Saudi Aramco-Construction Safety Manual

Saudi Aramco Construction Safety Manual PREFACE Dhahran, Saudi Arabia February, 1993 The purpose of the Saudi Aramco Construction Safety Manual (CSM) is to prevent injury, loss of life, and damage to assets. This is the fourth revision of the CSM. Since its 1974 introduction, the Construction Safety Manual has provided safety criteria for all construction work performed by Saudi Aramco and its contractors. Many of the requirements in this manual detail the need for Saudi Aramco services or equipment. Where references indicate that certain equipment (fall protection, safety shoes, etc.) should be provided or services rendered (bio-monitoring, etc.), the intent is that contractors must provide equivalent equipment or services (as approved by Saudi Aramco) from their own resources. The construction industry functions in a dynamically changing work environment in which updating of equipment and standards is a continuous process resulting from changes in operating variables, regulatory requirements, and safety practices. Although this manual has been updated to reflect the latest Saudi Aramco and construction industry practices, as time goes on there may be a need to consider new procedures, standards, or operating conditions. Such new developments, including potential conflicts with existing provisions, should be referred to the Loss Prevention Department for resolution. The Loss Prevention Department will issue interim revisions or updates where appropriate. Good loss prevention is an integral part of good project management. For our projects and maintenance programs to proceed safely, all Saudi Aramco and contractor personnel involved in construction activities, whether management or line employees, need to understand and follow the provisions in this Manual. Only with the active commitment of everyone can we ensure that Saudi Aramco maintains the safest possible work environment.

A. G. AL-GHANIM, Senior Vice President, Engineering and Management

Project

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February 1993 - A.1 Safety Competition Site Registration Form

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I. Administration....................................................1 1.0SAUDI ARAMCO LOSS PREVENTION POLICY AND PROGRAM........2 1.1 Loss Prevention Policy Implementation......................2 1.1.1 Compliance With Construction Requirements..............2 1.1.2 Operating Standards and Instructions.........................2 1.1.3 Personal Protection......................................................2 1.1.4 Inspection.................................................................... 2 1.1.5 Education and Training................................................3 1.1.6 Motivation and Recognition.........................................3 1.1.7 Job Placement..............................................................3 1.1.8 Response to Accidental Occurrences...........................3 1.1.9 Contractor Safety........................................................3 1.1.10 Off-The-Job Safety........................................................3 1.1.11 Traffic Safety................................................................3 1.1.12 Accountability..............................................................4 1.1.13 Compliance Reviews....................................................4 1.2 Saudi Aramco Loss Prevention Requirements For Contractors 4 1.2.1 Non-Compliance..........................................................4 1.2.2 Assistance...................................................................4 1.2.3 Standards and Instructions..........................................5 1.3 Contractor's Loss Prevention Program.......................5 1.3.1 Written Program..........................................................5 1.3.2 Hazard Identification Plan............................................6 1.3.3 Safety Supervisor........................................................6 1.3.4 Safety Discussion........................................................6 2.0SAUDI ARAMCO LOSS PREVENTION DEPARTMENT SERVICES.......7 2.1 Loss Prevention Program...........................................7 2.2 Program Management Services..................................8 2.3 Program Maintenance Services..................................9 3.0ACCIDENT INVESTIGATION, ANALYSIS AND REPORTING..............10 3.1 Reports Required by Saudi Aramco............................10 3.2 Accident Investigation...............................................11 3.2.1 Responsibilities for Investigation.................................11 3.2.1.1 Supervisor/Safety Representative....................11 3.2.1.2 Project Manager...............................................11 3.3 Cases to be Investigated...........................................12 3.4 Accident Investigation Guidelines..............................12 3.5 Accident Analysis.......................................................12 3.5.1 Classification...............................................................12 4.0RESPONSIBILITIES FOR SAFETY................................................16 4.1 Contractor Senior Management.................................16 4.2 Design Engineer........................................................16 4.3 Contractor's Safety Officer.........................................16 4.4 Construction Manager/Superintendent.......................17 4.5 Site Safety Supervisor...............................................18 4.6 Equipment Manager/Supervisor.................................18 4.7 Engineer/Supervisor..................................................18 4.8 Foreman...................................................................18 4.9 Worker.....................................................................19 February 1993 - A.1 Safety Competition Site Registration Form

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5.0EMERGENCY PROCEDURES.......................................................20 5.1 Action to be Taken.....................................................20 5.2 Contact After Office Hours.........................................20 5.3 Help in an Emergency................................................20 6.0SAFETY TRAINING....................................................................22 6.1 Safety Training for Supervisors..................................22 6.2 Safety Training for Workmen.....................................22 6.2.1 Integrated Practices....................................................22 6.2.2 Specialized Training.....................................................22 6.2.3 Use of Persuasion........................................................23 6.2.4 Course Requirements..................................................23 6.3 Scope of Training......................................................24 6.3.1 Safety Training Topics For Supervisors.........................25 6.3.2 Induction Safety Topics For Workmen..........................27 7.0SITE PLANNING AND HOUSEKEEPING........................................28 7.1 Initial Planning..........................................................28 7.1.1 Hazard Identification Plan............................................28 7.1.2 Loss Prevention Program.............................................29 7.1.3 Protection of Employees and Equipment.....................29 7.1.4 Transportation.............................................................29 7.1.5 Lifting Equipment........................................................29 7.1.6 Demolition...................................................................29 7.1.7 Excavations.................................................................29 7.1.8 Scaffolding...................................................................29 7.2 Site Layout...............................................................30 7.2.1 Site Accommodation....................................................30 7.2.2 Adequate Access Roads...............................................30 7.2.3 Project Sign.................................................................30 7.2.4 Safe Means of Access and Egress................................31 7.2.5 Parking Facilities..........................................................31 7.2.6 Drainage......................................................................31 7.2.7 Vehicle / Heavy Equipment Paths On Site Vs Pedestrian Paths ....................................................................................31 7.2.8 Sand............................................................................31 7.2.9 Fire Prevention.............................................................31 7.2.10 Site Illumination..........................................................31 7.3 Storage Areas...........................................................31 7.4 Welfare Facilities......................................................32 7.5 Good Housekeeping..................................................33 7.6 Construction Sites and Materials Storage Yards..........33 8.0FIRST AID................................................................................36 8.1 Provision of First Aid Facilities...................................36 8.2 First Aid Attendants..................................................37 8.3 First Aid Facilities At Work Site..................................38 8.4 Labor And Workmen Law...........................................40 9.0PERSONAL PROTECTIVE EQUIPMENT.........................................42 9.1 Head Protection........................................................43 9.2 Eye and Face Protection............................................43 9.2.1 Eye Protection from Impact.........................................44 9.2.2 Eye Protection from Radiant Energies..........................44 9.2.3 Face Protection............................................................44 9.3 Hand Protection........................................................44 February 1993 - A.1 Safety Competition Site Registration Form

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9.4 9.5 9.6

Foot Protection.........................................................44 Hearing Protection....................................................45 9.5.1 Ear Plugs.....................................................................45 9.5.2 Ear Muffs.....................................................................45 Fall Restraining/Arresting Devices.............................45

10.0 BREATHING APPARATUS.........................................................52 10.1 Selection of Equipment.............................................52 10.1.1 Requirements For Use.................................................53 10.1.2 Misuse.........................................................................53 10.1.3 Hazardous Substances................................................54 10.1.4 Contaminants..............................................................54 10.2 Respiratory Protective Devices..................................54 10.2.1 Air Purifying Respirators..............................................54 10.2.1.1 Gas Masks..................................................54 10.2.1.2 Chemical Cartridge Respirators..................55 10.2.1.3 Particulate Filter Respirators (Dust Respirators) 55 10.2.2 Supplied Air Respirators..............................................55 10.2.2.1 Air Line Respirators.....................................55 10.2.2.2 Abrasive Blasting Respirators.....................56 10.2.2.3 Air Supplied Suits.......................................56 10.2.3 Self Contained Breathing Apparatus (SCBA)................56 10.3 Training....................................................................57 10.4 Safety Precautions....................................................57 10.4.1 Air Compressors..........................................................57 11.0 FIRE PREVENTION.................................................................60 11.1 Before the Job Starts.................................................60 11.2 Layout......................................................................61 11.3 Equipment Protection................................................61 11.4 Control of Ignition Sources........................................62 11.5 Flammable Liquids....................................................62 11.5.1 Storage........................................................................62 11.5.2 Handling of Flammable Liquids....................................63 11.5.3 Ventilation...................................................................63 11.6 Combustible Materials...............................................63 11.7 Housekeeping...........................................................63 11.8 Emergency Equipment...............................................63 11.8.1 Water-Type Fire Extinguisher........................................64 11.8.2 Carbon Dioxide Type Extinguisher...............................64 11.8.3 Dry Chemical Type Extinguisher..................................64 11.8.4 Pressurized Water........................................................64 11.9 Reporting a Fire........................................................65 11.10 End-of-Shift Checks...................................................65 12.0 RADIO COMMUNICATIONS......................................................67 12.1 Equipment................................................................68 12.1.1 Remote Control Unit....................................................68 12.2 Safe Operation..........................................................68 12.3 Radio Phrases...........................................................68 12.4 Phonetic Alphabet.....................................................69 12.5 International Communications Union Agreement........70 12.5.1 Monitoring of Circuits..................................................71 12.5.2 Secrecy Act..................................................................71 12.5.3 Penalties......................................................................71 February 1993 - A.1 Safety Competition Site Registration Form

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Message Priorities for Company Operations...............71 Distress Messages....................................................73 12.7.1 MAYDAY.......................................................................73 12.7.2 Urgency Signal............................................................74 12.7.3 Priority Traffic..............................................................75

13.0 TRANSPORTATION................................................................76 13.1 Driver Requirements.................................................76 13.2 Driver's Responsibilities............................................76 13.3 Motor Vehicle Regulations: Saudi Arab Government and Saudi Aramco.....................................................................78 13.4 Vehicle Condition......................................................78 13.5 Driver Training..........................................................80 13.6 Enforcement of Safe Driving Practices.......................80 13.7 Action Taken After a Saudi Aramco Motor Vehicle Accident 81 13.7.1 Emergencies................................................................81 13.7.2 Remain at Scene.........................................................81 13.8 Passenger Seating and Seat Belts..............................82 13.9 Desert Driving..........................................................82 13.9.1 Stay With Vehicle.........................................................82 13.9.2 Sand Tires....................................................................82 13.10 Vehicle Admittance to Restricted Areas......................83 13.11 Operation of Motor Vehicles Within Saudi Aramco Communities.............................................................83 13.11.1...................................................................................Seat Belts............................................................................83 13.11.2 Traffic Regulations.........................................83 14.0 AIRCRAFT OPERATION..........................................................84 14.1 General Operating Responsibilities............................84 14.1.1 Captain/Pilot................................................................84 14.1.2 Camp Supervisors.......................................................84 14.2 Passenger Briefing/Instructions, General (All Aircraft Types) 85 14.3 Transportation of Dangerous Goods...........................86 14.4 Hours of Operation for Single-Engine Helicopters.......86 14.5 General Precautions for Helicopters...........................86 14.5.1 Life Vests.....................................................................86


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II. General And Civil...............................................87 1.0 WORK PERMIT SYSTEM..........................................................88 1.1 Definitions................................................................88 1.1.1 Restricted Areas..........................................................88 1.1.2 Issuer (Operation Supervisors)....................................89 1.1.3 Receiver (Authorized Craftsmen).................................89 1.1.4 Work Permit.................................................................89 1.2 Issuance and Approval..............................................89 1.2.1 Power Distribution Department Clearances.................90 1.3 Precautions..............................................................90 1.3.1 Checklist......................................................................90 1.3.2 Clear Area....................................................................90 1.3.3 Work Stoppage............................................................90 1.4 Handling of Issued Work Permit.................................90 1.5 Closing Out and Filing the Permit...............................91 1.6 Certification..............................................................91 1.7 12 Rules on Work Permit Procedure...........................91 1.8 Hold Tags and Multiple Lockouts................................91 2.0 EXCAVATIONS, TRENCHING AND SHORING...............................96 2.1 Before Work Starts....................................................99 2.2 Work Permit..............................................................99 2.2.1 Excavation near Saudi Telephone Cables.....................99 2.3 Underground Obstructions........................................100 2.4 General Precautions..................................................100 2.4.1 Shoring Protective Systems.........................................100 2.4.2 Personnel Protection....................................................100 2.4.3 Inspection....................................................................101 2.4.4 Clearance....................................................................101 2.4.5 Mechanical Excavator..................................................101 2.4.6 Walkways....................................................................101 2.5 Access and Egress.....................................................101 2.6 Hazardous Atmospheres and Materials.......................101 2.6.1 Ventilation...................................................................101 2.6.1.1 Hazardous Atmospheres...................................102 2.6.1.2 Emergency Rescue Equipment.........................102 2.6.2 Exhaust Gases.............................................................103 2.6.3 Organic Lead...............................................................103 2.7 Edge Protection, Markers and Fixed Lighting..............103 2.8 Roads, Streets, and Sidewalks...................................103 2.9 Backfilling.................................................................103 2.10 Borrow Pits...............................................................103 3.0 DEMOLITION..........................................................................124 3.1 Before Work Starts....................................................125 3.1.1 Responsible Supervisor...............................................125 3.1.2 Original Drawings........................................................125 3.1.3 Disconnections............................................................125 3.1.4 Adjacent Structures and Public Areas..........................125 3.1.5 Barricades/Signs..........................................................125 3.2 Method of Demolition................................................125 3.2.1 Demolition of Equipment Containing PCB: Polychlorinated Biphenyl (ASKAREL).....................................................126 February 1993 - A.1 Safety Competition Site Registration Form

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3.2.2 3.3 3.4 3.5 3.6

3.7 3.8

Demolition Of Buildings With Asbestos / Insulation Materials ....................................................................................126 Stability During Demolition........................................126 Working Place Clearance...........................................126 3.4.1 Access.........................................................................126 3.4.2 Glass Removal.............................................................126 Structural Steel Removal...........................................127 Tanks, Vessels and Pipe Work (Explosion Prevention). 127 3.6.1 Welding and Hot Cutting..............................................127 3.6.2 Cold Cutting................................................................127 3.6.3 Steaming and Ventilation............................................127 3.6.4 Residue Cleaning.........................................................127 Protective Clothing and Equipment............................127 Mechanical Equipment Guards...................................128

4.0 ASBESTOS AND OTHER FIBERS...............................................129 4.1 Types of Asbestos.....................................................129 4.2 Health Risks..............................................................129 4.3 Before Work Starts....................................................130 4.3.1 Air Sampling................................................................130 4.3.2 Job Details...................................................................130 4.3.3 Chest X-rays................................................................130 4.4 Storage and Transportation.......................................130 4.5 Work Area.................................................................131 4.6 Handling and Use......................................................131 4.6.1 Wetting/Ventilation......................................................131 4.6.2 Cutting........................................................................131 4.6.3 Protective Equipment..................................................131 4.7 Protective Clothing...................................................132 4.7.1 Types...........................................................................132 4.7.2 Contamination.............................................................132 4.7.3 Review.........................................................................132 4.8 Respiratory Equipment..............................................132 4.8.1 Type.............................................................................132 4.8.2 Use..............................................................................132 4.8.3 Care.............................................................................133 4.9 Washing and Changing Facilities................................133 4.10 Disposal of Waste Asbestos Materials/Clothing...........133 4.11 Cleanliness of Work Areas and Equipment..................133 5.0 WELDING, CUTTING, AND BRAZING.........................................134 5.1 Gas Welding: Oxy-Acetylene Equipment and Use.......134 5.1.1 Gases..........................................................................134 5.1.2 Color Coding of Cylinders............................................135 5.1.3 Storage Of Cylinders...................................................135 5.1.4 Handling of Cylinders..................................................136 5.1.5 Inspecting Equipment..................................................137 5.1.6 Faults...........................................................................139 5.1.7 Fuel Gas and Oxygen Manifolds...................................140 5.2 Electric Arc Welding..................................................140 5.2.1 Voltage........................................................................140 5.2.2 Welding Connections...................................................141 5.3 Protective Measures..................................................142 5.4 Welding and Cutting: Tanks, Vessels and Drums........144 5.5 Confined Spaces........................................................144 5.6 Personnel Protection.................................................145 February 1993 - A.1 Safety Competition Site Registration Form

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Health Hazards.........................................................145 5.7.1 Radiant Energy............................................................145 5.7.2 Respiratory Effects......................................................146

6.0 EXPLOSIVE MATERIALS...........................................................148 7.0 PILING OPERATIONS...............................................................149 7.1 Before Work Starts....................................................149 7.1.1 Cranes.........................................................................150 7.1.2 Pile Gates....................................................................150 7.1.3 Inspection....................................................................150 7.1.4 Wedges........................................................................150 7.1.5 Timber Block................................................................150 7.1.6 Ground Support...........................................................151 7.2 Driving Piles.............................................................151 7.2.1 Pitching.......................................................................151 7.2.2 Driving.........................................................................151 7.3 Pile Extraction..........................................................151 7.4 General Precautions..................................................152 8.0 ROADWORKS.........................................................................153 8.1 General....................................................................153 8.2 Street and Road Construction, Excavations, and Maintenance Traffic Controls..........................................................154 9.0 WORKING PLACES, LADDERS, AND SCAFFOLDING....................155 9.1 Working Places, General............................................156 9.1.1 Falls.............................................................................156 9.1.2 Access and Egress.......................................................156 9.1.3 Lighting.......................................................................156 9.1.4 Prevention of Falls.......................................................156 9.1.5 Ramps.........................................................................156 9.1.6 Falling Material............................................................157 9.1.7 Hot Surfaces................................................................157 9.1.8 Slipping and Tripping...................................................157 9.1.9 Roof Work....................................................................157 9.1.10 Insecure Structures.....................................................157 9.1.11 Work Over Water.........................................................158 9.2 Ladders and Stepladders...........................................158 9.2.1 Selection.....................................................................158 9.2.2 Condition.....................................................................159 9.2.3 Position........................................................................159 9.2.4 Use..............................................................................160 9.2.5 Stepladders.................................................................162 9.2.6 General........................................................................162 9.3 Scaffolding Components............................................163 9.4 Requirements Common to All Scaffolding...................168 9.4.1 Foundations.................................................................168 9.4.2 Posts............................................................................168 9.4.3 Runners.......................................................................169 9.4.4 Bearers........................................................................169 9.4.5 Board Bearers..............................................................169 9.4.6 Bracing........................................................................170 9.4.7 Ties..............................................................................170 9.4.8 Platform Units..............................................................171 9.4.9 Guardrail Systems and Toeboards...............................172 February 1993 - A.1 Safety Competition Site Registration Form

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9.5 9.6

9.7

9.8

9.9 9.10 9.11

9.4.10 Access.........................................................................172 9.4.11 Scaffold Ladders..........................................................172 9.4.11.1 Portable Straight and Extension Ladders....173 9.4.11.2 Vertical Ladder...........................................173 9.4.12 Workmanship...............................................................174 9.4.13 Inspections..................................................................174 Fabricated Tubular Frame and System Scaffolding......174 Tube and Coupler Scaffolds........................................176 9.6.1 Independent Tied Scaffold...........................................176 9.6.2 Light Duty Tube and Coupler Scaffolds........................176 9.6.2.1 Design, Loading and Dimensions.....................176 9.6.2.2 Platform...........................................................177 9.6.2.3 Limitations.......................................................177 9.6.3. Medium Duty Tube and Coupler Scaffold.....................177 9.6.3.1 Design, Loading, and Dimensions....................177 9.6.3.2 Platform...........................................................177 9.6.3.3 Limitations.......................................................178 9.6.3.4 Bearers.............................................................178 9.6.4 Heavy Duty Tube and Coupler Scaffolds......................178 9.6.4.1 Design, Loading and Dimensions.....................178 9.6.4.2 Platform...........................................................178 9.6.4.3 Limitations.......................................................178 9.6.4.4 Bearers.............................................................179 Free-Standing Tower Scaffolds...................................179 9.7.1 General Requirements.................................................179 9.7.2 Design, Loading and Dimensions.................................179 9.7.3 Runners and Bearers...................................................179 9.7.4 Bracing........................................................................179 9.7.5 Ties..............................................................................179 9.7.6 Platform.......................................................................180 9.7.7 Access.........................................................................180 9.7.8 Limitations...................................................................180 Mobile Tower Scaffolds..............................................180 9.8.1 Foundations.................................................................180 9.8.2 Operation....................................................................181 9.8.3 Limitations...................................................................181 Scaffolds for Tanks and Vessels..................................181 9.9.1 Bracket Scaffolds.........................................................181 Special Scaffolds.......................................................182 Scaffold Terminology.................................................182

10.0 HAND TOOLS AND POWER TOOLS.........................................193 10.1 Hand Tools, General..................................................194 10.1.1 Quality.........................................................................194 10.1.2 Cleanliness..................................................................194 10.1.3 Repair and Storage......................................................194 10.1.4 Selection.....................................................................194 10.1.5 Electrical Risks............................................................194 10.2 Individual Hand Tools, Precautions.............................194 10.2.1 Screwdrivers................................................................194 10.2.2 Hammer......................................................................195 10.2.3 Chisels.........................................................................195 10.2.4 Picks and Shovels........................................................195 10.2.5 Spanners and Wrenches..............................................195 10.2.6 Pipe Wrenches.............................................................195 10.2.7 Pliers...........................................................................196 10.2.8 Jacks............................................................................196 February 1993 - A.1 Safety Competition Site Registration Form

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10.3 10.4

10.5

10.6

10.2.9 Hacksaws....................................................................196 10.2.10...................................................................................Hand saws............................................................................196 Power Tools, General.................................................196 10.3.1 Quality.........................................................................196 10.3.2 Repair and Storage......................................................197 Pneumatic Tools........................................................197 10.4.1 General........................................................................197 10.4.2 Individual Tools, Precautions........................................198 10.4.2.1 Jack Hammer and Concrete Breakers.........198 10.4.2.2 Rock Drill....................................................198 10.4.2.3 Grinding Machine........................................198 Cartridge Operated Tools...........................................203 10.5.1 General........................................................................203 10.5.2 Storage........................................................................203 10.5.3 Selection and Training of Personnel.............................203 10.5.4 Personal Protective Equipment....................................204 10.5.5 Issue and Returns........................................................204 10.5.6 Work Permits...............................................................204 10.5.7 Use..............................................................................204 10.5.8 Maintenance and Repair..............................................206 Electrically Operated Tools........................................207 10.6.1 General........................................................................207 10.6.2 Maintenance and Storage............................................208 10.6.3 Personal Protective Equipment....................................208 10.6.4 Individual Tools, Precautions........................................209 10.6.4.1 Grinders......................................................209 10.6.4.2 Drills...........................................................209 10.6.4.3 Saws...........................................................209 10.6.4.4 Radial Saws................................................210

11.0 PAINTS AND COATINGS.........................................................220 11.1 Flammability Hazards of Coating Materials.................220 11.1.1 Flammable Materials...................................................220 11.1.2 Flash Point (Definition)................................................220 11.1.3 Flammable (Explosive) Limits (Definition)...................220 11.1.4 Fire Precautions...........................................................221 11.2 Health Hazards Associated With Paints......................221 11.2.1 Toxic Materials.............................................................221 11.2.2 Dermatitic Materials....................................................222 11.2.3 Prevention of Health Hazards......................................222 11.3 Ventilation in Confined Spaces...................................222 11.4 Surface Preparation..................................................223 11.4.1 Abrasive Blast Cleaning...............................................224 11.4.2 Hydroblast and Steam Cleaning..................................224 11.4.3 Hand and Power Tool Cleaning.....................................224 11.4.4 Chemical Cleaning.......................................................225 11.4.5 General Safety in Surface Preparation.........................225 11.5 Personal Protective Equipment..................................226 11.6 Paint Application.......................................................228 11.6.1 Paint Materials.............................................................228 11.6.2 General Safety In Paint Application..............................228 11.7 Scaffolding and Ladders............................................229 11.8 Tarring Operations....................................................229 11.9 General Safety for Paints and Coatings......................229


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12.0 CONCRETE, CONCRETE FORMS, AND SHORING.......................232 12.1 General....................................................................232 12.2 Reinforcing Steel......................................................232 12.3 Bulk Concrete Handling.............................................232 12.4 Concrete Placement..................................................232 12.4.1 Concrete Mixers...........................................................232 12.4.2 Guardrails....................................................................232 12.4.3 Bull Floats....................................................................232 12.4.4 Powered Concrete Trowels...........................................233 12.4.5 Concrete Buggies........................................................233 12.4.6 Pumpcrete Systems.....................................................233 12.4.7 Concrete Buckets........................................................233 12.4.8 Discharging on Slope...................................................233 12.4.9 Back-Up Man, Truck Spotter.........................................233 12.4.10 Pneumatic Hose.............................................233 12.5 Vertical Shoring........................................................233 12.5.1 General Requirements.................................................233 12.5.2 Tubular Welded Frame Shoring....................................234 12.6 Forms and Shoring....................................................234 12.6.1 General Provisions.......................................................234 12.6.2 Vertical Slip Forms.......................................................235 12.6.3 Tube and Coupler Shoring............................................235 12.6.4 Single Post Shores.......................................................236


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III. Mechanical Equipment And Materials.................237 1.0 CRANES AND LIFTING EQUIPMENT..........................................238 1.1 Competent Person.....................................................239 1.2 Saudi Aramco Crane Operations (General Requirements)239 1.3 Saudi Aramco Crane Operator Qualifications..............240 1.4 Special Crane Operating Procedures..........................240 1.5 Effect of Wind Speeds on Crane Operations................240 1.6 Overhead Power Lines...............................................240 2.0 SLINGS AND LIFTING GEAR (RIGGING).....................................245 2.1. Safe Working Load (SWL)..........................................245 2.2. Chain Slings..............................................................246 2.2.1 Grades.........................................................................246 2.2.2 Repairs........................................................................246 2.3 Wire Rope Slings.......................................................246 2.4 Synthetic Webbing Slings..........................................247 2.4.1 Removal from Service..................................................247 2.4.2 Repaired Slings............................................................247 2.5 Synthetic and Natural Fiber Rope Slings.....................248 2.6 Care of Slings...........................................................249 2.7 Hooks.......................................................................249 2.8 Spreader Bars...........................................................250 2.9 Eyebolts And Safety Hoist Rings................................250 2.10 Shackles...................................................................251 2.11 Rigger......................................................................251 3.0 MECHANICAL EQUIPMENT.......................................................257 3.1 Operators.................................................................258 3.1.1 Qualifications...............................................................258 3.1.2 Licensing Requirements..............................................258 3.2 Machinery Guards.....................................................259 3.2.1 Multi-Piece Tire Rims and Locking Rings......................259 3.3 General Requirements...............................................259 3.4 Compressors.............................................................260 3.5 Concrete Mixers and Batching Plants.........................261 3.6 Dumpers and Dump Trucks........................................262 3.7 Excavators................................................................263 3.8 Fork Lift Trucks.........................................................264 3.9 Generators...............................................................265 3.10 Graders, Dozers, Scrapers, Loaders And Miniloaders...266 3.11 Woodworking Machinery...........................................266 4.0 MATERIALS HANDLING...........................................................268 4.1 Planning...................................................................268 4.2 Machine Transport....................................................269 4.2.1 Dumpers......................................................................269 4.2.2 Tractors and Trailers....................................................270 4.2.3 Conveyor Belts and Monorails.....................................270 4.2.4 Concrete Pumps..........................................................270 4.3 Site Stores................................................................270 4.4 Manual Handling.......................................................271


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IV. Electrical And Radiation....................................275 1.0 ELECTRICITY..........................................................................276 1.1 Voltage.....................................................................277 1.2 Temporary Installations.............................................277 1.3 Hand Tools and Lighting............................................278 1.4 Work on Live Equipment............................................279 1.5 Overhead and Underground Cables............................280 1.6 Overhead Power Transmission and Distribution..........281 1.6.1 Initial Inspections, Tests, or Determinations................281 1.6.2 De-energizing Lines and Equipment............................282 1.6.3 Emergency Procedures and First Aid............................282 1.6.4 Night Work...................................................................282 1.6.5 Work Near/Over Water.................................................282 1.6.6 Hydraulic Fluids...........................................................283 1.6.7 Live-Line Tools (Hot Sticks)..........................................283 1.6.8 Material Handling........................................................283 1.6.8.1 Unloading.........................................................283 1.6.8.2 Pole Hauling.....................................................283 1.6.8.3 Storage............................................................283 1.6.8.4 Framing............................................................283 1.6.8.5 Attaching the Load...........................................284 1.6.9 Grounding for Protection of Workers............................284 1.6.9.1 Isolation and Voltage Testing............................284 1.6.9.2 Applying and Removing Grounds.....................284 1.6.9.3 Grounding Distance..........................................284 1.6.9.4 Removal of Grounds for Testing Purposes.........284 1.6.9.5 Grounding Electrode.........................................284 1.6.9.6 Grounding Cables And Clamps.........................285 1.6.10 Overhead Lines...........................................................285 1.6.10.1 Metal Tower Construction...........................285 1.6.10.2 Stringing/Removing De-energized Conductors287 1.6.10.3 Stringing Adjacent to Energized Lines........288 1.6.11 Underground Lines......................................................289 1.6.11.1 Work in Manholes.......................................290 1.6.11.2 Trenching and Excavating...........................290 1.6.12 Construction in Energized Substations........................291 1.6.12.1 Barricades and Barriers..............................291 1.6.12.2 Control Panels.............................................291 1.6.12.3 Mechanized Equipment..............................291 1.6.12.4 Substation Fences.......................................291 1.7 Electric Shock...........................................................292 2.0 IONIZING RADIATION..............................................................295 2.1 Methods of Protection Against Radiation....................295 2.1.1 Distance......................................................................295 2.1.2 Time............................................................................295 2.1.3 Shielding.....................................................................296 2.2 Classification of Personnel and Exposure Limits..........296 2.2.1 Radiation Workers.......................................................296 2.2.2 Non-Radiation Workers................................................296 2.2.3 Exposure Limits...........................................................296 2.3 Responsibilities for Safe Handling..............................297 2.3.1 Contractor...................................................................297 2.3.2 Competent Person.......................................................297 February 1993 - A.1 Safety Competition Site Registration Form

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2.3.3. Radiographer...............................................................297 Shipping and Transportation......................................298 Storage Areas...........................................................298


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V. Chemicals And Operations..................................300 1.0 LIQUEFIED PETROLEUM GASES...............................................301 1.1 General....................................................................301 1.2 Storage....................................................................302 1.3 Handling of Cylinders................................................302 1.4 Leakage....................................................................303 1.5 Transportation..........................................................304 1.6 Operation.................................................................304 1.7 Action in Case of Fire................................................305 1.8 Bulk Installations......................................................306 1.9 First Aid...................................................................306 2.0 PLANT OPERATIONS...............................................................307 2.1 Additional Information On Saudi Aramco Instructions and Standards.................................................................307 2.1.1 General Instruction Manual..........................................308 2.1.2 Producing Instruction Manual......................................308 2.1.3 Refinery Instruction Manual.........................................308 2.1.4 Saudi Aramco Engineering Standards..........................308 2.2 Work Permit System..................................................308 2.3 Operation of Plant Equipment....................................308 2.4 Shutdown and Maintenance in Plant Operations.........309 2.5 Commissioning..........................................................309 2.6 Emergency Procedures: Saudi Aramco Disaster Plan. .309 2.6.1 Gas Release Emergency Procedures............................310 3.0 PRESSURE TESTING................................................................311 3.1 Preparation..............................................................312 3.1.1 SAES-A-004 (Pressure Testing).....................................312 3.1.2 Supports......................................................................312 3.1.3 Vents and Drains.........................................................313 3.1.4 Valves..........................................................................313 3.1.5 Pipings And Joints........................................................313 3.1.6 Vacuums......................................................................313 3.2 General Requirements...............................................313 3.3 Test Liquid................................................................314 4.0 CHEMICALS...........................................................................316 4.1 Hazard Identification System.....................................317 4.2 Health Hazards.........................................................318 4.2.1 Inhalation Pathway Hazard..........................................318 4.2.2 Skin Hazards................................................................319 4.2.3 Hazards of Swallowing Chemicals................................319 4.3 Emergency Treatment...............................................319 4.3.1 Artificial Respiration....................................................319 4.3.2 First Aid.......................................................................319 4.3.3 Showers and Eyewash Fountains.................................319 4.4 Fire Hazards.............................................................321 4.5 Reactivity Hazards....................................................321 4.6 Transportation, Storage and Disposal.........................321 4.6.1 Transportation.............................................................321 4.6.2 Storage........................................................................322 4.6.3 Containers...................................................................322 4.6.4 Disposal.......................................................................322 February 1993 - A.1 Safety Competition Site Registration Form

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4.7

Work on Equipment Which Has Contained Tetraethyl Lead (Organic Lead Compounds)........................................324 4.7.1 Introduction.................................................................324 4.7.2 Precautions..................................................................325


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VI. Marine.............................................................329 1.0 COFFERDAMS........................................................................330 1.1 Design......................................................................330 1.2 Before Work Starts....................................................330 1.3 Construction.............................................................330 1.4 Potential Hazards......................................................331 1.4.1 Structural Collapse......................................................331 1.4.2 Overhead Loads...........................................................331 1.4.3 Dislodgment of Struts and Wales.................................331 1.5 Inspection.................................................................331 1.6 Leaks.......................................................................332 2.0 MARINE 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3.0

OPERATIONS.............................................................333 Other Publications....................................................333 General....................................................................334 Behavior on Floating Craft.........................................334 Preparation for Transportation by Sea........................334 Tide and Sea Effects..................................................335 Care of Tools and Equipment......................................335 Housekeeping...........................................................335

DIVING OPERATIONS.............................................................337 3.1 Employment of Qualified Divers.................................337 3.2 Diving Equipment......................................................338 3.2.1 Compressors................................................................338 3.2.2 Reserve Air Supply......................................................339 3.2.3 Bail-Out Equipment.....................................................339 3.2.4 Maintenance................................................................339 3.3 Safeguards...............................................................340 3.4 Physical Fitness........................................................344 3.5 Medical Diving Emergencies: Procedures and Responsibilities 345 3.5.1 Sports Divers...............................................................345 3.5.2 Commercial Divers......................................................345 3.5.3 Coordinator, Diving Emergencies................................345 3.5.4 Diving Medical Team....................................................345 3.5.5 Marine Department.....................................................346 3.6 Personnel Transfer at Sea..........................................346


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Appendix A.............................................................349 INDEX TO APPENDIX A..................................................................350 A.1.............................................................................................. PROJECT MANAGEMENT AND CONTRACTOR'S SAFETY COMPETITION SITE REGISTRATION FORM....................................................................351 A.2 CONTRACTOR SAFETY COMPETITION, RULES OF COMPETITION...352 A.3.............................................................................................. Saudi Aramco Safety, Health and Environmental Requirements...............357 1. Compliance With Safety Rules - Schedule 'D'.............357 2. Deviations From Safety Rules....................................357 3. Failure To Comply......................................................357 4. Saudi Aramco Assistance...........................................357 5. Loss Prevention Program...........................................358 6. Work Permits............................................................358 7. Welding And Cutting Equipment................................358 8. Personal Protective Equipment..................................358 9. Tools And Portable Power Tools..................................358 10. Cartridge Operated Tools...........................................359 11. Ladders....................................................................359 12. Scaffolding...............................................................359 13. Electrical Installations And Equipment.......................359 14. Cranes And Rigging Equipment..................................359 15. Mechanical Equipment..............................................359 16. Saudi Aramco Plant Operations..................................360 17. Transportation..........................................................360 18. Injury And Damage Reporting....................................360 19. Excavations..............................................................361 20. Work Over Or Adjacent To Water................................361 21. Fire Prevention.........................................................361 22. Formwork.................................................................361 23. Ionizing Radiation.....................................................361 24. First-Aid Facilities.....................................................361 25. Handling, Transportation And Disposal Of Hazardous Materials And Waste................................................................362 26. Explosives................................................................363 27. Sandblasting.............................................................363 A.4.............................................................................................. HAZARD IDENTIFICATION PLAN (HIP)..........................................................364 HAZARD IDENTIFICATION PLAN:...........................................365 I. Conduct Hazards Identification Review........................365 II. List Potential Hazards..................................................365 III. Hazard Classification...................................................365 IV. Corrective Action.........................................................366


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Appendix B: Emergency/Disaster Planning And Response ..............................................................................368 B.1.............................................................................................. SEARCH AND RESCUE PROCEDURES...........................................................369 B.2 EMERGENCY/DISASTER PLANNING AND RESPONSE....................370 B.2.1 General Provisions....................................................371 B.2.2 Definitions................................................................371 B.2.3 Plan Development Action Items.................................377


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Appendix C: Fire Safety Checklist For Evaluating Construction Materials Store Yard...........................397 C.1.............................................................................................. Fire Safety Checklist For Evaluating Construction Materials Store Yard. 398


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Appendix D: Saudi Aramco Crane Safety Handbook. 402 D.1..............................................................................................Crane Safety Handbook..........................................................................403


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Appendix E: Suggestion Form.................................404


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Appendix F: Distribution Form................................406


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Appendix G: Sanitary Code.....................................408 Implementing The Saudi Aramco Sanitary Code - GI 151.006..........409


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Appendix H: General Instructions Master Index.......410 General Instructions (GI) Master Index..........................................411


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Appendix I: List Of Figures.....................................415 List Of Figures.............................................................................416


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Appendix J: List Of Tables.......................................419 List Of Tables...............................................................................420


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Appendix K: Forms.................................................421 Preliminary Accident Report.........................................................423 Contractor Monthly Safety Report.................................................424 Injury Summary...........................................................................425 ............................................................................................ ............................................................................................ (Page ___of___).........................................................................425 Lift Plan For Cranes......................................................................426 Wire Rope Sling Inspection Log.....................................................427 Cartridge/Tool Issuance Control....................................................428 Emergency Reporting Instructions................................................429 Project Management And Contractor's Safety Competition Site Registration Form...........................................................................................430


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Saudi Aramco-Construction Safety Manual

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