Face the equipment and use the steps and rails provided by the manufacturer. Make sure the area is adequately lit, contact areas are clear and that steps and handrails are properly secured. Maintain three points of contact. Either one hand and two feet, or two hands and one foot, should be on the steps/handrails at all times.
Checklist
Safety Glasses and Full-face Shields Should Be Worn When: ✔✔ Welding, cutting, buffing and grinding could cause foreign objects to get in your eyes. Welder’s helpers need to use sealed safety glasses with face shields. ✔✔ Working with concrete, sand or hazardous chemicals. ✔✔ Exposed to electricity hazards (specialized equipment may be required). ✔✔ You are exposed to flying particles. ✔✔ Deemed necessary by regulatory agencies or management.
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6. Promote eye and back safety.
Eye and back injuries are preventable with both the proper personal protective equipment and safe work practices. Choose eye and face protection based on the kinds of hazards you may encounter. Do not touch your eyes without thoroughly washing your hands first.
Take special precautions to prevent back injuries. Use safe lifting techniques. Ask for help lifting heavy or awkward loads. Never operate hoists or other specialized equipment without proper training.
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9. Follow safe pressure testing procedures.
Inspect all equipment and materials required by the written test procedure, ensuring it is in safe working order and rated to withstand the test pressures. Clear the test area of unauthorized personnel. Ensure all testing personnel are a safe distance from the testing location and wearing their personal protective equipment. Barricade the hazard zone to protect workers and equipment against failure or unexpected pressure release. Ensure valve settings, supply lines and hose connections are secured with retaining devices and free from leaks. If a leak is found, depressurize before tightening the connection. Following the test, safely dispose of test medium.
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10. Understand and follow safe practices for material handling.
7. Engage your mind before your hands.
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Protect your hands. On pipeline jobsites, most hand injuries result from unsafe work practices. Use caution and gloves appropriate for the job at hand. Before starting a task, identify and avoid moving parts and pinch points on equipment. Pay particular attention to hand safety when rolling, stacking, clamping or aligning pieces of pipe. Never put your hands in the line of fire.
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8. Ensure hand and power tools are in proper working order.
All hand and power tools – from hammers and pipe wrenches to pneumatic, electrical and hydraulic equipment – must be inspected before every use. Inspect all components (pins, clips, cords, cases, etc.) for cracks, leaks, cuts or excessive wear. Do not use worn or damaged tools! Never modify equipment, remove or disengage safety equipment or guarding. Always use equipment according to the manufacturer’s recommendations.
When handling pipe or other heavy loads, proper load handling ensures the safety of everyone on the jobsite. Keep manufacturer’s load recommendations readily available and never load equipment beyond its capacity. Inspect the integrity of hoisting equipment, chains, cables, hooks and slings before every use, ensuring they are properly sized and free from excessive wear. Practice caution by staying clear of suspended loads. Use taglines to guide and maneuver the load from a distance while maintaining eye contact with the operator. Never walk under a load! Keep others aware by barricading the area and placing flags and signs warning workers of the hazards present.
The equipment training and safety teams at Caterpillar have spent decades working with customers around the world, across a wide spectrum of equipment applications and jobsite conditions. The key lesson learned is, when it comes to jobsite safety, no amount of equipment technology or advanced machine design can replace caution and good safety practices. The primary contributors to safe jobsites are awareness, proper training, and attention to detail on the part of business owners and their employees. Safety must be a priority and an ongoing part of your company culture. We hope this booklet is helpful as you strive to profitably grow your business. We also invite you to view and utilize additional Cat ® safety training resources by visiting SAFETY.CAT.COM™. This pamphlet is not intended to be a comprehensive analysis of all hazards related to Cat® products or to your specific application. More complete information is provided in the Operation & Maintenance Manual (OMM) for specific models. Caterpillar recommends you and your employees read and understand the OMM before operating or working on any machine.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. AEXQ0984 © 2009 Caterpillar
All Rights Reserved. Printed in the USA.
